What Do Metalworking Cutting Tools Do?

Whether you’re building your first Jeep or your tenth, you’ll need a reliable metal-cutting tool at some point. It is crucial to choose the appropriate equipment. Cutting a tomato with a chainsaw or eating soup with a butter knife are both examples of what might happen when you use the incorrect metal slicing gear.

We have collected a list of typical cutting tools and where we utilise them effectively to assist you in selecting the right tool for your Jeep chopping requirements. Although there is a wide variety of specialised metal cutting equipment on the market, we chose to focus on the tools that the typical garage fabricator would find most helpful and most often used.

How to Effectively Use Laser Cutting in Metal Sheet Fabrication?

Laser cutting is a manufacturing method that involves the use of laser technology to cut thin sheets of metal. We offer laser cutting services that are distinct from other metal fabrication firms in both application and design. Light Amplification by Stimulated Emission of Radiation is what the letters “laser” stand for, just so you know. Therefore, the following are the most important forms of laser cutting technologies that we have access to:

• Lasers that cut fibre optics and carbon dioxide

In terms of cutting methods, fibre lasers are now our go-to for your projects. In order to cut metal sheets according to your CAD plans, we run the CNC software.

After the metal is shaped, it will go through a finishing procedure to make sure it’s suitable for usage. Sharpening or polishing the metal with an abrasive will accomplish this goal, since it will smooth out any kinks or creases in the material. To guarantee that the metal is spotless before it is sent to the plant, it may also be swiftly washed or rinsed.

For this reason, sheet metal fabrication is crucial to the production of every metal part (from your laptop through to the paper clips holding your files together). To avoid wasting time and effort, you might have your materials fabricated by a professional fabricator instead. The greatest possible finish on your metal components will be achieved, and you’ll have more time to devote to making things. Check Out Sheet metal fabrication company

Cutting Tools for Metal Fabrication

Bandsaw

Similar to a circular saw, a bandsaw has an unending row of teeth that touch the material being cut. A band saw, in contrast to a circular saw, can make both deep and shallow cuts. Both vertical and horizontal bandsaws exist.

In a vertical bandsaw, the workpiece is held in place by a table and pushed towards a vertically rotating blade. The vertical bandsaw shines in its capacity to cut intricate forms by rotating the workpiece as it is pushed through the blade. (Just make sure your fingers aren’t in the way!)

In a horizontal bandsaw, the moving blade is pushed downward through the material by gravity. This saw is often used in metal machining facilities for making precise length cuts on billets, although it is less frequent in the fabrication industry. The machine may be left operating unattended, which is convenient, but it also takes up more area than a vertical bandsaw would.

Sheet Metal Snips

Normal packaging for sheet metal snips includes three of the tools. Both right- and left-handed snips, as well as a pair of straight snips, are included in each set. When it comes to your Jeep, we find that they are not worth the investment of time or money. These snips were made specifically for use on thin sheets of material used for ducting in an attic. They can only be used on the Jeep’s sheet metal body. They aren’t great at it, unfortunately. As a result, the edges they leave behind are generally rough and unpleasant. Another problem is that Jeeps often use sandwiched layers of sheet metal that are difficult to cut through with snips. There are places on a body panel where cutting is difficult due to the presence of hidden pockets that flex and edges that cannot be cut. If you aren’t making a hasty patch panel to hide a rust hole in the floor before winter, you may leave the tin snips in the toolbox.

Jig Saw

Although it was designed for wood cutting, a jigsaw may be used to make precise cuts in metal, even in the form of little circles. The jigsaw requires certain bi-metal blades, which must be loaded into the tool. It does a decent job of slicing through thin, flat sheets of metal like steel and aluminium to create the shapes you need. Taping the saw’s shoe with masking tape will prevent scratches. This aids, but does not completely eliminate, the possibility of the shoe damaging highly polished aluminium or delicately painted walls. We have discovered that the blades are often too flimsy for use in any on-Jeep bodywork or fender trimming. If you don’t have any other options, we suggest trying an alternative approach to cutting the fenders.

Cut Off Tool

If you need to make a clean cut or trim something precisely, a cutoff tool is the way to go. Because of their compact size and lightweight construction, they are ideal for usage with thin materials and in confined spaces.

Unfortunately, most of them need very large quantities of air in order to function. Regular use of a cutoff tool necessitates that the demand of the tool be met, which in turn necessitates that the compressor output and tank capacity be matched. Painted metal may be trimmed using a cutoff tool, but if the paint is flammable, you should take extra care.

When you need to get rid of tack welds or cut through some rusted bolts, this handy little tool is just what you need. Cutoff tools have also served us well as a makeshift mini-grinder while working in confined spaces.

Die Grinder

Using a rotary file on a die grinder may seem like a specialised task that calls for specialised equipment. When it comes to precise tasks like porting an engine, opening a pocket for a bolt head or tool clearance, or grinding out frame cracks so they can be welded, rotary files are your best bet. The metal shavings they leave behind are the sole trace of their presence.

Abrasive-using tools often leave behind dust and metal shavings after a cutting operation. A weld might get contaminated if dust is not removed beforehand. Use cutting oil or wax on the bit while dealing with aluminium to prevent metal from clogging the cutting blades.

Chop Saw

As its name suggests, a chop saw is used to cut things up. This basic and simple device is ideal for making quick work of rough cuts in tubing, bar stock, and steel plate up to around four to five inches wide. When the plate steel is standing on end, it can easily buzz through anything up to half an inch thick.

If you’re patient enough, you can use a chop saw to cut 3-inch 0.500-wall axle tubes. In addition to producing less-than-square cuts, this method is also notorious for creating a great deal of debris and sparks that fly all over the workshop. Outdoors, it’s a handy tool to have. Try to choose a chop saw with a motor that can provide at least 15 amps and a solid vice.

When using a chop saw, it’s convenient to have a vice that can be quickly removed. For less than ten dollars, you can get the standard 14-inch abrasive cutting wheel used in most chop saws. There are hundreds of cuts that can be made with a single wheel. Cages and bumpers often need tubing to be cut, and for this purpose, a chop saw is indispensable. Unless, of course, you can afford a cold saw, in which case you probably aren’t interested in reading this.

Torch

Any steel thickness is feasible when using an oxyacetylene torch. The correct tip and gas settings are all that’s needed. You may get a neat and tidy cut, or a sloppy and unattractive one. How well you can do so relies on the steadiness of your hand. Invest in cutting tips made specifically for the material you anticipate using most frequently.

Most Jeep tasks can be completed with the help of a set of three different sized tips (000, 00, and 0), which will allow you to cut through steel between 1/8 and 1/2 inches thick. Blow out welds on brackets with ease using a curved gouge tip. Most of us need to finish the process by grinding and smoothing the surface that was cut with a torch. With an oxyacetylene torch, you can also gas and braze weld, which is a huge plus.

You may use your torch to heat up and release jammed bolts or bend metal with the addition of a cheap rosebud tip. The use of a torch to cut thinner materials like sheet metal is not recommended.

Warping the metal is more vital than burning the paint. Torches are best used for cutting heavy materials like axle and frame brackets or steel plate. An oxyacetylene torch setup is bulky, but there are several various sizes of oxygen and acetylene tanks. It’s hard to see the point in installing one in a little garage if you don’t intend to use it very frequently.

Circular Saw Blades

An essential tool for every DIYer is the circular saw. In addition to being cheap, they are also exceedingly frequent. Most circular saws have the option to purchase abrasive wheels. It’s a nice concept in theory, but it doesn’t work very well when you try to cut straight lines in sheet metal. The best tool for slicing through tube stock and solid bars is a circular saw equipped with an abrasive wheel.

Aluminum may also be cut using special circular saw blades made of steel. Even though we haven’t tried it ourselves, we’ve also heard of folks successfully cutting aluminium with a plywood blade fitted backwards. In the end, there are more effective metal-cutting instruments available. The circular saw belongs in the woodshop where it belongs.

A round or rotary saw is far more productive. While this is in touch with the workpiece, it is cutting. Chop saws, so named because they are operated up and down in a chopping action, table saws (where the blade protrudes through the machine table), and mitre saws are all types of circular saws.

This fourth category includes saws that have been sliced to an angle, usually 45 degrees, for cutting mitre joints in section. The workpiece is secured in position horizontally and then chopped to size using a chop saw. Placing the material against a stop allows for uniform length cuts across several pieces. However, the blade’s radius must be greater than the thickness of the material being cut. The bandsaw is the most efficient tool for cutting through a thick steel billet.

Angle Grinder

There isn’t a more versatile and reasonably priced fabrication tool than a 4 1/2-inch angle grinder. This should be the first tool in your arsenal for fabricating, just after a drill. For cutting, grinding, and sanding, a wide variety of abrasive and sanding wheels is offered in a wide range of grits and thicknesses. Wheels with a thickness of 0.045 inches are optimal for cutting.

You can make short work of steel of almost any thickness. In the past, we have effortlessly sliced through steel brackets up to half an inch thick and U-bolts of even greater thickness. Cutting with a narrow cutting wheel on a 4 12-inch angle grinder takes a lot of arm power and hand control to avoid harming the disc.

This is more of a rough draught than anything else. After using an angle grinder to make a cut, there will be some finishing work to do, such as cleaning and smoothing. It’s possible for the tool to catch and spring off the workpiece. It will do harm to everything it comes into contact with if it gets away from you. Metal may become hot enough from the revolving cutting wheel to burn the paint. Because of these drawbacks, it is not an ideal tool for cutting painted body metal that must maintain a certain aesthetic.

In most cases, raw steel is the optimum material for use with the angle grinder. It’s perfect for slicing through corroded bolts and removing brackets from axles and frames. After the bracket has been eliminated, the area may be finished with a grinding or flap wheel. Use the 1/8-inch thick abrasive wheels to grind off the weld and remove the bracket.

The 1/4-inch-thick discs are best for vigourous surface grinding and shaping. The versatility of the angle grinder lies in its ability to grind or cut through metals of varying hardnesses. Not even the priciest saw blades are capable of that.

An angle grinder is the perfect tool for cutting Grade 8 bolts or tough steel. Angle grinders with a 7.5-amp motor, a good grip, and a smooth on/off switch are what you should be on the lookout for. A paddle-style switch is our top pick since it’s more secure and less taxing on the hands than other options.

An angle grinder is a kind of portable electric grinder. The electric or pneumatic motor is often housed in the body of the handle. When the shaft rotates, it transfers that motion via a right angle to the cutting wheel, which is placed perpendicular to the motor axis. (That’s probably where they got the “angle” from.)

Although there are many variations on the cutting wheel that may be attached to an angle grinder, they all serve the same purpose. Grit replaces the normally seen distinct teeth at the edges. Some are made entirely of grit, while others contain grit adhered to the perimeter of a steel carrier.

Each grit particle functions like a microscopic tooth, slicing away a tiny piece of material, while the actual cutting mechanism is identical to a saw. Of course, there are also important distinctions.

The first difference is the angle grinder’s substantially higher rotational speed (6,000 rpm or more) compared to that of a circular saw. Even while individual grit particles don’t do much in the way of material removal, when combined they may do a great deal in a short amount of time.

When the grit particles are ripped from the matrix that holds them together, the grinding wheel wears down. In contrast, a dull saw blade simply loses its cutting ability with time. Check out Austgens TOOL ROOM

Reciprocating Saw

If you treat the reciprocating saw like a demonstration instrument, you can’t go wrong. There’s no way to guarantee a straight cut, and it won’t create a clean one, even in sheet metal.

You may use this seemingly harmless cutting tool to split an automobile in two. Unless you only need to trim a reinforced region where numerous sheets of body metal are spot-welded together, you probably shouldn’t use it for precise cutting or bodywork due to its aggressive nature. There is a wide variety of blade lengths and tooth counts to choose from. Blades are easily bent or broken, so it’s important to have a stockpile on hand and use the right tool for the task.

In confined spaces, the lengthy stroke of a reciprocating saw might be a concern, so take care to avoid damaging any wires, gasoline or oil lines, or other solid objects with the tip of the blade. We find that the unrestrained power of a 120V corded reciprocating saw is superior than that of its battery-operated counterparts. Cordless devices, on the other hand, have several advantages in the field and the shop, especially if you have spare batteries.

If you’re on the market for a corded reciprocating saw, try to get one with a motor that puts out at least 9.5 amps. Generally speaking, the more volts a cordless model has, the more forceful it is while cutting. Also, we’d upgrade to a lithium-battery model for its less weight, greater runtime, and longer battery life.

Every tooth along a saw blade is precisely calibrated to remove a little piece of the substrate they’re cutting through. Metal removal rate and material characteristics are both affected by the tooth shape, making it a crucial factor. In a perfect world, you’d need to switch out your saw blades whenever you worked with a material other than wood, plastic, ceramic, or metal.

A blade with larger teeth may remove material more quickly, but it might be difficult to maintain control while cutting paper or other delicate materials. In order to keep at least three teeth in constant contact with the workpiece, a fine-toothed blade may be necessary.

One further thing to consider is kerf, or the breadth of the cut. Teeth that are larger have a greater thickness, allowing them to eat away at more food. A large-toothed saw may have a higher rate of cutting, but it wastes more material in the process. A slow blade with few teeth may be more economical, depending on the material being cut and the reason for doing so.

A hand saw’s blade should be the right length because of the reciprocating movement it uses. If it’s too short, your arm will be awkwardly stabby both ways. If it’s too lengthy, you won’t be able to comfortably utilise all of your teeth. Furthermore, it’s a fairly ineffective method.

Air Saw

An air saw is the best tool for cutting body metal and trimming fenders. Due to its compact size, low weight, and high manoeuvrability, it may be used with great precision. Slicing in a straight line requires practise, but it’s not impossible. However, air saws do need a fair amount of breathing space.

Match the air saw’s consumption with the compressor’s output to ensure its continued operation. Blades come in several shapes and sizes. In our experience, hacksaw blades have shown to be really effective. A hacksaw blade may be shortened by two to three inches and then inserted into an air saw. It’s far more cost-effective than purchasing new air saw blades.

About four or five air saw blades may be fashioned from a whole hacksaw blade. Cut carefully and use at least two layers of masking tape to safeguard a painted surface. To push the shoe away from the metal of the vehicle’s frame, you may invert the blade so that it cuts on the forwards stroke. After cutting, just running a file over the surface eliminates any sharpness.

An air saw will move much more slowly through thicker materials, such as sandwiched sheet metal that has been spot welded together, or through any material with a high wall thickness. Furthermore, the teeth on the blades wear out fast when cutting through thicker materials. The thicker pieces should be cut using a reciprocating saw or angle grinder, and then the job should be finished with an air saw.

Plasma Cutter

A plasma cutter is not as adaptable as a torch, but it is safer, cleaner, and produces less heat than oxyacetylene welding. The process is so fast that the material being cut doesn’t have time to absorb as much heat as it would during a torch cut. The prevention of warping in thinner materials is one possible benefit.

Compressor output should be matched to the plasma cutter’s need, as with any tool that requires compressed air. The majority of Jeep improvements may be finished using a plasma cutter that can cut steel up to 3/8 of an inch thick. Extremely robust and pricey plasma cutters are usually unnecessary. In many situations where an angle grinder or reciprocating saw would be more appropriate, a plasma cutter may serve the same purpose.

By angling the torch head away from the welds, you may remove and reuse axle and frame brackets without damaging the bracket or the base metal. Although there is a learning curve, this method is significantly less dangerous and more efficient than using a torch or a grinder. The rusty heads of bolts and rivets may be easily removed with compressed air, leaving you frustrated and unsatisfied by any other approach you may have tried in the past.

If you have a steady hand, you can cut out almost any form for use as a bumper, suspension, or axle brackets. After you’ve honed your talents, there won’t be much finishing work to do on the cuts. However, you still can’t use a plasma cutter on painted surfaces, despite the fact that it operates colder than a torch. It will look terrible and burn the paint. In contrast, if aesthetics aren’t a concern, a plasma cutter can cut through sheet metal for a car’s frame far more quickly than any other approach.

A plasma cutter can cut through steel, aluminium, copper, brass, and other electrically conductive metals with ease, but a gas torch can only cut through non-ferrous metals. The plasma cutter is the finest instrument to use if you need to remove several brackets from a sheet and then cut out new ones.

Cutting using the latest inverter-based plasma cutters is convenient because of their small size and portability.

Conclusion

The use of lasers to cut thin sheets of metal is known as laser cutting, and it is a common manufacturing technique. When it comes to laser cutting, we offer services that are unique in comparison to other companies in the metal fabrication industry, both in terms of their practicality and aesthetic appeal. Metal sheets are cut with fibre lasers and CNC software, following detailed CAD blueprints. The metal undergoes a finishing process after it has been shaped to ensure that it is fit for its intended purpose. The metal parts you’re working with will have the best possible finish, and you’ll have more time to actually make stuff.

Bandsaws are circular saws with an endless row of teeth that make contact with the material being cut. It’s possible to find both vertical and horizontal bandsaws, and it’s capable of both deep and shallow cuts. Despite their name, sheet metal snips aren’t the best tool for cutting the thin metal sheets used for ducting in an attic. In order to make accurate length cuts on billets, a jig saw is used instead of a vertical bandsaw, but it requires more space. Even though the jigsaw is a must-have for any do-it-toolbox, yourselfer’s cutting metal accurately calls for specialised bi-metal blades.

Cutting tube stock and solid bars is easiest with a circular saw, and steel circular saw blades can also be used to cut aluminium. There are better metal-cutting tools out there, though; for example, a round or rotary saw, chop saw, table saw, or mitre saw. To efficiently slice through a steel billet of substantial thickness, the bandsaw is the best tool available. A 4 1/2-inch angle grinder can be used for a variety of fabrication tasks, including cutting, grinding, and sanding, and it doesn’t break the bank. It’s great for cutting through corroded bolts and removing brackets from axles and frames, and it can handle steel of almost any thickness with ease.

Because of its sharp, angled blade, an angle grinder can grind or cut through a wide range of metals with ease. The best angle grinders have a 7.5-amp motor, a comfortable grip, and a straightforward on/off switch. A portable electric grinder with a cutting wheel mounted at right angles to the axis of the motor is known as an angle grinder. Although the teeth you’d expect to find on a saw are replaced by gritty material, the cutting mechanism is otherwise identical. The angle grinder differs from the circular saw in that it can rotate at a faster rate (6,000 rpm or more).

Because blades are so fragile, it’s important to always have a supply on hand and always use the appropriate tool for the job. When using a reciprocating saw in a confined space, take care not to nick any wires, gas or oil lines, or other solid objects with the blade’s tip. The advantages of cordless tools in the field and the workshop justify the purchase of a powerful motor (at least 9.5 amps) and a lithium-battery model (lighter, with more runtime and a longer battery life). Metal removal rate and material properties are both affected by the tooth shape. The blade’s length is important because of the reciprocating motion it employs, and so is the kerf, or the width of the cut.

Because of its portability, light weight, and ease of use, an air saw is the ideal tool for cutting body metal and trimming fenders. Keeping the air saw running smoothly necessitates balancing its air intake with the output of the compressor, which requires a sizable free area around the tool. To save money on air saw blades, you can shorten regular hacksaw blades by two or three inches and use them in your air saw instead. However, cutoff tools need a lot of air to work, so they’re best used on thin materials and in open areas. Using a cutoff tool is safe for cutting painted metal, but if the paint is flammable, extra precautions should be taken.

If you need to port an engine, open a pocket for a bolt head or tool clearance, or smooth out cracks in a frame, you’ll need to use a rotary file on a die grinder. A chop saw is a handy tool for making quick work of rough cuts in tubing, bar stock, and steel plate up to about four or five inches in width. By adjusting the torch’s tip and gas flow, it is possible to cut steel of varying thicknesses with a single tool. Get some cutting tips that are designed for the material you’ll be using the most. Cutting steel between 1/8 and 1/2 inches thick, blowing out welds on brackets, and gas and braze welding are just some of the many uses for a set of three different sized tips (000, 00, and 0).

Axle and frame brackets and steel plate are best cut with torches, while plasma cutting is preferable to oxyacetylene welding because it is safer, cleaner, and generates less heat. The compressor’s output must be adjusted to meet the requirements of the plasma cutter. A plasma cutter, which can slice through steel as thick as 3/8 of an inch, is all you need to complete the vast majority of Jeep upgrades. Compared to using a torch or a grinder, this approach is both safer and more effective. It can make precise cuts in almost any shape, making it ideal for fabricating bumpers, suspension components, and axle brackets, though it cannot be used on painted surfaces.

Unlike a gas torch, which can only cut through non-ferrous metals, it can cut through steel, aluminium, copper, brass, and other electrically conductive metals. Modern inverter-based plasma cutters are compact and easy to transport.

Content Summary

• Whether you’re building your first Jeep or your tenth, you’ll need a reliable metal-cutting tool at some point.
• It is crucial to choose the appropriate equipment.
• We have collected a list of typical cutting tools and where we utilise them effectively to assist you in selecting the right tool for your Jeep chopping requirements.
• Laser cutting is a manufacturing method that involves the use of laser technology to cut thin sheets of metal.
• A band saw, in contrast to a circular saw, can make both deep and shallow cuts.
• Normal packaging for sheet metal snips includes three of the tools.
• They can only be used on the Jeep’s sheet metal body.
• Although it was designed for wood cutting, a jigsaw may be used to make precise cuts in metal, even in the form of little circles.
• Taping the saw’s shoe with masking tape will prevent scratches.
• There isn’t a more versatile and reasonably priced fabrication tool than a 4 1/2-inch angle grinder.
• In most cases, raw steel is the optimum material for use with the angle grinder.
• An angle grinder is a kind of portable electric grinder.
• That’s probably where they got the “angle” from.)Although there are many variations on the cutting wheel that may be attached to an angle grinder, they all serve the same purpose.
• In contrast, a dull saw blade simply loses its cutting ability with time.
• Reciprocating SawIf you treat the reciprocating saw like a demonstration instrument, you can’t go wrong.
• If you’re on the market for a corded reciprocating saw, try to get one with a motor that puts out at least 9.5 amps.
• An air saw is the best tool for cutting body metal and trimming fenders.
• If you need to make a clean cut or trim something precisely, a cutoff tool is the way to go.
• Painted metal may be trimmed using a cutoff tool, but if the paint is flammable, you should take extra care.
• Using a rotary file on a die grinder may seem like a specialised task that calls for specialised equipment.
• As its name suggests, a chop saw is used to cut things up.
• When using a chop saw, it’s convenient to have a vice that can be quickly removed.
• The use of a torch to cut thinner materials like sheet metal is not recommended.
• A plasma cutter is not as adaptable as a torch, but it is safer, cleaner, and produces less heat than oxyacetylene welding.
• Compressor output should be matched to the plasma cutter’s need, as with any tool that requires compressed air.
• The majority of Jeep improvements may be finished using a plasma cutter that can cut steel up to 3/8 of an inch thick.
• However, you still can’t use a plasma cutter on painted surfaces, despite the fact that it operates colder than a torch.
• In contrast, if aesthetics aren’t a concern, a plasma cutter can cut through sheet metal for a car’s frame far more quickly than any other approach.
• The plasma cutter is the finest instrument to use if you need to remove several brackets from a sheet and then cut out new ones.

FAQs About Metal

What Tool Is Used for Cutting Metal?

Tin Snips. Like a pair of scissors, tin snips are an inexpensive handheld tool that cuts straight, or if the blade is curved, can cut curves and circles. Tin snips are ideal for cutting soft metals like aluminum and copper, and are especially useful for cutting sheet metal, gutters, metal roofing, and studs.

What Is Main Purpose of Metal Cutting?

Metal cutting tools have a primary purpose of removing leftover material from a manufactured piece of metal by using the process of shear deformation. There are mainly two types of metal cutting tools that are normally used; single point tools and multi-point tools.

How Do You Make Metal Easier to Cut?

An angle grinder fitted with an abrasive metal-cutting disc works well to cut all kinds of metal, including bolts, angle iron, rebar and even sheet metal. But the discs wear down quickly, cut slowly and shrink in diameter as you use them. Instead, we recommend using a diamond blade that’s rated to cut ferrous metal.

What Is the Process of Cutting?

Cutting is a technique where the operator moves a material (workpiece) such as metal and the tool in relation to each other in order to shape the workpiece into the desired form through shaving, drilling, etc.

What Is the Importance of Cutting Tools?

The basic function of a metal cutting tool is to remove extra material from work piece and help in producing better finished products.