Which disk is better to cut aluminum. Correct cut

Choose the correct cutting disk for metal for angular grinder

Cutting disk for metal: purpose, design, types and labeling. Features of the structure of the discs for aluminum. Choice criteria and calculation of the cost of a saw disk. Popular manufacturers and price review.

Corner grinder with a cutting disk for metal for a long time almost completely replaced a locksmith. This tool has no equal where, without high accuracy, it is necessary to quickly and carefully cut off excess reinforcement, divide the pipe into two parts or work out measured parts from the rental for further welding of volumetric structures. The main working tool for angular grinding when cutting metal is a thin disk made of abrasive mixture based on resins and reinforced with a fiberglass grid. Despite the very high cutting speeds, these products are much safer than monolithic grinders. Reinforcement does not allow large parts to be abandoned, and the destruction of the disk, as a rule, occurs only due to violation of the rules of operation and non-compliance with the cutting modes.

Types of cutting disks for metal

The technical characteristics of the cut.off circles (or otherwise discs) for metal work are regulated by GOST R 57978-2017, which provides for two types of this tool: flat (ISO 41) and with a drowned center (ISO 42). The same GOST set the dimensional rows and other normalized parameters for both types. Structurally cutting disk for metal is a structure of the sandwich type consisting of alternating layers of a reinforcing mesh and cutting composite, into which a metal sleeve is pressed (see see. rice. below).

Reinforcing mesh, as a rule, are made of fiberglass and, depending on the conditions of the use of the tool, can have different thicknesses and sizes of cells. The cutting composite consists of abrasive powder and ligament. For cutting metals as an abrasive, powders from various types of electrocorundum and silicon carbide are used, and bakelite resins usually serve as a bunch (although GOST also provides for the use of volcanoes).

The constructive and physical properties of the cutting discs depend on the type of processed metal. On this basis, international standards provide four types of tools: for work on structural steel, cast iron, stainless steel and non.ferrous metals. The latter have many options for hardness, fragility and viscosity, so manufacturers often indicate in their catalogs, for which particular type of metal a particular type of disk is intended. In addition, a cutting tool for manual and machine work is distinguished, in particular, metal disks designed for Bulgarians should contain the code “RD” in the marking.

In addition to reinforced abrasive circles on the ligaments of the resins, there are carbide disks for cutting metal on stationary pendulum and end saws. Such a tool is usually used in procurement workshops of metalworking enterprises, it has highly specialized use and refers to disc saws. Another type of cutting tool is diamond discs, but in accordance with GOST 32833-2014 they cannot be used for cutting metals. Sometimes the saw wheels used in woodworking on circular machines are also referred to. Outwardly, they are somewhat similar to cutting circles for wood processing. But in fact, such saw discs have a different purpose, and GOSTs are classified as “disc saws”.

Why is it dangerous to cut aluminum with a corner grinder

Cut aluminum is not only difficult, but also not safe! Especially when using high.power corner grinders. Due to the viscosity of aluminum, the disk will get stuck, and the tool will try to break out of the hands.

And this will not happen immediately, but only when the cut reaches a certain depth. And this may be a surprise to an inexperienced tool user. And indeed, with a disk linening in the metal, it will not be easy to cut.

A small story about how to cut an aluminum tank. And what came of it

One of my friends, once they fitted the work, it was necessary to cut the angular grinder of the aluminum tank. “Field business,” he thought to drink aluminum, there is nothing easier!

But his joy quickly disappeared when he got down to business.

The disk constantly stuck, stuck in this metal. Corner grinder strove to jump out of her hands. Sawing one torment, things went very slowly. Different abusive thoughts did not get out of my head. )))

So what to do? I took up the work, I would do it! So several hours of difficult work passed. The old man came to the rescue.

Seeing the torment, he began to try to give advice, but the tips sometimes accepted hard, especially when the nerves are already at the limit. After all, work, which seemed simple at first, was already pretty exhausted. Therefore, the first reaction to advice is the desire to send to hell.

Nevertheless, the advice was given and in the end, as his friend said, he followed him. What was his surprise when after that the matter went much more fun.

The choice of the necessary corner grinding

The light mass of the device simplifies the work, and the necessary parameters of the size allow you to perform work in hard.to.reach areas.

When buying, many people are afraid to purchase powerful devices, since, in their opinion, it is much harder to do work with them. But this is far from the case. In construction tools that have small power, can jam the disk. The device cannot withstand heavy loads. As soon as the load becomes smaller, the car will break out of your hands, the disk and corner grinder may be damaged, and it is also likely that you will get a serious injury.

For those people who just want to start working with a grinding device, it is necessary to buy a corner grinder, which should be suitable for a disk of 125 millimeters. The power of this construction tool should be approximately 1000 watts, and the spindle perform 10 thousand. rpm. These indicators are great for cutting a material such as iron.

The main thing is that the device should be convenient to use. The handle of this construction tool is desirable that it is made of rubber or other material. The material of the handle should be such that during work you do not feel vibration.

The handle should have special recesses that are intended for the fingers. Bulgarians have small power, such a handle is missing.

If you feel discomfort when working, you should look for a device for another model.

Than and how to cut aluminum products correctly

Such circles are similar to the topic, which are installed for cutting on circular pollen, while soft metals are processed due to attacks.

In order to choose the correct cutting circle for processing aluminum, it is important to look not only at the design of the product, but also its size and thickness. The quality and convenience of work depends on the correctness of the selection of a cutting circle.

It should be understood that not only the time of work, but also the quality of the material processed depends on the correct choice of the tool.

Aluminum products are used in various fields of industry and agricultural activity. From aluminum products, greenhouses, vineyards, supporting structures and much more are made. The correctly selected tool for work will provide convenience and comfort when processing and cutting aluminum.

Features of aluminum processing

Many questions from the townsfolk are raised by cutting soft metals. In particular, aluminum. To process such material, there is a wide variety of nozzles for sawing, which have different diameters. Also released and circles for grinding aluminum. Description of cutting circles for corner grinders must be started with their size. So, the external diameter of such products varies from 125 mm to 230 mm. The thickness of the cutting nozzles is in the range from 1 to 3.2 mm. As a rule, a larger disk diameter corresponds to a larger width. As for the circles of small diameter, their thickness can be any, depending on the purpose.

If we talk about aluminum, then for its processing, circles are used with a thickness of about 1 mm. This choice is explained by the alloying of this metal. During operation, the thick nozzle of aluminum becomes viscous from friction and begins to score an abrasive circle with its particles. In such a situation, the disk just stops cutting.

As for the configuration and coating of the cutting part, most often circles for aluminum have diamond fine spraying and cutting edge in the form of several sectors. In fact, this is a saw disk by concrete. It is for them that it is convenient for them to carry out work on cutting aluminum structures. For example, cut a profile. The diameter of such a disc is minimal, that is, 12.5 cm.

Circles of the maximum diameter of 23 cm are most often multifunctional and cut not only metals, but also concrete, plastic pipes and even a tree with nails.

I must say that only by appearance to understand the exact purpose of such a nozzle is almost impossible. Therefore, when buying, it is best to consult with the seller or study the characteristics indicated on the disk itself.

Aluminum processing options

Most often, a corner grinding is carried out, since this method is most acceptable for production and at home. It is important to know that the thick cutting sheet of aluminum will be problematic, because the circle is getting stuck in an aluminum product.

If it turns out to cut something, then only on condition that the cuts are done to a small depth. You can use a special cutting circle for soft metals. Such a circle you can cut copper and aluminum.

Than and how to cut aluminum products correctly

Such circles are similar to those that are installed for cutting on circular saws, while soft metals are processed due to attacks.

In order to choose the correct cutting circle for processing aluminum, it is important to look not only at the design of the product, but also its size and thickness. The quality and ease of work depends on the correct choice.

Today, a large selection of cutting circles for corner grinders is represented by customers in online stores, where in the product catalog you can choose exactly the product that suits you in terms of purpose and characteristics.

It should be understood that not only the working time, but also the quality of the processed material depends on the correct choice of the tool.

Aluminum products are used in various fields of industry and agricultural activity. From aluminum products, greenhouses, vineyards, supporting structures and much more are made. The correctly selected tool for work will provide convenience and comfort when processing and cutting aluminum.

Milling processing

The uniqueness of the method is that work is possible with complex surfaces, in t.h. With screw. Be sure to configure milling equipment precisely for work with aluminum, that is, choose the type of cutter and the frequency of its revolutions in accordance with the recommendations.

Modern CNC machines and the possibility of 3D design are not inferior to laser and plasma devices in terms of cutting accuracy. They are used when creating cast forms, volumetric products of their aluminum, complex structures. However, there is a lack of work with equipment-the risk of deformations and the appearance of defects on the surface due to high plasticity of the material is growing.

Using various saws

For cutting aluminum, tape and disk saws are suitable. The advantages of the first:

If the user regularly faces the need to cut aluminum, he can find a home.made installation version that is characterized by small dimensions.

The design of modern devices includes useful devices, including a rotating saw frame, a thread tension meter (tape), a variator for a smooth change of cutting speeds, a built.in system of cleaning a saw canvas. The quality of the equipment is comparable to laser and plasma, only the master will save a lot (with money, work and space).

Ribbon saws allow you to cut an aluminum profile with a diameter of up to 300 mm with an error of less than 0.5 mm. Therefore, they are used even at home.

The second type of saws used in aluminum cutting is disk. They are divided into front and cutting down, they may look like a floor or desktop, have one or two working heads. In devices of the middle price range there are clamps for fixing the workpiece at an angle. Active element. a disk with a diameter of up to 550 mm. should have diamond spraying on the teeth and indication that it is suitable for cutting aluminum.

Advantages of work with disc saws:

• Modern installations guarantee the security of the operator during operation;
• automatic cutting is possible;
• smooth supply of the cutting element;
• The presence of waste compartments.

Disk material. high.speed steel (with hSS marking). Some installations allow turning the workpiece to an angle up to 45 degrees for ease of work.

Aluminum profile cutting manual tools

All cutting technologies are divided into two groups:

• Using manual and compact electric tools.
• Using industrial equipment (consider in the corresponding section).

The first group includes cutting the profile using tools such as:

Let us dwell on the features of each method.

Kryazuvka for metal.

Not everyone has a end saw, often you have to use something less complicated. The category of simple tools includes a hacksaw for metal, it can be cut a thin aluminum profile and sheet aluminum. Work order: starting to cut from the ribs, we go to the back, we saw the side parts.

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Scissors for metal.

It is also a very simple tool, it is even easier for them to work than a hacksaw: you need to mark and cut the metal along it.

• cutting is not as slow as when using a hacksaw;
• The tool is cheap;
• An experienced master with good scissors can achieve a good result.
• On the ribs, the blanks are easy to leave the marking line and cutting will go crookedly, while you can also bend the workpiece or completely ruin it;
• To cut the aluminum profile exactly according to the marking, before starting work, you will have to care well on unnecessary scraps.

Electric.

It is necessary to use the canvas designed for metal. A wood saw can also cut an aluminum profile, but the result of the work will definitely not please. It is recommended to cut the back of the back first, then saw the side sides separately.

• It’s easier to work with an electric tool than manual;
• Excellent cut quality is achieved: no bevels or burrs;
• Cutting goes much faster;
• Correctly selected canvas can be used many times;
• This is the cheapest power tool in the group in question.

Angle.grinding machine.

Corner grinder is a tool capable of a lot. Perfectly cuts aluminum profile. Of course, for cutting, not grinders are used, but detachment circles. You need to choose a small thickness equipment to reduce metal losses. It is important not to forget about the protection of the eyes and skin from sparks.

• Fast cutting with excellent cut quality;
• Corner grinder is relatively inexpensive;
• minimum of the effort of the master;
• The equipment for cutting aluminum serves for a long time.
• possible burning of the workpiece;
• It is extremely difficult for an inexperienced master to make an even incision;
• To achieve high accuracy of cutting, the angular grinder is best fixed in a special rack, which is sold separately and is not always available in stores (if not, they can help a vice).

A circular saw.

Performs the same work as a manual saw, but in terms of power significantly surpasses it.

• cutting along, across and at an angle;
• the ability to start cutting the profile from any side;
• The saw gives a signal or automatically turns off when overheating (modern saws);
• The choice of speed mode is available.
• Disks for work on metal are durable;
• speed of work;
• maneuverability;
• Aluminum profile cutting is available at an angle of up to 45 degrees;
• at the cost of the circular saw is close to end saws for cutting aluminum.
• Powerful models drank bulky and heavy, which complicates the work;
• The purchase of a saw for cutting an aluminum profile is justified only with a large amount of work;
• .

Circular Saw.

As an example, consider the desktop sawing machine Yilmaz Ky 305. This is a machine for cutting an aluminum profile of a small section with non.weed walls. Can be used both in a small workshop and in production. In any case, the participation of the operator is required.

The machine is equipped with a mechanical press for fixing the workpiece. You can choose a fixed cutting angle (15 °, 22.5 °, 30 ° or 45 ° in both directions). You can also set any angle up to 45 ° (to the left).

• The machine cuts larger blanks than the circular saw (up to 130×65 mm);
• It works quickly and with high accuracy;
• Cutting at a given angle is possible;
• accessibility of equipment for cutting profile (300 mm disk).

In its design, it looks like the saws described above. It differs in that it is equipped not by all.metal, but by an abrasive saw disc. This is the best saw for cutting an aluminum profile in not very large (non.thought) quantity. It has the following features:

• cuts aluminum profile across, along, with a bevel;
• The design allows the operator to do without much physical effort, you only need to smoothly press the handle;
• The workpiece is firmly fixed in the clamps;
• Cutting long profiles is possible;
• There are models comparable in cost with similar disc saws, but their functionality is ahead.

Consider, for example, the characteristics of the Makita LF 1000 end saw. It gives a cut depth to 50 mm when cutting an aluminum profile at an angle of 45 ° and up to 68 mm when working at a right angle. The maximum width of the cut. up to 210 mm. The saw gives up to 2,700 revolutions per minute. Its power is 1,650 watts, mass. 32 kg. Spacious desktop.

So it makes sense to buy this end only if it is planned to use it constantly, otherwise this acquisition will not pay off.

Industrial cutting of aluminum profile

Plasmical equipment for cutting aluminum profile allows you to get the perfect quality of cutting. For processing aluminum, a plasma cutter should be chosen as plasma.forming gases of hydrogen, argon, or nitrogen. inactive gases.

Laser cutting of metal. Fry of metal powder painting metal welding work

Active gases (oxygen, air) are used for plasma cutting of ferrous metal.

Compressed air is also applicable for cutting aluminum blanks, but only if they are not thicker than 70 mm. The nitrogen-argon mixture for cutting aluminum is not suitable.

Cutting aluminum using pure nitrogen is quite acceptable if the workpiece is not thicker than 20 mm. To cut aluminum blanks, the thickness of which reaches 100 mm, a mixture of nitrogen with hydrogen will be required.

A mixture of an argon with hydrogen is optimal for working with aluminum, it is suitable for cutting aluminum blanks of significant thickness. over 100 mm. For the stability of the plasma arc, mixtures with M hydrogen are not higher than 20 % should be used.

Hydrobrazive equipment for cutting an aluminum profile allows you to get products with a high.quality cut and medium indicators of roughness of the edge.

Metal loss when using this technology is minimal. Hydroabrasive cutting is not accompanied by heating of the workpiece, it is a fire and explosion-proof.

Cutting occurs due to the exposure of a narrowly directed stream of water under high pressure. Abrasive grains are added to the water, the composition and value of which can be different depending on the parameters of the processed material and the conditions of work.

Hydroabrizative technology allows you to cut metal up to 300 mm thick. It is possible to cut a whole stack of thin sheets of metal at once.

With the help of hydro.carbrane cutting of an aluminum profile, you can get parts of a complex shape, cutting them out with high accuracy. So it is possible to qualitatively perform even such difficult operations as the formation of bevels, internal radii and even sharp corners.

Hydroabraseic cutting is safe for the environment, since during operation there is no formation of harmful chemicals and microparticles that clog air. For processing large quantities of the profile, a hydro.carbraise machine with numerical control (CNC) is used. The operator only looks after the equipment that independently cuts the aluminum profile in a given mode, according to the established program.

Guillotine is a blacksmith-press installation. There are three options for such attitudes: guillotics working in manual, mechanical and hydraulic regime.

Mechanical guillotine functions according to the principle of a kinematic chain, and hydraulic. using a working fluid.

Hand guillotines make it possible to easily cut thin aluminum sheets with a lever-spring mechanism.

Mechanical guillotics are connected to the power source.

This kind of device is used when when processing metals (including aluminum), high accuracy is not required, since cutting on mechanical guillotics allows deviations of 2 mm or more.

Only stationary hydraulic guillotines equipped with the rear ruler provide a very accurate incision.

As a result of replacing hydraulic guillotines engines more powerful and modern analogues, installations are created that can cut aluminum almost any thickness.

The properties of the duralumin

The most common durable aluminum.based alloy is duralumin D16 (from French. DUR. solid), which includes the following elements:

• The percentage of aluminum in duralley is 90–94 %.
• Copper is the main alloying element, the percentage reaches 3.8–4.9 %.
• In equal parts, approximately 0.5 %, iron and silicon are added to the composition, which is a prerequisite.
• The amount of zinc is not more than 2.5 %.
• Percentage magnesium. 1.8 %.

In addition to the listed elements, the composition contains approximately 1 % chromium, manganese and titanium.

Depending on the chemical composition and manufacturing method, the technical parameters of the duralumin may vary.

Duralum cutting has the following technological characteristics:

• Relatively low cost of work due to the simplicity of production. The lack of the need to use high temperature to heat the components contributes to a significant reduction in the process of cutting. In addition, work in ordinary modes contributes to a decrease in cost.
• Small proportion of material. This is due to that in the duralumin aluminum is the main component.
• The melting temperature of the duralumin, which is about 650 ° C, allows it to be used as the main structural material of aircraft parts, missiles, high.speed trains and other specialized equipment. It must be taken into account that in conventional aluminum the melting temperature is much lower, which is reflected in the main technological characteristics and the ability of the material to withstand deformations.
• The density of the alloy is 2.5 g/cm 3 (for example, the same steel parameter is 8 g/cm 3). This is what determines the low weight of duralumin parts. The density indicator can vary in the range from 2.5 to 2.8 g/cm 3.
• Duralumin has a fairly high static strength, which allows it to be resistant to short.term loads. This technical characteristic allows you to use it to make responsible parts. The tests conducted that it is very difficult to destroy such material.

But there is a drawback. weak resistance to the influence of high humidity. To protect products from corrosion, they are treated with a protective coating, which is reflected in an increase in the cost of the finished part.

D16 duralumin is widely used in various industries for the manufacture of parts. It shows excellent performance at temperatures up to 250 ° C. It should be noted that at a temperature of 80 ° C, corrosion is already beginning to manifest at the inter.qurystalline level.

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In recent years, duralumin in its pure form has practically not used. The reason here is not only in the high probability of corrosion, but also in the presence of other disadvantages that aluminum alloys have.

To increase operational characteristics in the modern industry, the following types of thermal improvements are used:

• Duralumin is subjected to hardening to increase the strength characteristics. This type of heat treatment is marked with the letter “T”.
• The technology of artificial aging is designated as “T1”.
• When using special varnishes or anodizing the part in the marking, the letter “A” is present.

Corrosion resistance can decrease not only due to fever, but also due to mechanical influences. Therefore, technologies for additional improvement of operational characteristics are given special attention.

Laser cutting of metal. Fry of metal powder painting metal welding work

One of the alloys with increased operational qualities is the brand of Durali VD95. To increase the technical characteristics of such material, a metal aging procedure is used.

method of cutting different types of duralumin rolling

The range of duraluminated stoves in accordance with GOST 17232-99 is from 11 to 200 mm, therefore, when processing, the methods of plasma and hydro-carbard cutting of duralumin are selected.

Such technologies allow you to provide smooth sections with minimal effects on the metal processing zone at high process speed. The property of the thermal conductivity of the duralumin when cutting massive blanks has a positive effect on the cooling of zones under thermal exposure.

The thickness of duralumin sheets is up to 10 mm, which allows you to cut one of the methods below:

• The usual cutting of thin.walled sheets is carried out by mechanical cutting.
• In serial production with increased requirements for the accuracy of surface processing or when processing products with complex contours, it is necessary to use plasma, laser or hydro.carbonated metal technologies.

Cooling the processing zone during thermal cutting of the duralumin avoids the melting or dealing of the part. The use of the protective gases environment prevents the interaction of chemically active aluminum at high temperature with the air.

The diameters of the round assortment of aluminum alloys according to GOST 21488-97 can be up to 300 mm. Such a parameter is the main one when choosing the method of cutting a round section. The cutting of the blanks is mainly mechanical methods. using disk saws, on tape equipment (including duralumin with large diameters).

Cutting duralumin rods.

Around (or rod) is a cylindrical workpiece having a section diameter from 3 to 100 mm. When choosing a cutting method, the main attention should be paid to the requirements for the quality of the surface. Before starting cutting, the bar is fixed along the entire length with the help of workers to eliminate the deformation of the cutting surface during processing.

Milling installation

It is important that this equipment is configured by the operator specifically for aluminum work. This is due to the softness and plasticity of the metal. It is also important to choose small speeds of the milling device (from 5,000 to 9000 per minute) and first drip kerosene to the cut area. The feed is smooth, neat, so as not to damage the cutter. Advantages and disadvantages are similar to plasma cutter and laser, but the quality of the processing of the part is slightly worse.

A circular saw

An analogue of a hand saw, but more powerful. It has the following capabilities:

• performs a longitudinal, transverse, inclined cut;
• can be sawed from any place of the workpiece (not only from the end);
• Modern devices prevent overheating, turning off in a timely manner or applying a signal to the operator;
• The user can choose the speed of work based on the thickness of the workpiece.
• The durability of the equipment is a disk for working on metal (better. in aluminum);
• speed of work;
• maneuverability;
• the ability to cut at an angle up to 45 degrees;
• The cost comparable to more suitable analogues (end saws for aluminum).
• As a rule, the equipment is bulky and weighs a lot than complicates the work;
• The price will seem high if the tool is bought for one.time work;
• ).

Circular Saw

For example, the Yilmaz Ky 305 desktop saw. This is a special device for cutting small metal profiles with a small wall thickness. The mechanical clamp fixes the workpiece, the cutting angle is set up to 45 degrees (in any direction), it is possible to choose a fixed angle (0, 15 degrees., 30 degrees and t.D.).

• allows you to cut larger blanks (up to 130×65 mm);
• compactness;
• the possibility of angular cutting;
• high speed and accuracy of work;
• Availability of equipment (300 mm saw).

End (pendulum) saw

Structurally resembles previously described, only the working body is not a whole metal, but an abrasive disk, as for an angular grinder. It is considered the best solution for cutting aluminum profiles at home for the following reasons:

• cut straight, along and under inclination;
• When working, the user only needs to lower the curtain (pendulum) to the workpiece, and without much effort;
• reliable fixation of the workpiece in the clamps;
• the ability to work with long aluminum profiles;
• there are models similar to disk price range, but more functional.

In confirmation of the latter approval, the Makita LF 1000 end saw was considered. Her characteristics:

The maximum depth of cut. 68 (at 90 degrees.) and 50 mm (at 45 degrees.);

Such a ending will cost the user 60 thousand, but subject to constant work. Otherwise, the investment will not pay off.

• If the cutting of an aluminum profile is carried out irregularly, a manual tool is enough. hacksaws, corner grinders and even scissors.
• With constant work, it makes sense to purchase a portable saw, preferably end, since it is multifunctional. Investments will pay off after 2-3 months.
• For the work of an enterprise engaged in serial production of metal profiles, plasma cutters or laser installations will be required.

Setting up machine fixing profile performance of profile cutting

In short, this is all you need to know about the cutting of aluminum profiles. If you have something to supplement, share knowledge in the discussion to this article.

Comparison of consumables of popular manufacturers

In addition to abrasive cutting circles for metal for Bulgarians, you can find similar products intended for another power tool on sale. These are cutting wheels with a diameter of 350 ÷ 400 mm for Husqvarna rail cuts and the like, as well as Ø32 mini-disks of the Dremel type for attachment to equipment with a cylindrical shank.

How to calculate the consumption of a cutting disk

The main disadvantage of this method is the problem of the unique parameters of cutting circles of the same type acquired by users in the modern market. Therefore, it is best for each batch of purchased discs to take its own standard, having carried out several of them test cutting on certain types of metal blanks (sheet, pipe, reinforcement, etc. P.). In this way, over time, you can accumulate a sufficient database, analyze patterns and develop your standards with correction factors.

Often there is a statement that with cuts on stone you can cut non.ferrous metals without problems. What do you think about this? Please share your opinion in the Комментарии и мнения владельцев.