How to cut metal at home • CIMFLOK.COM

Metal cutting

Metal cutting is a method of processing sheet, cast and sectional workpieces, which consists in cutting them into parts with special tools.

The machining of workpieces can be cold and hot.

In the first case, tools are used to cut metal mechanically. various saws, scissors, etc. д.
When cutting hot, the material melts at the point of impact of the tool. Droplets are removed by the gas stream. This method of processing requires more complex equipment: auto-generators; machines for plasma, oxygen, laser cutting, etc. п.

Professional and industrial metal cutting tools

Professional metal cutting tools are used for processing workpieces in industrial conditions.

Tools and machines for mechanical cutting

Mechanical cutting has the following advantages:

The main disadvantage is that only straight cuts can be made mechanically.

Angle grinders are most commonly used for cutting small and medium-diameter bars. Angle grinders are used to cut rebar, angles, and tubes of square and round cross-section. The method is notable for its low productivity, but the amount of waste tends to be minimal.

Consumable material for metal processing with angle grinder. abrasive and diamond wheels.

Circular saws. They can be used to make angled cuts. Advantages of the method. high precision and quality. Limitations in depth of cut, great amount of waste.

Photo : metal cutting with circular saw

Guillotines. Billets are cut into pieces using the chopping method. This method of processing is considered the most productive and cheapest, but is not designed for manufacturing parts of complex configuration.

Picture : cutting metal with guillotines

Band saws are designed for cutting all metals and alloys. The method is distinguished by its low waste volume. The edges of cuts are as smooth as possible. There are restrictions on the size of blanks.

Picture : cutting metal on a band saw

Water-jet cutting

Metal is cut on a special equipment with a solution (water, abrasive sand), which is fed under high pressure through a narrow nozzle. This innovative technology is designed for cutting metal with a thickness of up to 30 cm. The parts obtained do not require additional processing. The metal is not deformed. к. There is no thermal effect.

Photo : waterjet cutting of metal

This process is very expensive and not suitable for corrosive metals.

Hot cutting technologies

Laser. Workpieces are machined on special machines. Part of the metal evaporates when exposed to the laser beam. The remains of the molten material are blown out with a gas mixture.

Laser cutting produces high-precision parts of any configuration that do not require additional processing. However, the method has disadvantages:

metal thickness limitation. workpieces up to 20 mm thick can be processed on laser machines;
Expensive. the of machines and their operation are kept on a high level;
Limitations on the type of metal. laser cutting is not suitable for stainless steel, aluminum and other alloys with high reflectivity.

Gas. Workpieces are machined on special machines. Cutting technology is based on intense melting of the metal. It takes place under the influence of a directional flow of the gas-oxygen mixture.

The method is suitable for rough cutting of metals and alloys with low thermal conductivity. The high temperatures cause the formation of scale and overlap in the machining area. The resulting parts require additional machining.

Plasma. Metal is cut with a high-pressure gas mixture. melts and burns the material, while the residue and scale are completely blown away.

Photo : plasma cutting metal

Plasma cutting has the following advantages:

Cost-effectiveness. the amount of waste is minimal, and the parts obtained do not require additional processing;
productivity. plasma cutting is 4, 8 and 10 times faster than laser, waterjet and mechanical cutting, respectively;
flexibility. the technology is suitable for any electrically conductive metal from 1 mm up to 15 cm thick.

Plasma cutting is used for both batch and single-piece production.

Electric jigsaw

One way to cope with the problem is to use an electric jigsaw. The power tool is versatile, so you just need to select the appropriate cutting blade to use it. It is convenient to use the jigsaw for thin material (thickness up to 3 mm) and when it is necessary to make shaped cuts. For the latter, it is advisable to choose a narrow blade. The cut is accurate and precise.

Metal shears are also effective in cutting. Depending on the type and thickness of the material, the following types of tools are distinguished:

ordinary hand scissors (used for sheet steel thickness of 0.4. 1.1 mm);
chair scissors (have large dimensions and are suitable for steel up to 2.5 mm);
power shears (for steel up to 5.0 mm);
Lever or fly shears (for long material with thickness up to 3.0 mm)
guillotine shears (have inclined knives, suitable for thick steels up to 32 mm).

angle grinder

The most popular tool in the household is the angle grinder. It can also be used to cut metal. For this purpose, you need to buy an appropriate cutting wheel. They come in different thicknesses. If there is thin sheet metal and precise cutting is necessary, the fine wheel is better suited. If you need to cut reinforcement, it is more convenient to do it with a circle of greater thickness.

The main features of working with metal with a sabre saw is the absence of sparks and convenience of working in hard-to-reach places. It produces a smooth, clean cut. But it should be remembered that the saber saw only works in a straight line. This is the main difference between it and the jigsaw. High probability of damage to the cutting blade when bending. It is also important not to overheat the cutting material. This requires working at low rpm.

Cold types of metal cutting

Cutting metal mechanically is a complex process, because metal products have high strength and hardness. Cold types of metal cutting include:

Cutting with guillotine.

This method of cutting uses special mechanical tools. scissors and metal knives. Workpiece is placed on the work table and clamped with a clamping beam. Then a special blade is used to cut. The result is a perfectly straight edge, with no extra edges, burrs, or nicks. Cutting material across the entire width of the sheet at once, so the curvature of the cut is zero.

The following types of guillotines are currently used for cutting metal:

They do not differ from each other in principle of operation, but the last three types are supplemented by electronics, ensuring accuracy and safety of cutting. There are also machines that can cut metal not only crosswise, but also lengthwise. Most often the guillotine type of processing is used for blank work.

Disadvantages of this method:

May not be used for all types of metals and has a limit on the thickness of the workpiece. For example, hydraulic machines are designed for metal thicknesses up to 6 mm.
Obtained as a result of cutting blanks often do not correspond to the desired size, since the accuracy of processing depends on the skill of the operator.
Not possible to perform curved cuts.
Laser cutting copper: advantages and disadvantages of the technology
Types of metal cutting: industrial applications
Metal processing according to drawings: convenient and profitable

Band saw cutting.

Currently, this type of metal cutting is very popular due to the low cost of equipment, good productivity and easy maintenance. The cutting tool is a band saw, stretched on pulleys.

Modern band saws (LPS) are supplemented by a variety of equipment and electronics, thanks to which the unit is easily integrated into a particular production line for trimmer. The average cutting speed of this type of machine is about 100 mm/min and higher.

The cutting method on the LPS allows you to achieve an exact fit with the specified parameters, and the place of the cut does not need additional processing. Good for high-precision parts and those with smooth surfaces. LPS is suitable for any metal, and the cutting width is only 1.5 mm.

When cutting metal of this type, it is important to observe a number of conditions:

exact choice of blade tooth pitch according to the cross section of the profile to be sawn with the help of special tables;
feed rate;
cutting speed.

The LPS allows you to cut a metal workpiece at an angle, which is a big advantage compared to the guillotine.

The disadvantages of this type of metal cutting include the inability to get a shaped cut and the limitation on the size of workpieces depending on the capabilities of the machine.

Cutting metal with a circular saw and “angle grinder.

Good quality and precise cuts are made with the circular saw. This tool allows you to control the angle of the cut.

The disadvantages of this type of cutting include a large amount of waste, slow speed and shallow depth of cut.

For cutting rolled sections, you can use an angle grinder. No dross or oxides are left at the point of cut, little waste.

But the low productivity of this type of metal cutting is its major disadvantage compared to other methods.

How to hold an angle grinder correctly

Many people have an angle grinder, but most people do not know how to use it correctly and how to hold it. This leads not only to defects in the work, but also to serious injury. An angle grinder is a rather dangerous power tool. The wheel must be installed with the pattern upwards and clamped with a special nut.

The person with the right hand holding the angle grinder by the handle with the right hand. The wheel should be positioned on the left side of the machine and the safety guard should cover the wheel from above. The rotation is such that sparks fly to the worker while he is cutting. If the angle grinder’s wheel jams and the angle grinder comes out of his hands, it will not go toward the cutter, but in the opposite direction.

The left hand holds the machine by the handle, which is screwed into a threaded hole in the housing. There are several of them for special use cases, but the correct position of the handle is only at the top.

This position of the machine requires the use of protective equipment. To protect your eyes and the exposed part of your face are safety glasses, or better yet, a face mask. To protect the exposed parts of the body from sparks and small splinters during cutting, you must wear a suit of thick material.

How to properly hold an angle grinder

Many people have an angle grinder, but most people don’t know how to use it correctly and how to hold it. It leads not only to defects in the work, but also to serious injuries. An angle grinder is a pretty dangerous power tool. The wheel should be set with the pattern upwards and clamped with a special nut.

The person with the right hand holding the angle grinder by the handle with the right hand. The wheel must be on the left side of the machine and the guard must cover it from above. The rotation is such that sparks fly at the worker while cutting. If the angle grinder’s wheel jams and the angle grinder gets out of his hands, it will not go toward the cutter, but in the opposite direction.

The left hand holds the machine by the handle, which is screwed into the threaded hole on the body. There are several for special applications, but the correct handle position is only upward.

This position of the machine requires the use of protective equipment. To protect eyes and open part of face. safety glasses, and even better. a protective mask. A suit of thick material must be worn to protect the exposed parts of the body from sparks and small fragments while cutting.

Hot Cutting Metal

Modern industrial production requires highly productive methods of metal cutting, allowing to produce the maximum amount of blanks of the required quality in the shortest possible time. These requirements are met by hot-oxygen types of metal cutting.

Gas-oxygen cutting.

The working principle is based on the fact that in pure oxygen at a temperature above 1000 ° C, the metal melts and burns out. Cutting area should be preheated to the ignition temperature of the material. Acetylene is commonly used as a cutting gas. Heating times are affected by metal thickness, grade, and surface condition of the workpiece.

After the cut area is heated, a jet of burning oxygen is poured into the nozzle of the cutter. It cuts through the entire thickness of the workpiece while moving smoothly along the cutting line. In the process of oxygen combustion oxides formed on the surface of the semi-finished product are also removed.

In order to make a quality cut, it is important to maintain the same distance between the torch and the workpiece during machining. This is not an easy task when using a hand-held oxy-fuel torch. In case of automation of the process, cutting is performed at high speed by high-pressure oxygen, and as a result the productivity and quality of cut significantly increase.

The uniqueness of the method lies in the possibility:

The disadvantages of gas-oxygen cutting include:

impossibility of using when cutting non-ferrous metals (copper, aluminum), nickel-chrome and high-carbon steels;
large width of the cut, the formation of oxides, swellings, poor quality;
The impossibility of processing curved surfaces;
change in the physical properties of the material in the area of the cut due to the high temperature effect.

Plasma metal cutting.

Cutting with plasma is based on the principle of intense melting of metal along the cut line by means of the thermal effect of a compressed electric arc and its subsequent evaporation. The arc produces a fully or partially ionized gas, or plasma. The temperature inside the gas plasma flow reaches 15 000 20 000 °C, which enables a many-fold increase in productivity compared to oxy-fuel cutting, and makes it possible to avoid the drawbacks of the latter.

Of all the above types of metal cutting, plasma cutting is currently the best choice for modern metalworking industries due to its advantages:

plasma cutting is precise and does not leave any overlap;
Allows cutting along curved lines;
The physical properties of the metal (overheating) are excluded due to the narrowly-directed heating of the cutting area;
titanium, copper, cast iron, and specialized steels can be cut without tool change
the equipment does not have cylinders with explosive gas, respectively, does not require refueling and delivery of these containers;
no special regime of compliance with fire safety measures is required;
there is no preparatory stage of cleaning, because the high-temperature impact effectively removes foreign impurities (in the form of rust, dirt, paint), the quality of the cut remains unchanged;
no special additives are needed for non-ferrous metals, cheap electricity and air are used, consumables are only nozzles and electrodes, so plasma metal cutting is a cost-effective process.

Disadvantages of this type of metal cutting:

Because of the impact of high temperatures, the properties of the edges of the workpiece change. They become harder, some material is lost, so additional edge work is needed. In any case, the quality of the edges after plasma cutting is much better than after gas-oxygen cutting: no dross, the width of the zone with colors is five times less.

Laser metal cutting.

This type is an innovative process. The essence of it is the intense exposure of the metal to a narrow laser beam, which has a stable frequency and wavelength. It can focus on a small area of the surface by means of optics controlled by a special computer program. Thanks to this technological solution, laser cutting has unparalleled precision parameters.

High energy density, characteristic of directional and narrowly concentrated laser radiation, allows to heat and vaporize a precisely defined area of the metal workpiece.

Laser cutting occurs as follows:

When the laser beam plunges into the metal, the temperature rises, causing the material to melt and boil. This process consumes a lot of energy, so in order to save energy an auxiliary gas is fed into the cutting area with which plasma cutting is carried out. Depending on the material’s thermal properties, auxiliary gases may be regular air, nitrogen, oxygen, inert gas.

Advantages of the laser type of metal cutting:

the narrowest possible cuts;
No deformation when cutting thin sheets of steel and soft semi-finished products;
Precise cutting of complex contours is possible;
minimum amount of irregularities;
Small area of thermal effect;
The versatility of the method. suitable for all alloys
Uncomplicated operation of the laser cutting machine.

The only disadvantage of laser cutting is the small allowable thickness of the metal.

How to cut thin sheets flat

To quickly and accurately perform work related to cutting sheet metal, you need to choose the right power tool such as an angle grinder. For cutting thick or thin sheets, you need to select an angle grinder of appropriate power, as well as the diameter of the cutting wheel. over, when buying, it is recommended to pay attention to the functionality of the power tool (availability of soft start system, adjustment of disk rotation speed).

For everyday household use, when it is necessary to cut a thin metal, fit an ordinary low-power angle grinder (up to 1 kW). However, in order to cut thicker sheets, it is preferable to acquire a powerful angle grinder (2 kW and higher), which are equipped with a soft start system. There are several types of angle grinders, differing from each other both by scope and functionality. Such power tools are:

professional type;
semi-professional type;
household;
with the presence of one or more handles;
With soft start and self-set speed control.

In addition, there are angle grinder of medium, small, and high power. This power tool can be used to cut both metal and other hard surfaces (concrete, stone). The angle grinder is often used for a variety of works related to scraping, sanding, and polishing work surfaces.

For cutting thin sheets you can use a low-power angle grinder, the power of which is about 0.6-1 kW, with a disc diameter of 125 mm.

However, such an angle grinder is not recommended for cutting thick metal, because in this case, during the work of the angle grinder will often jam the cutting disk, which is fraught with the possibility of serious injury.

In order to accurately and evenly cut a thin sheet metal, the thickness of which is about 1 mm, you need to exercise extreme care and attention. After all, when machining such materials with an angle grinder, the cutting blade can “bite. Therefore, before carrying out the work, you should inspect the cutting disc and make sure that its surface is free of any defects and chips.

If the integrity of the disk is compromised, then it is not recommended to use it to perform work on cutting products made of metal. Otherwise, a deformed or damaged disc may break during cutting.

To evenly cut a thin sheet metal with an angle grinder, you need to make on its surface to draw a line for the trimmer, along which the cut will be carried out. Beginning to cut the sheet should be from its far edge, gradually moving backwards, in the opposite direction. Using this method, the user will pull the angle grinder in its direction, gradually moving along the sheet to its second edge.

Keep an eye on the blade when cutting thin sheets. Do not allow it to sink too deeply into its surface during cutting. The maximum depth of penetration should not exceed the mark of 5-6 mm. This way of cutting eliminates the possibility of a hooked disk. Otherwise, when the depth of penetration of the cutting disc into the sheet will exceed the mark of 6 mm, because of the reduction of the contact area, there is a high probability of hooks.

How to cut a thick sheet metal evenly

For cutting thick sheet metal, it is advisable to use an angle grinder with a power of more than 1 kW. In this case, cut the product with an angle grinder in the direction forward from its edge. First you must draw a line on the sheet for the trimmer, along which the cut will be made. Then along the drawn line you need to put a steel corner or even wooden bar. With the help of clamps the angle (bar), tight to the surface of the sheet.

Then along the corner, strictly along the drawn line it is necessary to pass the angle grinder and make a small groove, the depth of which is about 1-2 mm. After completing this procedure, the angle grinder can be dismantled and normal metal cutting can begin.

Done on its surface, along the marked line, the groove will not allow the saw blade to move away from the predetermined trajectory, so you get a perfectly smooth edges at the cutting points.

Important! When working with the angle grinder must comply with safety rules and use personal protective equipment.

Also during the work, it is necessary to take into account the direction of rotation of the wheel of the angle grinder, as well as its size. You can not on a small angle grinder (125 mm), put a large disc (150 mm or more), after removing the protective cover.

Specialist recommendations for certain types of work

Next, we will tell you how to work with an angle grinder with various metal products.

Chainsaw chain sharpening

Picture 2: chain saw chain sharpening with angle grinder

Chain is being sharpened on the chain saw arm. A 2.5 mm thick sharpening disc is used for the work. You need to mark the first tooth you will be cutting. With competent actions, you can renew the chain 4-7 times before it finally breaks down.

Cutting pipes

It is better to start cutting thick metal with an angle grinder from the edges. If you start in the middle, the disc can jam and bend. During processing, apply force to the lower part of the cutting tool, which ensures the efficiency of the cut.

Cutting moldings

Picture 4: cutting corners with an angle grinder

You can use worn-out discs or a small-diameter tool to cut metal angles. It is important to remember that the work is staged: first they cut one part of the molding, then the second.

Sharpening a circular saw blade

Picture 5: sharpening a circular saw blade with an angle grinder

Start by fixing the angle grinder with clamps, leaving access to the rotating part of the tool. Then bring the saw blade to the sharpening wheel, do not force it. The wheel should run tangentially along the workpiece. When working carefully observe the plane of sharpening.

Polishing is a complex operation of workpiece finishing. It is used to remove minor defects such as scratches, chipping and scrapes. The surface is left with a fine luster and the workpiece has a saleable appearance.

Cutters with indexable inserts. it is a compound metal cutting tool, which contains removable working components, fixed on the body. Products are used to form grooves, inclined surfaces and ledges. Use it to prepare holes, create complex technological cutouts.

Grooving and shoulder milling involves simultaneous multi-surface machining. Actions are carried out with the use of profile cutters, ensure the preparation of technological protrusions and openings for the subsequent connection of parts.

Cutter wear and tear is a complex phenomenon resulting from the use of the tool. Cutting edge wear reduces sharpness, weight, geometry and mechanical stability of the product.

Calculation of cutting modes is carried out for mechanized and manual metal processing. Based on the results of calculations, you select the tooling, determine the best way to carry out the work and the amount of production costs.

Multifunctional power tool

The Renovator is now available from many leading manufacturers as the optimal tool for the home. You can do everything around the house with just one piece of equipment. It is a handy, not heavy machine with a manual drive and access to mains power. There are battery-powered models, but they break down faster. The essence of the device in a large number of nozzles, one of which is designed for sawing metal parts. It can really help cut through wire or thin sheet metal, but you should not expect high quality from a device for domestic use. Usually the golden rule is quality over function.

This hand tool is used for cutting thicker sheet metal, rolled sections, bars, pipes.

The hacksaw consists of a hacksaw blade fixed in a horizontal or slanted frame. The hacksaw can be bent to the length of the hacksaw blade (usually up to 25-30 cm), which is replaceable.

The lower part of the blade has 60-degree tapered teeth that are bifurcated for easy metal work. There is a tooth setting and a blade setting. In the first case, each tooth is bent in turn; in the second case, every two or three teeth are bent.

Depending on the metal to be worked with, it is necessary to choose hacksaws with a certain number of teeth. For example, to cut tool steel, you will need a blade that has 22 teeth per 2.5 cm in length. For different hardnesses of metal, hacksaw blades with teeth of different lengths may be used.

When replacing a hacksaw blade, the blade should be set with the tip of the teeth facing forward (in the direction of the handle), adjusting its tension. Tension can be checked by taking the blade with two fingers and turning it 1/8 of a circle.

When working with any cutting tool it is necessary to observe the rules of use and safety precautions.

Professional methods of metal cutting

We listed them above, the most popular solution at the moment is plasma cutting. But factories still use manual equipment that allows a minimum amount of work to be done quickly and efficiently. In the article, we told you how and what you can cut thick or thin metal at home and in the shops. To summarize, let’s look at a few

Contact the managers at; (473) 239-65-79 to clarify the information you are interested in;. They will answer all your questions.

Professional metal cutting methods

We listed them above, the most popular at the moment is plasma cutting. But factories still use manual equipment, which allows you to quickly and efficiently do the minimum amount of work.

In this article we told you how and with what you can cut thick or thin metal at home and in the shops. To summarize, let’s look at a few

To clarify the information you are interested, contact the managers by phone; (473) 239-65-79;. They will answer all your questions.

Oxygen cutting of thick metal

Oxygen cutting thick metal is often mechanized through portable equipment, gas cutting machines. It is necessary to understand that during such processing acetylene is used, as well as a number of other combustible gases: natural, petroleum, hydrogen, in addition, such fuels as kerosene, gasoline are used.

In terms of its qualities, performance, this cutting technology is superior to most others, so it is often used in industries.