What Is the Best Way to Cut Metal?

Each of the 116 metal components and their many variants has its own unique cutting requirements. This has led to the development of a wide variety of methods for cutting metal. Protective gear should be worn first and foremost while cutting metal profiles, since the resulting edges may be very sharp and quite unpleasant to remove. Wear protective equipment such as goggles, gloves, and overalls if you must cut.

There are several methods and a wide variety of equipment for cutting metal. Metals such as steel, iron, aluminium, copper, and brass see heavy use among do-it-yourselfers.

Cutting mild steel plate may be done in a number of methods, some of which are amenable to mechanisation. Some work well with the thinner plate, while others like the broader one. Some of them are quick while others are sluggish. Not all of them are equally priced. The truth is somewhere in between. This article provides a concise overview of the four most common approaches used by CNC shape cutting machines, discusses the advantages and disadvantages of each, and then offers some criteria that may be used to determine which approach is ideal for a given situation.

Steel may be found in many various shapes and gauges. The term “gauge” describes the thickness of steel. Thicker steel is associated with lower gauge numbers. Similar to sheet metal, thin steel may be cut using a wide range of equipment. When working with thicker steel, such as pipes, tubes, and plates, it may be necessary to employ power tools like saws and torches. Although saws and torches may be utilised, they are not practical unless you need to cut steel often or at a large volume. If you want clean cuts, wipe the surface off first. Get your dimensions right and then draw cut lines on the steel.

Are you looking for the perfect cutting tools to complete your art or craft project? Look no further than Australian General Engineering, we’re sure to have the product you need.

Oxy-Fuel Cutting

An early technique for cutting mild steel was with a flame, also known as an oxy-fuel torch. The supplies and tools required are minimal in cost, and many believe the process to be simple. Using an oxy-fuel torch, cutting through the thick plate is possible; the only limiting factor is the amount of oxygen available. The use of an oxy-fuel torch to cut through steel as thick as 48 inches is commonplace. Steel plates with a thickness of 12 inches or less are used for the vast majority of plate cutting and shaping jobs.

In the hands of an experienced welder, an oxy-fuel torch can produce a sharp, squared-off corner. Preheating flames have only slightly rounded the top edge, and the bottom shows very little slag. The properties of this surface make it ideal for a wide range of applications.

Oxy-fuel cutting works best with plates thicker than 1 inch, but it’s possible to use it with plates as thin as 1/4 inch with a lot of work. Maximum speed on 1-inch material is about 20 inches per minute. The ability to use multiple torches simultaneously is another advantage of oxy-fuel cutting.

Plasma Cutting

Plasma arc cutting is second only to oxy-fuel in terms of speed when cutting mild steel plate, but it has a lower quality of cut. That’s one of the challenges plasma has by design. In terms of edge quality, the optimal cutting thickness varies from about 1/4 inch to about 1.5 inches, depending on the cutting current. Increasing the plate’s thickness or width causes a decline in edge squareness, even if the plate’s smoothness and dross performance remain satisfactory.

When compared to an oxy-fuel torch, the cost of a plasma system is higher because it requires a power supply, water cooler (for systems above about 100 Amps), gas control, torch leads, interconnecting hoses & cables, and the torch itself. Due to their significantly higher output, plasma systems pay for themselves much more quickly than oxy-fuel ones do.

Plasma cutting allows for the use of multiple torches at once, but the high cost of doing so usually prevents this from happening. High-end manufacturers who need to cut multiple identical components for a production line are typically the ones who request multiple plasma systems on a single machine.

Laser Cutting

In terms of mild steel, the optimal thickness range for laser cutting is somewhere between a few gauges and about 1.25 inches. Reliable operation beyond the 1-inch limit depends on a number of factors being just right, including but not limited to the material (laser grade steel), gas purity, nozzle condition, and beam quality.

Since the laser method is similar to burning with a preheat flame except that it uses the high heat of a concentrated laser beam, it is not very fast. Therefore, the rate is constrained by the kinetics of the chemical reaction between iron and oxygen. However, laser technology allows for extreme accuracy. It can precisely cut tight shapes and tiny holes due to its narrow kerf width. The typical edge quality is extremely square, with very few serrations or lag lines and almost no dross.

Another plus of the laser method is its dependability. Long consumable life and superior machine automation make laser cutting suitable for many “lights out” processes. Just picture yourself setting up a 10-foot by 40-foot plate of 1/2-inch steel, pressing the “Start” button, and then heading home for the night. Upon waking up the following day, you may find hundreds of components already cut and waiting to be unloaded.

Due to the complexity of the beam delivery, CO2 lasers are not suited for use in multi-head cutting machines. But fibre lasers enable concurrent cutting with multiple heads.

Waterjet Cutting

Waterjet cutting, which results in a sharp, clean edge, is also useful for cutting mild steel. Considering that waterjet cutting typically produces smoother edges and no heat distortion during the cutting process, it may even outperform laser cutting in some circumstances. On top of that, the waterjet can slice through any thickness of material, which is not the case with laser or plasma cutters. The practical limit for waterjet cutting is between 6 and 8 inches in thickness due to the time required to cut through that thickness and the tendency of the water stream to diverge.

Waterjet cutting has some drawbacks, one of which is that it can be quite costly to maintain. The initial equipment investment is typically lower than with a laser but higher than with plasma due to the high cost of an intensifier pump. Waterjet cutting, however, is prohibitively expensive due to the cost of the garnet abrasive used in the process.

In waterjet cutting, multiple cutting heads can be used, each of which can be powered by a single intensifier pump. Each additional cutting head, however, necessitates either a more powerful pump or a more restricted opening.

Multiple Tools

How many torches would you need to cut the pieces? Two, four, or more? Therefore, if this is the case, oxy-fuel will eventually outpace plasma and laser. Cutting with multiple plasma torches is technically possible, but the high cost quickly makes it unfeasible. With a high-enough-flow-rate intensifier pump, waterjet can use multiple cutting nozzles at once. Fibre laser technology has made it possible to use multiple cutting heads at once, a feat that was previously impossible.

The Monkey Wrench

Another factor that adds complexity to any calculation is multi-process cutting, in which more than one of these cutting processes is used on the same component. Using a combination of either waterjet and plasma or waterjet and oxy-fuel is the most rational option. Improvements in fibre laser technology have made it possible to fuse lasers with plasma or oxy-fuel.

An advantage of multi-process cutting is that it allows you to use the slower, more precise method for some contours and the faster, less expensive method for others. Therefore, you can mass-produce components to the required accuracy without spending as much as you would if you had to use the high-precision method for each and every cut.

Cutting Thin-Gauge Steel and Sheet Metal

Compound Snips Cut Thin-Gauge Steel

Aviation snips and tin snips are both names that have been used to refer to compound snips. These shears function similarly to scissors, allowing you to cut through 24 gauge steel with the same ease as paper. When working with very thin metal, snips are the tool of choice for making clean, precise cuts quickly. The three distinct varieties of compound snips each have distinctively coloured handles for quick identification.

• Yellow-handled straight snips may be used to make precise straight cuts.
• Red-handled snips with a left-cutting blade let you make cuts in the opposite direction of the clock.
• If you’re looking for the ability to cut in a clockwise direction with green handles, you’ll want some right-cut snips.

Nibblers make longer cuts in thin-gauge steel

A pair of compound snips are ideal for quick, precise cuts, while a nibbler is the tool of choice for longer lengths. A nibbler is a small, portable instrument. They are low-priced and can perform precise cuts at fast speeds with little to no noise or distortion. When used for cutting, they do not produce any sparks. Nibblers can usually handle metal up to 14 gauge in thickness, however, this varies by manufacturer.

• Varieties that may be operated by hand, a drill, electricity, or air pressure are all available to consumers.
• After each pass, the nibbler punches a tiny hole in the metal. When you’re done, the floor will be covered with countless little crescent-shaped steel scraps.
• The sharp small edges may become stuck in the bottoms of shoes and cause injuries, therefore it’s important to clean them out as quickly as possible.

Rough Cuts with an Angle Grinder and Metal Cutoff Wheel

Inexpensive and versatile, an angle grinder may be used for a wide range of grinding and cutting applications. Its adaptability stems from the fact that it can accommodate a wide range of blades. A metal cutoff blade is the kind of blade required to sever steel. If you’re in a need, a cutoff blade may make quick work of cutting, but at the expense of pretty harsh results. Perfect precision is hard to achieve with this instrument.

• Put on safety goggles, ear muffs it’s noisy, and heavy duty work gloves before picking this machine up. Make sure there is nothing combustible around, since sparks will fly as the blade strikes the metal.
• Read the handbook thoroughly and use the appropriate blade for steel cutting.

If you are looking for the best metal laser cutting services, you can visit Austgen Metal Fabrication Melbourne and can get the best assortment of brands at an affordable price.

Hacksaw Simple, Shallow Cuts

A hacksaw can produce straight cuts in sheet metal, but its unusual design restricts its usefulness for other cutting tasks. You won’t have much control over the saw, it won’t be able to make deep cuts, and the cuts could be a little harsh. A hacksaw, however, is a handy tool to keep on hand for cutting steel in an emergency.

• Waxing the blade after each usage will prolong its useful life.
• Use a piece of masking tape on both the underside and the top of the sheet metal to facilitate a more precise and clean cut. You won’t have to worry about scratches happening.

While there’s certainly nothing wrong with a good, old-fashioned hacksaw, there are certainly better and quicker methods to cut metal. Learn how to use power tools safely and effectively to cut the most common metals used in home improvement projects, including their thicknesses.

Ditch the Abrasive Grinder Discs

Bolts, angle iron, rebar, and even sheet metal are easily cut with an angle grinder and abrasive metal-cutting disc. On the downside, the discs lose their cutting edge and diameter fast under heavy usage. A diamond blade designed for cutting ferrous metal is what you should be reaching for instead. These will outlast abrasive discs by a wide margin, cut more quickly and cleanly, and wear out considerably more slowly. Diamond blades designed for cutting ferrous metal may be purchased for between $13 and $40 at most home improvement shops, hardware stores, and on the internet.

Cut Metal with Your Circular Saw

Although a circular saw isn’t the first instrument that comes to mind when you think of metal cutting, when equipped with the proper blade, it makes for an excellent option. Tested by us, it sliced through rebar like a hot knife through butter. Cuts mild steel up to roughly 3/8 in. thick with a blade designed to cut ferrous metals. Don’t let it make you careless, however! Flaming metal fragments will scatter in all directions. Wear protective clothing, keep onlookers at a safe distance, and shield anything you don’t want covered in metal dust from the blast zone. Blades designed for cutting ferrous metals may be purchased in home improvement shops, hardware stores, and even online. Blades with steel teeth are affordable, whereas carbide teeth cost between $8 and $40. Blades with carbide teeth cost more but last far longer.

Cut Aluminum with Your Miter Saw

If the motor housing on your saw is open and might gather metal chips, tape a piece of cloth over the holes to protect the motor windings and bearings while you cut the aluminium. This will allow you to make clean cuts on aluminium rods, tubes, and angles. (Remove it before putting the saw back into normal usage, otherwise the engine might become too hot.) Reducing the risk of flying metal shards and making it simpler to keep the metal in place for cutting are both benefits of the depicted method of trapping the aluminium with a wood backer. When working with materials with a thin wall thickness, this piece of advice is invaluable. The blade catches on the metal and distorts it, rendering it useless, if there is no supporting board.

Find the best metal laser cutting in Melbourne for your specific task and get instant metal laser cutting data recommendations for your operations.

Tips for Cutting Metal Safely

Metal chips and fragments fly everywhere when it’s cut or ground. And some of them are fiery and piercing. Following these safety precautions while cutting metal can help reduce the risk of serious injuries, including cuts, burns, and even eye damage:

• Always read and follow the safety instructions on metal-cutting discs and blades.
• Put on some earplugs, a face shield (they cost between $8 and $30), and safety glasses.
• Wear long sleeves, trousers, and gloves to protect your skin.
• Don’t touch any newly cut metal until it’s cooled down.
• Avoid cutting your hands by handling metal without gloves.
• Before you start sawing, make sure the metal is firmly clamped.
• Do not let anybody near you while you are cutting metal unless they are also wearing protective gear for their ears and eyes.

There is a wide range of sheet metal thicknesses and strengths available. Sheet metal may be cut using a variety of tools, each optimised for a certain design and material. Use an electric saw for straight cuts, or experiment with tin snips, dremels, or metal nibblers for intricate patterns and curves. With the correct equipment, slicing through sheet metal is a task that can be accomplished in a single afternoon.

Conclusion

There are numerous approaches to metal cutting because different metal components and variants have different cutting requirements. Cutting metal profiles requires the use of safety equipment, and most plate cutting and shaping jobs use metal plates with a thickness of 12 inches or less. Cutting with oxyfuel produces a sharp, squared-off corner that is most effective with plates thicker than 1 inch, but can be used with plates as thin as 1/4 inch with considerable effort. When it comes to cutting speed, plasma arc is second only to oxy-fuel, but the quality of the cut is lower. The laser cutting process is slow because the chemical reaction between iron and oxygen has a slow kinetics, making it similar to burning with a preheat flame.

With its high precision and long consumable life, laser technology is well-suited for many “lights out” operations. In contrast to fibre lasers, which allow for simultaneous cutting with multiple heads, CO2 lasers are not well-suited for multi-head cutting machines. Cut components more efficiently by using the slower, more precise method for some contours and the faster, less expensive method for others with multi-process cutting. For quick, clean cuts, use compound snips, while nibblers are better for longer cuts in thin-gauge steel. There is a wide selection of power tools to choose from, such as hacksaws, angle grinders, and metal cutoff blades.

Before using any power tool, make sure you have on protective eyewear, ear plugs, and leather work gloves. Blade life can be extended by waxing it after each use, and masking tape applied to both sides of the metal before cutting can ensure a clean, precise edge. Cutting ferrous metal requires diamond blades or a circular saw, both of which are effective tools. There are many tools that can be used to cut sheet metal, such as electric saws, tin snips, dremels, and metal nibblers. Sheet metal can be cut through in a single afternoon if the right tools are used.

Content Summary

• Metal components and their variants have their own unique cutting requirements, leading to the development of a wide variety of methods for cutting metal.
• Protective gear should be worn when cutting metal profiles, such as goggles, gloves, and overalls.
• Metal plates with a thickness of 12 inches or less are used for the vast majority of plate cutting and shaping jobs.
• This article provides a concise overview of the four most common approaches used by CNC shape cutting machines, discusses the advantages and disadvantages of each, and offers some criteria that may be used to determine which approach is ideal for a given situation.
• Oxy-fuel cutting is a sharp, squared-off corner that is ideal for a wide range of applications.
• It works best with plates thicker than 1 inch, but it is possible to use it with plates as thin as 1/4 inch with a lot of work.
• Plasma arc cutting is second only to oxy-fuel in terms of speed, but it has a lower quality of cut.
• The optimal thickness range for laser cutting is somewhere between a few gauges and about 1.25 inches.
• Reliable operation beyond the 1-inch limit depends on a number of factors, including material, gas purity, nozzle condition, and beam quality.
• The laser method is similar to burning with a preheat flame, but is not very fast due to the kinetics of the chemical reaction between iron and oxygen.
• Laser technology allows for extreme accuracy and long consumable life, making it suitable for many “lights out” processes.
• CO2 lasers are not suited for multi-head cutting machines, but fibre lasers enable concurrent cutting with multiple heads.
• Waterjet cutting, which produces smoother edges and no heat distortion, can slice through any thickness of material, but is prohibitively expensive due to the cost of the garnet abrasive used in the process.
• Multi-process cutting is the most rational option for cutting components, as it allows you to use the slower, more precise method for some contours and the faster, less expensive method for others.
• Improvements in fibre laser technology have made it possible to fuse lasers with plasma or oxy-fuel, making it possible to mass-produce components to the required accuracy without spending as much as if you had to use the high-precision method for each and every cut.
• Compound snips are the tool of choice for making clean, precise cuts quickly, while nibblers make longer cuts in thin-gauge steel.
• Varieties of power tools are available to consumers, such as a hacksaw, angle grinder, and metal cutoff blade.
• A hacksaw can produce straight cuts in sheet metal, but its unusual design restricts its usefulness for other cutting tasks.
• An angle grinder can be used for a wide range of grinding and cutting applications, while a metal cutoff blade can make quick work of cutting, but at the expense of harsh results.
• Safety goggles, ear muffs, and heavy duty work gloves should be worn before picking up a power tool.
• Waxing the blade after each usage will prolong its useful life, and masking tape should be used on both the underside and the top of the sheet metal to facilitate a more precise and clean cut.
• An angle grinder and abrasive metal-cutting disc are great for cutting bolts, angle iron, rebar, and sheet metal, but they lose their cutting edge and diameter fast.
• Diamond blades are the best choice for ferrous metal, and can be purchased for between $13 and $40 at most home improvement shops, hardware stores, and on the internet.
• A circular saw is also an excellent option, and can cut mild steel up to 3/8 in.
• thick with a blade designed to cut ferrous metals.
• If the motor housing on your saw is open, tape a piece of cloth over the holes to protect the motor windings and bearings.
• Cutting metal safely involves following safety precautions such as reading and following the safety instructions on metal-cutting discs and blades, wearing earplugs, face shields, and safety glasses, wearing long sleeves, trousers, and gloves, avoiding cutting hands, and making sure the metal is firmly clamped.
• Sheet metal can be cut using a variety of tools, such as electric saws, tin snips, dremels, or metal nibblers.
• With the correct equipment, slicing through sheet metal is a task that can be accomplished in a single afternoon.

FAQs About Metal

What Is the Proper Way to Cut Metal?

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 Tool Is Used to Cut Metals?

Snips and shears are used for cutting metal. Various types of snips and shears are used for different metals and thicknesses.

Is It Safe to Cut Metal?

When cutting metal, you should be wearing gloves to protect your hands from the vibration and excess friction that can occur. You should also wear safety glasses to protect your eyes while providing clear visibility, and a face mask to guard against any stray fibers being blown around.

What Is the Best Tool for Cutting Steel?

An angle grinder or hand grinder is perhaps the most indispensable of all metal cutting tools.

How Do You Cut a Hole in Metal?

In general, it’s a good idea to drill through metal using as slow a speed as possible using a drill bit for metal. Hard metals like steel and larger drill bits require even slower speeds. With a small twist bit (1/16 in. to 3/16 in.), you can drill through most metals at 3,000 rpm.