Features of wire saws
There are many different saws that people use in their daily lives, and the wire saw is one option.
This product is lightweight, simple design and operation, but not everyone knows what a Jiggly saw is and how to use it.
How to work a two-handed saw and making a handy hacksaw with their own hands
To make a more powerful machine for cutting metal parts, you need to use a separate motor. In addition to this you need to prepare drawings of the device in the assembly, tools for making home-made cutting equipment, consumables. These include:
- Metal profiles, angles, plates to make a frame with a working table.
- Bearings, shaft, two pulleys.
- Electric drill, angle grinder, welder.
In addition, you will need fasteners, tooling on the power tool.
To assemble a quality machine with their own hands will be possible only by studying each of the key elements separately.
Engine
The power of the electric motor depends on how hard kind of metal will be processed, how often the homemade machine will be used. Optimal power range. from 1.5 to 3 kW. The number of revolutions should be no less than 2500 per minute. Do not forget about the required amperage. For the home handyman the best choice would be a 220 volt power supply. It is desirable to choose a motor with the possibility of changing the number of revolutions.
Separately we need to talk about the diameter of cutting discs. The optimal size of 300 to 400 mm. The bigger the blade, the more revolutions it needs for good cutting. However, any consumable specifies the maximum number of revolutions per minute that are allowed during cutting. Most often the maximum is at 4400 rpm.
Drive
To make the drive, you must use a belt drive. To make it, you need to find two pulleys, which will be equal in diameter. One pulley to fix on the shaft from the electric motor. The second is installed on the drive shaft of the abrasive disc. Further the equipment shaft is fixed on two bearings. The motor should be mounted to the back of the finished pendulum. Four bolts are used for this. The fasteners must be installed in the slots, which will allow the motor to be displaced, by 5 centimeters. This will make it possible to choose the optimal tension of the belt. With a sliding motor on a homemade machine, it is easier to change consumables, belts.
Console Pendulum
The arm is a key part of the equipment, the assembly of which determines the accuracy of cuts. For the base of the pendulum you’ll need two bushings, which need to be made from a metal square with dimensions 4×4 cm. Their height must not exceed 10 cm. It is necessary to make holes in the stands, which are necessary for fixing the shaft sleeve. Then the rocker arm is welded to it. To install the surface for fixing the electric motor. Lever for lowering the disk to the workpiece is calculated according to the person’s desire.
Work table
- Make a cut, through which the disk will pass while cutting metal workpieces.
- Sizes are chosen depending on the stroke of the pendulum, the diameter of the tool.
- It is also possible to construct a broaching mechanism.
- Set the side clamping, so you can clamp the workpiece during cutting.
The optimal thickness of sheet metal for the working table is about 4 mm.
Self-made working table
How to saw with a two-handed saw alone
It often happens that it is difficult to find a partner for sawing, so it becomes necessary to use the tool alone. It is impossible to do it without pre-machining the saw, so it remains to figure out how to make a two-handed hacksaw into a one-handed one, while maintaining the length of the blade. There is a way out, and it is quite simple. to turn a flexible hacksaw into a rigid archer saw. All you need is to make a frame.
- The first method of making the frame is that it is necessary to attach a bar or a small board with self-tapping screws to the existing handles from above. This completes the making of the long hand saw blade. The disadvantage of self-made is that the blade will vibrate, so if you want to get a more reliable tool, you should choose the second option
- The two-handed saw uses two handles made of wood, which are removable. In the cylindrical holes on the blade, you must install two elongated sticks, between which across to place a lath of the required length. In the upper part, parallel to the rail, a rope is stretched, which provides the tension of the blade. As a result, it is possible to work the device alone without a partner, adjusting the degree of tension
If it is planned to use the hacksaw for work on its own, the frame can be welded from metal pipes. Such construction will be more reliable and will last as long as the tool blade. The principle of conversion is simple and uncomplicated, so if you have a pile of thick logs, it’s time to saw them with a two-handed hacksaw alone.
This is interesting!You can buy a crosscut saw, as modern manufacturers continue to produce this type of device, allowing themselves to modernize it. Instead of primitive handles in the form of cylindrical bars, full-fledged handles are used, as on conventional hand saws.
How to make a pendulum saw for metal with your own hands?
Since metal is very strong, not every saw can cope with it.
The pendulum saw is popular because it does its job effectively, and it doesn’t matter if you bought it in a store or if it’s homemade. If the price of a suitable saw does not suit you, you can make the tool yourself.
To assemble the saw with their own hands is not difficult: in the article you will learn about its main functions and how to make it.
Mechanical saw for metal with their own hands: photo and description
To make a more powerful machine for cutting metal parts, you need to use a separate motor. In addition to this, you need to prepare drawings of the device in the assembly, tools for the manufacture of homemade cutting equipment, consumables. These include:
- Metal profiles, angles, plates to make a frame with a working table.
- Bearings, shaft, two pulleys.
- Electric drill, angle grinder, welding machine.
In addition, you will need fasteners, accessories for power tools.
To assemble a quality machine with your own hands will be possible only by studying each of the key elements separately.
Motor
Electric motor power depends on how hard the metal will be processed, how often the homemade machine will be used. Optimal power range. from 1.5 to 3 kW. Number of revolutions should be at least 2500 per minute. Do not forget about the required amperage. For the home workshop, the best option for connection will be a general network of 220 volts. It is desirable to choose the motor with the possibility of changing the number of revolutions.
We must separately talk about the diameter of the cutting discs. The optimal size is 300 to 400 mm. The larger the disk in size, the more revolutions it requires for quality processing. However, on any consumable, the maximum number of revolutions per minute that are allowed during cutting is indicated. Most often the maximum is at 4400 rpm.
Drive
To make the drive, a belt drive must be used. To make it, you need to find two pulleys that are equal in diameter. One pulley to fix on the shaft from the electric motor. The second one is mounted on the drive shaft of the abrasive disc. Next, the equipment shaft is mounted on two bearings. The motor must be mounted on the back of the finished pendulum. Four bolts are used for this purpose. The fasteners must be installed in slots, with which the motor can be displaced, by 5 centimeters. This allows you to choose the optimal tension of the belt. With a moving motor on a homemade machine is easier to change consumables, belts.
Console pendulum
Console is a key part of the equipment, the assembly of which determines the accuracy of cuts. For the base of the pendulum we need two bushings, which need to be made from a metal square with dimensions 4×4 cm. Their height should not exceed 10 cm. It is necessary to make holes in the columns, which are necessary for fixing the shaft sleeve. Then a rocker arm is welded to it. The surface for fixing the electric motor is established. Lever to lower the disc to the workpiece is calculated according to the wishes of the person.
Work table
- Make a cut, through which the disk will pass during the cutting of metal workpieces.
- The sizes are chosen depending on what stroke of the pendulum, the diameter of equipment.
- In addition, you can build a broach mechanism.
- Set up a side hold-down so you can clamp the workpieces while cutting.
The optimum thickness of sheet metal under the work table is about 4 mm.
Homemade work table
Homemade Mechanical Hacksaw For Metal With Your Own Hands
Metal cut-off saw with your own hands
How to make a cutting machine with a Bulgarian
Angle grinder or Bulgarian is used by professionals and amateurs. It polishes and buffs, cuts through almost any material. However, for accurate and precise cutting, you need a machine with a solid base. It turns out that turning a Bulgarian (USM) into a homemade metal cutting machine is not difficult.
Machine advantages
The main advantage of the tool is mobility. If you often work with an angle grinder, you will probably notice some inconvenience. The advantages of the Bulgarian turn into disadvantages:
- Sometimes it is impossible to rigidly fix the material to be machined, its vibrations disturb the cleanliness of cutting and can lead to the destruction of the disc;
- it is difficult to make a perfect perpendicular when cutting by hand, hold the material and match the size of the disc to the markings;
- It is difficult to cut many small identical pieces. After cutting, they must be brought back;
- your hands are always busy during work;
- The tool is considered one of the most dangerous.
For example, if the disk is stuck in the material, you can cancel the impact. Failure of the grinder, which is accompanied by a split cutter. Sharp blades can injure workers. This phenomenon is characteristic of the last centimeters of the cut. It is necessary to stop the bolt cutter, take out the disk and finish the work at the other end.
A simple cutting machine from Bulgaria makes the work safer and eliminates the listed inconveniences.
READ Hand held saw blade sharpening machine
Simple homemade machine for Bulgarian
It is not always possible to convert a ready-made metal lathe with your own hands to a Bulgarian lathe. After all, every craftsman has his own requirements. But in the process of change, craftsmen face many problems: it is impossible to overbuild with their own hands, there are no little things that are very important for the work or do not meet the specific requirements. For example, the spring is too soft or the ruler needs smaller divisions. Therefore, it is much easier to make the cutter from Bulger itself than to try to remake the finished one.
The simplest design, requiring no blueprints, assembles in a couple of hours. The off-the-shelf version of the chopper cutter is a metal frame (tube) that combines the function of the handle.
- Not reaching the end of the tube, cross-welded from the metal on which the USM will be mounted, a couple of holes are drilled for fixing.
- A small part of the angle is welded to this side of the tube and attached to the movable shaft. The angle is rigidly bolted to the floor of the workshop or workbench.
- A return spring is welded to the opposite end, which moves the movable part to its original position.
- The bolt is bolted to the rod.
Metal cutting machine with your hands
It is very common to see metal parts at different angles. Using the ESM does not always work.
Metal cutting machine
READ Shaped metal cutting at home
With such a device you can do your own homework. For more sophisticated craftsmen, a second version of the Bulgarian milling machine is available.
Precision work machine
To assemble this device with your own hands, you will need:
- metal conduit;
- shaft;
- Spring;
- bearings;
- Pedal and relay;
- metal angle;
- tube profile;
- Chipboard;
- electric drill;
- welding machine and working skills with all of the above.
Instead of welding, you can use screw fasteners; such a machine can be disassembled for transportation or storage.
The steps of making a cutter from Bulgarian.
- Choose suitable drawings, carefully study them. The drawing of the finished machine must be suitable for the specific model of Bulgarian (USM). Therefore, it is best to create your own, unique.
- The stand for the homemade machine is a common axis and two frames. The bottom is connected to the platform, which can be made of wood to lighten the construction or sheet metal. The heavy large Bulgarian is securely mounted on a platform of metal. Attachments are placed on the upper frame, it performs a rotational motion in the vertical plane like a pendulum in relation to the lower frame. A spring is provided as a probe at the starting point. Fasteners from movable clamp and pressure bracket are welded to the bottom frame.
- A handy and important detail of the homemade cutting machine is a ruler with millimeter divisions. It must be movable, welded to the pipe and provided with a stop. Precise marks are made with a ruler, the material is fixed and can be machined.
- To operate it more conveniently, manually set the starter pedal or toggle switch connected through the downshift relay.
READ How to make a snow blower out of a cultivator with your own hands
This model is easy to use, allows you to make accurate and clean cuts without any health hazards. The design does not use a vise, and measurements are made quickly, clearly. If necessary, the machine is dismantled, and the master gets a mobile angle grinder.
Safety rules when working with a homemade machine
It is important to follow safety rules during work.
- The guard of the machine should cover the area in which the worker is located;
- Many people want to do their own woodworking with their hands. But you need to know that the special gear wheel is not designed for such high speed and quickly worn out. In addition, it is very dangerous to work with saw blades. To work on the machine you need to use special cutters for angle grinders with an abrasive surface.
Before you start, you need to run the grinder for 60 seconds to check the rotation. There must not be any beating, strong vibration. The wheel should move freely without touching parts.
The original idea
In modern jigsaws, an eccentric mechanism turns the shaft through a gearbox to move the saw. The eccentric transmits reciprocating motion through the rod to the saw. Such a device for a drill with their own hands to make is not easy. The originality of the recommended drill bit idea is in the special arrangement of the bearing on the shaft.
An angled bearing drives the shaft in a pendulum motion as it rotates, through stops in the rod. The movement speed of the crank-rod with the metal cutting blade connected to it, directly depends on the rotation speed of the shaft.
The figure shows a schematic of the idea of the presented attachment to the drill.
It remains for this scheme to design a fixture, and makeshift nozzle on the electric screwdriver or drill will be ready.
Note! If there is no power supply. you can install it on a cordless electric screwdriver and even on a hand drill. In this case, the nozzle can be used when working with wood, if you use a wood blade.
Tools and materials required
Since there is no need to forge and harden the future blade, all tools can be found in the garage, which is equipped with at least a little. We will need:
- markers: black and silver;
- a ruler, a sheet of paper and a caliper;
- angle grinder (angle grinder);
- files with different grains;
- as well as sandpaper and masking tape;
- epoxy glue;
- A sharpening and drilling machine;
- a container of water for cooling;
- hammer, core and vice.
Drilling machine is, of course, cool, but an electric drill is also sufficient. And so with any of the tools on the list. You will need materials for making the handle, but about this a little further.
Methods of cutting metal. Hacksaw for metal manual. Mechanical hacksaw. Circular saw machine.
Unlike chopping, Another type of mechanical cutting is cutting by removing a portion of material. This process consists in the fact that the cutting tool and the material to be cut move one against the other and at this time the tool separates some of it from the material, turning it into a chip. Bands and discs with teeth are commonly used for cutting metal in this manner. Teeth are reciprocating cutters. The spacing (or pitch) between teeth depends on the width of the workpiece and the hardness of the metal. The wider the workpiece or the softer the metal, the greater the pitch.
Saws whose working part is a band include hand hacksaws, mechanical hacksaws, band saws. Saws with a disk-shaped cutter include circular saws and sliding or friction saws.
Metal hand saw.
A hacksaw for manual metal cutting is a thin steel band with cutting teeth along the rib. a hacksaw blade that is stretched between the ends of a staple machine 1. The tension of the blade in the machine is realized by the wing nut 4 by the sliding clamp 3 called sliding shackle. Hacksaw blade is the cutting element of the hacksaw. its working part. The worker, moving the hacksaw back and forth with his hands and lightly pressing the metal to be cut, cuts the metal.
There are two types of hacksaw machine: one-piece and sliding, of which the latter is more convenient, as it gives the opportunity to insert a blade of different lengths.
How to set a metal hacksaw blade?!
The hacksaw blade has holes in the ends for securing the hacksaw to the machine. The blade must be taut enough in the machine to prevent bending and breakage.
Metal hacksaw blade length.
The length of the bandsaw blades is from 150 to 400 mm in width of 10 to 25 mm and thickness from 0,6 to 1,25 mm with number of teeth from 10 to 32 pcs. per inch (25.4 mm)
How to Choose a Metal Hacksaw Blade?!
Hacksaw blade for work is selected depending on the size and shape of the product, as well as the hardness of the metal: the harder the metal is, the shallower and more frequent should be the teeth of the hacksaw blade. Thin products are cut with hacksaw blades with small and frequent teeth, and for cutting wide products blades with large teeth are used.
Hacksaw teeth.
High-carbon steel uses a blade with 18 teeth per 1 inch. When cutting mild steel, as well as brass and copper, choose a blade with 24 teeth per 1 inch. When cutting sheet metal, blades with a high number of teeth up to 32 per 1 inch are used
Cutting Metal with a Hacksaw.
Before starting work with a hacksaw you must mark the place of the cut by notching it with the edge of a three-edged file to prevent the saw blade from sliding on the metal surface. If the blade retracts while cutting to the side it is necessary to turn the workpiece 1/4 turn around its long axis and start cutting again, otherwise the blade may break. The teeth of the hacksaw blade are tilted to one side, so they cut only when the hacksaw moves forward. This must also be taken into account in order to save effort for the operator: only apply pressure on the hacksaw during the working movement, i.e. е. at the end of the cut, the pressure is released when the saw blade moves forward.
Pressure on the hacksaw should be equal. the force of the pressure on the hacksaw depends on the hardness of the metal of the article and its size: the pressure is lower for soft metals and articles of small size, and higher. for hard metals and big articles. At the end of the cut the pressure is reduced. Incorrect pressure on the hacksaw can cause breakage of teeth and blade.
Work with a hacksaw is performed without cooling, but to reduce friction of the blade on the walls of the kerf use lubricant of lard or graphite ointment.
The breakage of one tooth often leads to the breakage of other teeth adjacent to it. Therefore, in order for the hacksaw to work satisfactorily after a tooth breakage, it is necessary to grind two or three teeth next to the broken one on the grinder and remove the remains of the hacksaw tooth from the kerf. The new blade must be introduced into the kerf with care, with little pressure, since the new blade.is thicker than the old one and can break under great pressure.
Mechanical Hacksaw.
With the aim of increasing productivity and to replace manual labor, mechanical hacksaws are used for cutting The working cutting part, similarly to a hand hacksaw, is the hacksaw blade tensioned on the moving part of the machine. Pressure on the blade is created by a movable weight. The reciprocating motion of the blade is carried out by the crank mechanism driven by the electric motor. The feed is either manually or by means of a screw drive from an electric motor.
For band saws the blade is an endless band with teeth, stretched on two pulleys.
One of the pulleys is driven by an electric motor.
Saws with bands as a working part are not widely used in boiler construction because of their low output.
Circular saw machine.
Circular saw blades are used almost exclusively in boiler construction
frame; 2. slide; 3. head; 4. disc; 5. rotary table.
Material for circular saw blades is carbon and high-speed steel. For diameters up to 400. 500 mm the saw blades are produced from the whole plate with teeth cut along the circumference. To avoid jamming of the disk in the material to be cut the teeth are set apart.
In the case of large-sized saw blades, the teeth are made of quality steel and are inserted into the blades. The disc to which the teeth are attached is made of mild steel. Saws are sharpened on sharpening machines.
The disc is driven by an electric motor and the feed rate depending on the profile to be cut can be adjusted automatically by means of a screw drive from the electric motor or manually by means of a lever. Disc is cooled by emulsion during operation.
Machines are equipped with a clamping device to secure the material to be cut. Cutting on circular saws produces a clean cut that does not require further processing. The cutting operation is, however, very unproductive.
Friction saw (friction saw).
Friction or friction saws, as they are called, are much more productive. The blade of these saws is made of specially rolled mild steel. Drive is accomplished by an electric motor that drives the disc at a cutting speed of up to 6,500 m/min.
Machine table has a clamping fixture for securing material. The principle of friction saws is based on the fact that a disc rotating at high speed brings the material in contact with the cut material to its melting point. The heated particles are easily separated by the rotating disc and ejected to the outside.
Cutting metal on a friction saw (friction saw).
Water must be continuously directed at the friction zone during sawing. Water applied significantly reduces heat build-up in blade and material being cut. The cut is smooth and clean, but with overlaps along its edges. The build-up can easily be removed with a chisel. A zone of weak structural changes with a width of 1-2 mm is formed near the edge of the cut metal, which must be removed if critical designs are to be fabricated. band and circular saws are mostly used in construction of boiler structures for cutting profile material: angles, channels, I-beams, pipes, etc. д.