How to cut metal in the field

How to cut the metal in field conditions

The device is 5 times faster to cut the same P65 than the machine considered earlier. Compactness, relative lightness, efficiency make it possible to use it for cutting products at home criteria. The only disadvantage of equipment. the highest ).

Using a chisel

• install the rail as in pt above;
• all around the perimeter with a chisel and a hammer (kiyanki) incisions are made small depth (1-2 mm);
• A blow is made with a sledgehammer at the notches and the rail is splintered.

Advantages and disadvantages of the method repeat the above, but it takes a little more time.

Possible ways of cutting rails

Despite the apparent complexity of the operation, to divide the iron element into small sections is not difficult. To do this, you can use one of the following devices:

Each method is complicated in its own way, but the expected result (a rail cut into pieces) will be obtained. Now. carefully about each method.

Cutting rail with a hacksaw

A popular method, although energy-consuming. It is fundamental to know a few requirements for the saw blade:

• The handle is comfortable, placed vertically rather than horizontally, with a slight tilt to the side of the stroke “away from you”;
• The teeth of the blade have a spray on them;
• the teeth are set in the direction from you;
• When working, move the blade so that the contact area of the teeth with the cutting surface is the largest;
• the blade is selected according to the density and hardness of the rail material.

How to cut a rail using a hacksaw? The sequence is as follows:

• the rail is placed on a horizontal surface;
• if you want a clean cut, it is worth using a chisel to make notches on the base;
• Saw through the base on both sides up to the neck of the rail;
• put a stop under the place of the notch;
• make a pointed blow with a sledgehammer.

There are other methods to cut the notched rail into two parts. For example, to throw it from a height if you have a manipulator-loader at hand.

• the method is not dangerous;
• sawing goes without excessive noise;
• the equipment for the work is cheap.
• the process can take more than an hour (depending on professionalism);
• Several saw blades will be needed (3-7 depending on their properties).

Cutting with a sewing needle

• the rail is placed by its edges on the two supports with the base downwards;
• on the expected place of the break is placed a thick sewing needle perpendicular to the product;
• use a hammer to hit the point where the needle touches the rail firmly and clearly, cutting it in half.
• rapidity;
• a minimum of tools at hand;
• low injury risk;
• the ability to do the job alone.
• you need experience. it is not easy to hit the right place precisely;
• line for trimmer cutting (cutting) from time to time comes out crooked;
• you only need to make one clear cut; several unsuccessful attempts will compromise the integrity of the blade.

Using an angle grinder

The work is done similarly. the base is sawed on both sides, then hit with a sledgehammer. The operation takes 5-10 minutes.

• quickness;
• efficiency;
• minimum of consumables.
• danger of injury (disc can “bite” and cause breakage, flying sparks in the eyes, etc.).д.);
• noise at work;
• highest silliness);
• The method is bad for home criteria because of the resulting dust, dirt, iron chips.

Basic types of metal cutting

There are the following types of cutting metal:

Cold (mechanical). Cutting is performed by mechanical action on the metal with a special cutting tool made of a material with a hardness much greater than the hardness of the processed product. The following tools are used:

Hot (thermal). The workpiece being cut is melted along the cut line, and the metal residue is removed by gas. The hot type of metal cutting is subdivided into the following types of cutting:

But not all types of metal cutting. both cold and hot. allow you to get a product of a given purity. Let’s dwell in more detail on each of the above methods.

Cold types of metal cutting

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

Cutting with a guillotine.

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

Currently, the following types of guillotines are used for cutting metal:

They do not differ from each other in the principle of operation, but the last three types are supplemented by electronics, ensuring accurate and safe cutting. There are also machines that can cut metal not only across, but also along. Most often the guillotine type of machining is used in blank work.

The disadvantages of this method:

• Can not be used for all types of metals and has limitations on the thickness of the workpiece. For example, hydraulic bandsaws are designed for metal thicknesses up to 6 mm.
• The resulting cut workpieces often do not match the desired size, as the accuracy of machining depends on the skill of the operator.
• It is not possible to carry out shape cutting.
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Bandsaw Cutting.

Nowadays this type of metal cutting is very popular due to low cost of the 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 built into a particular production line for the trimmer. The cutting speed of such a machine is on average about 100 mm/min and higher.

The way of cutting on LPS allows to achieve exact compliance with the specified parameters, and the place of the cut does not need additional processing. The method is good for high-precision products and parts with a smooth surface. LPS is suitable for any metal, and the width of the cut is only 1.5 mm.

It is important to observe a number of conditions when this type of metal cutting:

• precise selection of the tooth pitch of the cutting blade according to the section of the profile to be sawn with the help of special tables;
• feed rate;
• cutting speed.

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

The disadvantages of this type of metal cutting include the inability to obtain shaped cuts and the limitation in the size of workpieces depending on the capabilities of the machine.

Metal cutting with a circular saw and “angle grinder.

Good quality and precise cuts are made with a 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.

You can use an angle grinder to cut rolled sheet metal. There is no dross or oxide residue on the cut, and little waste.

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

What can you cut metal with other than an angle grinder??

Attachments with a saw blade can be used to cut materials such as metal, natural stone, brick, concrete, etc. Gasoline edger can grind welds.

How to 4 Cut with an electric jigsaw with a metal saw.

The jigsaw can be used for cutting, including shape cutting, thin (up to one or two millimeters thick) metal sheets, as well as small cross-section angles, rods, pipes, etc.п.

Cutting speed is low, but it is accurate enough. When cutting more or less thick sheets of iron, it is recommended to lubricate the saw and the cutting surface itself with solidol.

Safety precautions when working with angle grinders

This question is the most important one. After all, if the rules of operation of the angle grinder are violated, you can get serious, sometimes incompatible with life injuries. Let’s consider the main ones that must be observed.

• Disc size. Many people believe that if a small angle grinder put a large disc, removing the protective cover, nothing terrible will happen. They say that a larger angle grinder is more powerful. This misconception is life-threatening. The fact is that the small angle grinder has a much higher speed, and therefore they need different discs. If a large blade is inserted, the master will most likely not even have time to start working. the blade will fly apart when switched on, which, in the absence of a protective cover, will lead to disastrous results.
• Direction of rotation. Some “craftsmen” don’t like sparks flying under their feet when working. They unfold the hood, move the handle, and start working. This is what most often causes the disk to fly off when caught on a sharp edge. The angle grinder must rotate the wheel on its own, not the other way around.
• Personal protective equipment. Use protective goggles or face shield, wear gloves, mask or respirator. It will save you from burns, eye injuries, which, unfortunately, are not uncommon during such work.

The use of personal protective equipment when working with an angle grinder is mandatory

Are cut-off saws used for cutting profiled sheet metal??

Yes, they are used. They have three major advantages:

• They cut metal faster than an electric jigsaw, and are comparable in speed to an angle grinder.
• They can be used to start cutting not from the edge, but in the middle of the sheet (the tool cuts a hole in the right place in the sheet).
• Do not deform the edges of corrugated sheet. A fishing line for a trimmer cut turns out to be straight.
• Cut profiled sheet of any wave height and any steel thickness.

The only disadvantage of the tool is a fairly high cost.

When to use?

For longitudinal and cross cutting of profiled sheeting, for straight and curved line cutting in hard-to-reach places (the tool has high maneuverability).

Attention: adjust tool before you start working. Cutting edge should be strictly perpendicular to the surface of corrugated board to avoid “jagged” edges on the sheet.

A lot of waste is formed in the process of cutting. a sharp metal chip. Do not forget to promptly remove it from the surface of profiled sheeting with a soft cloth.

Cutting with a gas cutter

The technology involves influencing the material with a directional jet of burning gas. Because of the low cost of equipment, this technique is of interest to those who are interested in what is the best way to cut metal at home or in small businesses. There are practically no restrictions on the thickness of the workpieces to be machined. However, there are significant disadvantages:

• Low quality of the cut, which requires additional processing of parts.
• Large heating zone that causes deformation.
• Increased material consumption.
• The necessity of strict adherence to safety precautions. Only specialists who have been properly trained and know how to cut metal with a gas cutter are allowed to work.

All this limits the application of the technique.

Processing disadvantages

Low carbon steel is best suited for flame cutting, but medium and high carbon steel are not suitable for cutting. High carbon content results in higher flash point and lower melting point. And this condition complicates the cutting process.

Cutting metal with a gas mixture is difficult if it has a low thermal conductivity. Therefore, these types of material are not suitable for machining.

Gas cutting of metal should be performed only by a qualified and experienced specialist. It is important to observe all key factors for proper processing: oxygen pressure and cutting speed. It is necessary to take into account the thickness of the product and the diameter of the nozzle of the torch. If the speed of oxidation and metal cutting do not match each other, you get poor quality processing.

Oxygen cutting involves the use of explosive substances. If the safety rules are not observed there is a high probability of an explosion of the gas-air mixture, it is necessary to monitor the condition of the gas equipment. Personal protective equipment is required for protection against burns.

Significant disadvantage is the possibility of metal deformation and poor cutting precision.

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Can metal be deformed??

Cutting with gas involves thermal influence on the material, and deformation changes are not always avoided as a result. The deformation consists of lengthening, shortening or bending the product. The cut part may be turned inward or outward.

There are factors that contribute to metal deformation:

It is necessary to eliminate the effect of these factors, otherwise you will have to correct the resulting defect. There are some simple methods that allow to return the workpiece to its correct shape: use baking or tempering, use steel straightening on rolls.

Deformation can be avoided by preheating the workpiece, watching the rate of flow of the gas mixture, and following proper cutting techniques. It is important to carry out all stages consistently, select the mode of cutting, based on the thickness and type of material. Do not start processing at high cutting speeds of the gas mixture.

If you do not have much experience, start with small workpieces rather than cutting from solid sheets.

Equipment

The main equipment for gas cutting is a torch. Includes welding and fusion nozzle.

The torch allows controlled dosing of the gas mixture and oxygen. Also with the help of this equipment combustible mixture is ignited, the flame is fed to the place of processing.

The torch consists of two units: a cutting unit and a heating unit. The first is represented by an oxygen outlet pipe, a valve and an internal nozzle.

Heating unit includes valves that are designed to regulate the pressure of the gas mixture and oxygen. There is also a feeding tube, an external view nozzle, a mixing chamber, and an injector cell.

Torches come in handheld and machine. The latter are stationary, so it is preferable to use hand tools for repair work.

Additionally, the following gas cutting equipment is used:

• The pressure reducer is designed to reduce the pressure;
• a device for changing pressure;
• A steel cylinder with gas and oxygen;
• connecting hoses.

Before use of the equipment it is important to check its condition in order to avoid explosion of a cylinder or a reducer. the torch is pre-flushed with oxygen.

Using an electric jigsaw

Here is a good way to cut metal at home, with high precision and without serious physical effort. With this device it is not difficult even to saw some shape, not to mention the fact that to separate a piece of pipe or angle. The only disadvantage is that it is a relatively slow process, although with the same hacksaw you will take longer and spend more effort. Well, and some power consumption is also implied, although the amount should not be serious.

This category includes processing on plasmatrons, the use of lasers, electroplating machines, multifunctional machines, and other specialized equipment. The bottom line is that you do not solve the problem yourself, and assign the company, for which it is a specialized service, and it makes the required number of parts in a specified time and is responsible for the quality, accuracy, cleanliness of the seams. The company sells bandsaws, to clarify the information you need, contact our managers by phone at the contact numbers listed on the page. They will answer all your questions So, you know what tools are used when cutting metal at home, what is better to cut. gas or plasma technology, and much more. We hope that now it will be easier for you to choose how to process workpieces.

What does the price of cutting sheet metal to order depend on

If in the course of work will be used a large amount of raw materials, the cost of the order can be reduced by reducing the value of the price of the calculated unit (kilogram, linear meter).

Today manufacturers use a variety of technologies for cutting sheet metal, but the main criteria for the customer are still the quality of work, production time, cost, as well as the availability of additional services for transportation.