How can you cut the metal manually. Oxygen cutting of metal

How to cut metal: select a hand tool

When conducting some types of construction and finishing work, it may be necessary to cut the metal (sheet, profile, etc.P.) at home to obtain products of the necessary sizes and shapes. In this article, we will consider the most affordable and popular manual tool that should be in the arsenal of any owner for this kind of work.

Such a tool can cut most sheet metals with a thickness of 0.7-1.0 mm, aluminum-up to 2.5 mm. The design of the scissors consists of two cutting knives fixed at a certain angle and two handles. For ease of use (reducing efforts during cutting), the mounting angle is from 7 to 12 degrees. Cutting knives have the shape of a wedge with an angle of pointing from 65 to 80 degrees. The smallest angle allows you to work with the softest metals, the largest is designed to cut solid metals.

Scissors for metal can be the following types:

• Scissors for direct cut can be used in order to cut the metal in a straight line or cut a circle of large diameter.
• To cut a small part along the contour, make a curved part or make a hole in a metal sheet with scissors with curved blades.
• Finger scissors have narrow thin blades and are usually used for the same purposes as curvilinear. Scissors can be right or left cut. It depends on the location of the upper blade in relation to the lower.
• Chairing (roofing) scissors are used when working with sheet metal slightly larger thickness (up to 2-3 mm.). A distinctive feature of such scissors is the design of the handles, the lower of which has a bend at the end. With this end, the stool scissors can be attached to the workbench and, pressing the handle with the whole hand, increase the power of cutting.
• Power scissors (scissors n.BUT.Vasilieva). In these scissors, one handle consists of two levers interconnected by a hinge. A special scissors design allows cutting sheet metal up to 2.5 mm thick. Another feature of power scissors is interchangeable knives and the presence of disks for cutting metal rods with a diameter of up to 8 mm.
• Lever manual scissors are motionlessly fixed on the workbench with the base, in the case of which there is one knife blade. Control of the second (mobile) knife is carried out using the handle. Lever scissors are used for cutting soft sheet metal (for example, brass) up to 6 mm thick and steel sheet. up to 4 mm.

Hand hacksaw for metal

This hand tool is used to cut thicker sheet metal, profile rolling, rod, pipes.

The hacksaw consists of a hacksaw sheet fixed in a horizontal or inclined frame. The hacksaw can be extended to the length of the hacksaw fabric (usually up to 25-30 cm), which is a change.

The lower part of the canvas is pointed at an angle of 60 degrees of teeth, which is diluted for ease of work with metal. There is a wiring on the tooth and wiring on the canvas. In the first case, each tooth is bent alternately, in the second case-every two or three teeth.

Depending on the metal with which you have to work, it is necessary to choose hacksaws with a certain number of teeth. For example, to cut the instrumental steel, a canvas is required, which has 22 teeth by 2.5 cm long. For metal of various hardness, a hacksaw canvas with teeth of different lengths can be used.

When replacing the hacksaw cloth, it is necessary to install the canvas with the point of teeth forward (in the direction from the handle), adjusting its tension. The tension can be checked by taking the canvas with two fingers and turning it on 1/8 circle.

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

Metal sheets cutting tools

Initially, when choosing tools, you need to decide on the tasks. Not only the amount of work is important, but also the time frame, the accuracy of the cut and the possibility of damage to the protective coating. At a construction site, they often use electrician. At the same time, you should not expect a very flat edge. The advantage of such a device is the speed of work.

How to cut off a sheet of metal evenly? At home, the problem is solved quite simply. using metal scissors. But this method requires a lot of time and physical strength. Scissors are not suitable if you need to cut long stripes. The most even cut can be obtained using slotted scissors. Such a tool is quite expensive and it is usually used by professionals.

Equipment for cutting a profiled and galvanized sheet:

Possible methods of cutting rails

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

Each method is complicated in its own way, but the expected result (cut into parts of the rail) will be obtained. Now. in detail about each methodology.

Cutting with a sewing needle

The method was popular in the last century, when there were no more convenient devices for cutting metal rails. At the same time, the product was not sawed, but broke.

• The rails are installed on two supports with the base down;
• A thick sewing needle perpendicular to the product is placed in the expected place of the break;
• A strong and accurate blow to the place of fit of the needle is made with a sledgehammer, as a result of which the rail is cut in half.
• Experience is necessary. it is not easy to hit the right place for sure;
• a fishing line for a cutting trimmer (cut) sometimes turns out a curve;
• It is necessary to deliver only one exact blow; With several unsuccessful attempts, the integrity of the canvas will be violated.

Use of the chisel

Here, a metal blank is also divided not through cutting, but a blow.

• set the rail, as in the paragraph above;
• around the entire perimeter, with a chisel and a hammer (kiyanka), notches of a small depth (1-2 mm) are performed;
• At the place of notches with a sledgehammer, a blow is carried out, the rail is split.

The advantages and disadvantages of the methodology repeat the above, only time takes a little more.

Rail cutting with a hacksaw

A popular way, although energy consumption. It is important to know several requirements for the sawing canvas:

• The handle is comfortable, located not horizontally, but vertically, a little with an inclination towards the course of “from yourself”;
• There is spraying on the cloves of the canvas;
• The teeth are located in the direction of “from themselves”;
• When working, move the canvas so that the area of ​​contact of the teeth with the cutting surface is maximum;
• select the canvas based on 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 an accurate cut is required, it is worth using a chisel to make notches on the basis of;
• Sprink the base on both sides to the neck of the rail;
• Put the focusing under the place;
• make a point blow with a sledgehammer.

How can you cut the metal: processing steel by disk and saber saws

The name comes from visual similarity to the saber. The cutting part protrudes from the body to a distance of up to 40 cm (such sizes are used only in industrial industries). The device resembles an electric jigsaw. Movements-progressive-reflective, which provides a good even cut. For use requires access to the network and dexterity. It is difficult enough to use a saber’s saw.

Disk is much easier in circulation, but it will not give such a deep cut. But the cut is narrow and clean, and the chips are the minimum amount. You need to carefully monitor the degree of sharpening of the teeth. It is best to choose alloyed alloys of increased hardness from the manufacturing material.

Corner grinder and ribbon.sawing machine

A locksmith, a person who cuts metal uses a corner grinder only for small and medium details. It is much easier to perform small tasks by the machine. to make a shallow incision, remove surplus, etc. Cutting a metal sheet is much more comfortable using a strip saw. In this case, the workpiece is placed on the bed, and then moves exactly along the runners to prevent the wrong cut or deformation. In this case, the ideal edge is obtained, which does not need further grinding.

Earlier we talked about the mechanical impact provided, but with all the positive aspects the process can be noted of the low performance of such works. Now we will discuss options that instantly heat the desired zone to the melting point with the subsequent evaporation of substances. Typically, technologists are used exclusively in large industries, since they are quite costly.

Gas cutting

The procedure happens like this. Abrasive is what you can cut metal. They are covered with abrasive discs. But modern methods help supply air or other gas with such pressure that the sand particles contained in it produce an even section. At the same time, oxygen passes through the burner and heats up to such temperatures in order to overcome the threshold of plastic steel deformation.

Gas.electric technology

An electric arc is lit in the machine, as during welding, which is aimed at a certain area. Nearby is a tube (nozzle), which leads a stream of oxygen to this place. The air accelerates to a very high speed and simply blews the molten metal substance.

Plasma cutting

This is the most modern and economical way from the above with the maximum degree of accuracy. The main element is ionized gas, which is subjected to multi.stage processing and turns into plasma. The stream is very accurate and quickly cuts. At the same time, it is so thin and even that the procedure is suitable for artistic patterns.

The disadvantages of plasma cutting

• a large amount of noise in the workshop;
• difficult equipment. not everyone can handle it correctly, the need for preparation;
• maximum workpiece thickness. 10 cm;
• high cost of the machine.

Now let’s talk briefly about the methods used in everyday life.

How to hold a corner grinder correctly

Many have a corner grinder, but most people do not know how to use it correctly and how to keep it. This leads not only to marriage in work, but also to severe injuries. Corner grinder is a rather dangerous power tool. The circle should be installed by the pattern up and clamped by a special nut.

A person with the leading right hand holds an angular grinding of the handle with his right hand. In this case, the circle should be located on the left side of the machine, and the protective casing should close it on top. The rotation is so that during cutting sparks fly to a worker. If the corner grinder jams the circle and the corner grinder will break out of the hands, then it will not go to the cutter, but in the opposite direction.

The left hand holds the car by the handle, which is wrapped in a threaded hole on the case. There are somewhat for special cases of use, but the right position of the handle is only the upper.

This position of the machine requires the use of protective equipment. To protect the eyes and open part of the face, these are protective glasses, and even better. a protective mask. To protect the open parts of the body from sparks and small fragments during cutting, it is necessary to put on a suit made of dense material.

Hot metal cutting

Modern industrial production requires high.performance metalworking methods that allow you to produce the maximum possible number of preparations of a given quality in the minimum time. These requirements are met by hot types of metal cutting.

Gas acid cutting.

The principle of operation is based on the fact that in pure oxygen at a temperature above 1000 ° C, the metal melts and burns out. The cutting place is previously warmed up to the ignition temperature of the material. Acetylene is usually used as a warm.up gas. The thickness of the metal, its brand and the state of the surface of the workpiece are affected during the heating.

After the cutting place warms up, a stream of burning oxygen is supplied to the cutting nozzle. She cuts out the workpiece throughout the thickness, smoothly moving along the cut line. In the process of burning oxygen, oxides formed on the surface of the semi.finished product are also removed.

In order for the incision to get high.quality, it is important to observe the same distance between the cutter and the workpiece during processing. This is a difficult task when using a manual gas acid cutter. In the case of automation of the process, cutting occurs at high speed by oxygen of high pressure, as a result, the performance of the work and the quality of the cut significantly increase.

The uniqueness of the method lies in the possibility:

The disadvantages of gas acid cutting include:

• the impossibility of using non.ferrous metals (copper, aluminum), chromium.nickel and high.carbon steels;
• large cut width, the formation of oxides, influxes, low quality;
• the impossibility of processing curved surfaces;
• change in the physical properties of the material in the section of the section as a result of high.temperature effects.

Plasma cutting of metal.

The type of cutting using plasma is based on the principle of intensive melting of the metal along the cut line due to the thermal effects of the compressed electric arc and its subsequent evaporation. Under the influence of an electric arc, a fully or partially ionized gas, or plasma is formed. The temperature inside the gas.plated flow reaches 15,000 20,000 ° C, which allows you to significantly increase the productivity of the process compared to the gas acid harsh, as well as get rid of the shortcomings of the last.

Of all the listed types of metal cutting at present, due to its advantages, plasma processing is the best choice for modern metalworking industries:

• The plasma cut is high and does not leave the influx;
• allows you to cut on crooked lines;
• The change in the physical properties of the metal (overwhelming) is excluded due to the narrowly focused heating of the cutting section;
• It is possible to cut titanium, copper, cast iron, specialized steel brands without changing the tool;
• The equipment does not have a cylinder with explosive gas, respectively, does not require refueling and delivery of these containers;
• a special regime for compliance with fire safety measures is not required;
• There is no preparatory stage of cleaning, because high.temperature effect effectively removes extraneous impurities (in the form of rust, dirt, paints), the quality of the cut remains unchanged;
• Special additives for non.ferrous metals are not needed, cheap electricity and air are used, consumables. only nozzles and electrodes, therefore plasma cutting of metals is an economically profitable technological process.

Disadvantages of this type of metal cutting:

• Due to the effects of high temperatures, the properties of the edges of the workpiece change. They become more solid, part of the material is lost, so additional costs for processing the edge are needed. In any case, the quality of the edges after plasma cutting is much better than after a gas acid: there is no scale, the width of the zone with fiction flowers is five times less.

Laser cutting of metal.

This type refers to innovative technological processes. Its essence is in the intensive effect of a narrow laser beam on the metal, which has a stable frequency and wavelength. It can focus on a small area of ​​the surface using optics, controlled by a special computer program. Thanks to this technological solution, laser cutting has unsurpassed accuracy parameters.

The high energy density, characteristic of directed and narrowly concentrated laser radiation, allows you to heat and evaporate a strictly defined section of a metal blank.

Laser cutting occurs as follows:

When the laser beam is immersed into the metal, an increase in temperature occurs, as a result of which the material melts and boils. This process consumes a lot of energy, therefore, auxiliary gas is supplied to its economy, with the help of which plasma cutting occurs. Depending on the heat engineering properties of the workpiece material, auxiliary gases can be ordinary air, nitrogen, oxygen, inert gas.

Advantages of laser type of metal cutting:

• the most narrow cuts;
• lack of deformation when cutting thin sheets of steel and soft semi.finished products;
• the possibility of accurate cutting along complex contours;
• minimum number of bumps;
• small area of ​​thermal exposure;
• Universality of the method. approaches any alloys;
• Simple control of the laser cutting machine.

The only drawback of laser cutting is a small permissible metal thickness.

Criteria for choosing an industrial method of cutting sheet metal

Когда встает вопрос о необходимости на выходе иметь точные детали, вопрос об использовании механического способа резки даже не встает.

How to decide on the optimal cutting method for each specific case?

First of all, start from the thickness of the metal.

• Material up to 20 mm thick can be cut with laser method.
• The material up to 30 mm thick can be cut with a plasma or laser method.
• The material up to 65 mm thick can be cut with a plasma or hydro.carbrane method.
• It is better to cut the material thicker than 200 mm with a gas acid method.
• The material is 50 mm thicker than the gas acid or hydro.carbrane method.
• 30 mm thicker material can be cut by a hydro.carbrane, plasma or gas acid method.

Secondly, decide how accurate edges you need.

• Will you have enough quality that is achieved by plasma harsh? For most industries, this quality is enough.
• If the thermal effect that occurs with laser, gas acid or plasma cutting is unacceptable, then your option is hydro.carbraneic cutting.

Price or performance that is in priority?

• If productivity is very important to you, then hydro.carbonated cutting will not work for you.
• If you do not have any special budgets for investments and the cost of operating the machine should not be high, then you should look closely at gas acid cutting.
• If the appearance of scale on the bottom of the plate is unacceptable for you, then you can use hydro.carbrane or laser cutting.
• If the holes on the surfaces should be absolutely round with even edges, then your version is hydro.carbraise or laser cutting.
• If you can cut more than 4 burners, then it is better not to consider plasma and laser cutting, because the gas acid technology will be more productive. But take into account that working with several burners makes cutting more expensive. Therefore, your spending on machines at the initial stage will be higher than when using other technologies.

When cutting by the hydro.carbrane method, one pumping pump with several cutting nozzles is operating. It is important that the performance of the pump is enough to ensure the operation of several heads. Limiting laser cutting is only one cutting head, while fiber lasers can cut several heads at the same time.

It is also worth paying attention to such a factor as the ability to cut one part using several technologies at the same time. The best “friends” in the process of cutting hydro.carbon and gas.oxygen, hydro.carbraise and plasma technology. Laser and gas acid, laser and plasma technology became possible to combine thanks to the use of fiber lasers.

Why use several technologies in one process? On one contours you can cut slowly and accurately, and on others. quickly and cheaper. As a result, we receive expenses below with the necessary accuracy than in the case when the whole part needs high.precision processing.

It is not always easy to choose a cutting method, because sometimes the thickness of metals intersect in a particular method and the similar capabilities of some technologies. Therefore, those companies that cut various metals and are dealing with steel products, in most cases choose machines that support at least two cutting technologies. This makes it possible to try several methods, compare the resulting products and choose the right option for the final cutting.

Cutting with a gas cutter

Technology implies the impact on the material with directed stream of burning gas. Due to the low cost of equipment, it is precisely this technique that is of interest to those who are interested in than to cut metal at home or at small enterprises. There are practically no restrictions on the thickness of the processed blanks. However, there are significant shortcomings:

• Low cut quality, requiring additional processing of parts.
• A large heating zone contributing to the occurrence of deformations.
• Increased material consumption.
• The need for careful compliance with safety precautions. Only experts who have undergone appropriate training and know how to cut the metal with a gas cutter are lowered to work.

All this limits the application of the methodology.

Equipment for oxygen cutting

Since acetylene is often used to work, installations for acetylene welding are often taken as equipment for oxygen cutting. Instead of welding burners, gas cutters are used there. The most common option is the cutter of the injector type.

In their design, the cutters differ significantly from the burners. They have additional tubes through which cutting oxygen is supplied, and tips with small holes for a mixture of gases. The central hole is provided for the supply of cutting oxygen.

Figure 4. installation diagram for oxygen cutting

The principle of operation of the machine for oxygen cutting:

• The workpiece is located horizontally, the valves of the cutter are closed;
• oxygen valve opens, and then. a fan of combustible gas;
• The mixture is ignited and adjustable by power;
• the metal is heated by the area of ​​the cut;
• a valve opens with cutting oxygen that activates combustion when heated metal reaches;
• Oxides appear in the process, they are removed by a stream of oxygen;
• At the end of the work, first closed the valve of cutting oxygen, then combustible gas, at the end. the burner.

The main tool of the kit of oxygen cutting is the cutter. There are classifications of these elements:

• by the type of combustible gas (cutters for liquid combustible mixtures, acetylene, gas-replacement gas);
• degree of automation (manual, machine);
• purpose (special and universal);
• mixing of gases (non.index and injector);
• flame power (large, medium, small).

Tools and equipment for cold metal cutting methods

Next, consider which tool it is more convenient to cut a thin.leafy metal. Cold processing methods are based on physical exposure, the cutting area does not heat up.

This means that the master will have to make significant efforts to process the metal. The main advantage of such methods is their small cost. At the same time, the workpiece will be cut accurately and accurately, with even edges. The only drawback is to cut off part of the workpiece only in a straight line.

Metal is processed using the following tools:

Hand scissors

The difference between manual scissors and shlitsevs is that they do not have an electric motor. Also, the principle of action of manual scissors is not the same as that of guillotine. If you do not know how simple and quickly cut the metal yourself, choose manual scissors. Such a tool can always be bought in a specialized store, the cost of scissors is small.

Using manual scissors, you can cut off the strip, moving along the marked line. It is important that the cutting edges are sharp.

These models differ in design, as well as the effort to attach.

In addition to manual, there are slotted scissors, with their help you can cut metal in a limited space. Guillotine scissors will allow you to achieve the perfect result with a flat edge.

The best option is a hacksaw. Using such a saw, you can cut a metal profile into parts, make a figure blank.

• Sable. The principle of action is similar to an electrolobian. The main element is a shift canvas of 100-350 mm, it is fixed in the case and during operation makes reciprocating movements. The shift canvas should be narrow if the radius of the workpiece is small. Sable saws are powered by a centralized network or from the battery, this is the advantage and lack of this tool. The saber can be transferred, but a large amount of electricity is consumed when processing the metal, which entails cash expenses. Only an experienced master with a developed eye can use such a tool.
• Disk. It’s easy to work with them, so they are ideal if you are looking for an option than cutting metal. The cutting elements are made of solid alloy, so the life of the tool is unlimited. The main advantage. after work there will be a little chip, and the grooves will turn out narrow. When choosing a disk saw, remember that the universal model is with a wide circle. The disadvantage of such a tool is high cost, impressive size and weight.

It is recommended to choose models with a sliding frame. On such a saw, canvases of different diameters can be installed. It is best to buy hardened canvases, the hardness of which is 60–63 HRC. It is important that there are many universal teeth on the canvas: 16–18 per inch.

Angular grinding machines (angular grinder)

Every master has such an instrument. this is the so.called corner grinder with a disk. The main difference is the corner grinder. good performance, the minimum amount of scale. Angle grinding machines are used in order to clean the surfaces from roughnesses.

However, the corner grinder is universal: with their help it will be possible to cut metal without much effort, make squares, stripes, figured elements from leaf blanks. At the end of the work, you can polish the resulting workpiece with the same equipment.

The advantage of the corner grinder is that by installing a new disk, with teeth or abrasive, with the necessary roughness, you can perform a variety of operations. Even if the disk is erased, you can always purchase new. The service life of the corner grinder is large, the main thing is to be careful about the instrument, which is always useful in the household or in production.

Pipelines

Using this tool, metal is cut with a diameter of 0.25 to 4 inches. Thanks to the constructive features (the tool is made of three rollers), it is possible to achieve the desired result: the first two videos are motionlessly fixed on the device case, the third provides a screw clamp.

You can quickly process the metal with a pipeline without making efforts, while the cut will be even.

Kusachki

Kusachki should be used for cutting rods, small.diameter rods, wire, wires. The edges of the nippers are end or lateral, which affects the final result of cutting. If you need to cut thick reinforcement or a small fastener, bolt cutters are used. They have a two.leaf structure, so it is possible to create the desired load and cut the workpiece without applying excessive efforts.

When choosing a method of cutting metal of different thicknesses, remember that it is necessary not only to choose the right tool, but also to be able to use it.

Mechanical metal cutting methods

Mechanical methods of cutting metal on an industrial scale are used less and less. This method often arises the question: which machine for metal is better to choose, but usually for these purposes, tape, disk and guillotine machines are used for metal. The disadvantage of such equipment in its limited capabilities and a fairly high labor intensity of the process.

Metal cutting on the tape machine

This machine is a fixed cutting canvas with teeth on one side. Thanks to the work of the motor, continuous rotation of the tape occurs.

Guillotine equipment

The processed metallic material is fixed in a horizontal position and is subjected to a chopping impact of the refine machine.

Metal cutting with a disk machine

The essence of the action is similar to the operation of the strip machine. The difference is only in the possibility of rotating the metal blank by 360 degrees.

How to cut metal at home

Metal cutting at home is carried out using mechanical devices. They can include both industrial models of machine tools and improvised tools. The most commonly used devices for cutting metal at home can be attributed:

Hand scissors for cutting metal

Hand scissors allow you to cut metal up to 3 millimeters thick.

Different types for cutting

Manual saws, disk, end, tape and pendulum.

Corner grinder for cutting metal products

Corner grinder is quite popular and universal at home.

How to cut the metal manually

Metal cutting is one of the most common ways to process this durable, solid and elastic material. Without the use of complex equipment, using simple mechanical devices, you can get parts of the required shapes and sizes at home. Consider the main tools and the circle of tasks that with their help solve.

Manual cutting of the metal is performed with or without collapse. In the first case, hacksaws are used, in the second. scissors, pipelines, nippers. Based on the thickness, shape, as well as the size of the metal profile, they prefer one or another tool.

Hand scissors are used for cutting sheet steel with a thickness of 0.5 to 1.2 mm. They allow you to develop significant efforts thanks to their long handles and short blades that are hardened to high hardness (52. 60 HRC).

Distinguish left and right scissors. Lefts are called scissors in which the bevel of the cutting part of the lower blade is located on the left. It is convenient to cut metal in a straight line, as well as counterclockwise.

Hand scissors can be with straight or curved blades. The latter are used when cutting holes, details of complex shapes.

The edges of the scissors should be sharply sharpened and fit to each other with a small gap along the entire length. If the gap is small, this will lead to the rapid wear of the tool, if large. to the crushing of the metal.

Manual reinforced scissors have the same sizes as ordinary. However, they make great efforts to develop a system of two levers, sequentially connected to each other.

Lever scissors are used for cutting steel with a thickness of up to 4 mm and non.ferrous metal. up to 6 mm. They consist of two knives, one of which is motionlessly fixed on the bed, and the other is set in motion with a long handle. In addition to sheet steel, hand.handed lever scissors allow you to work with rod and profile metal.

Manual hacksaws consist of a frame and a hacksaw cloth. They are used to cut profile, sheet metal, clipping blanks. The scope of hacksaws is made whole or sliding, allowing the use of paintings of various lengths.

The hacksaw canvas is a narrow steel plate with teeth hardened to 60 ÷ 63 HRC. The thicker the cut part, the larger the teeth should be. Their number per unit length can be different. In a locksmith business for soft metals, hacksaw cloths are usually used, having 16-18 teeth per inch.

Pipelines are used for cutting metal pipes of various diameters. ¼. 4 inches. Compared to hacksaws, they are more productive.

Small diameter pipes are cut with three.rope pipelines. They have two videos (disk) fixed in the case on fixed axes. The third video in the cutting process is pressed to the pipe using a screw.

Kusachki are designed for cutting metal rods, wires, wires. Two types of this tool are distinguished by the location of the cutting edges: end and side nippers.

Bolt cutters are used to sniff thick wire, bolts, reinforcement. They allow us to develop significant cutting efforts due to their two.leaf structure.