Metal cutting 101

[Thumper68]

Since this question comes up at least once a month I figured that we should have a goto about all the different ways to sever metals.

I have lots of different machines in the shop to cut metals and each one has its strengths and weaknesses so I will list out what I think of each one here and hope that others will add their own thoughts.

Starting with the very basic tools will be best I think and work up to the more exotic.

Hack saw:
Pros:
Cheap
Portable
With practice and patience you can make a great cut

Cons:
Effort
Throat depth limited

Reciprocating saw:
Pros:
Affordable
Many different blades and sizes
Easy to use
Corded or Cordless

Cons:
Cut quality
hard to follow a line
poor blade life


Jig saw:
Pros:
Affordable
good for curves
many blade choices

Cons:
poor blade life
only good for thin materials

Angle grinder
Pros:
affordable
corded or cordless or air
use for cutting or grinding
wide range of consumables
great for hard materials

Cons:
sparks
dust
weak on soft materials
long cuts can be awkward


Porta band saw:
Pros:
Portable
corded or cordless
many blade choices
accurate

Cons:
Cost
throat depth

I have to admit that right now I do not have a portaband in the shop, the last one died and I have yet to replace it.

Abrasive saw (14")
Pros:
good for hard materials

Cons:
dust
sparks
consumable life
noise

Horizontal band saw:
Pros:
Accurate
affordable (used, off shore)
Quiet
can be left to complete cut
blade cost
large throat

Cons:
slow
large foot print


Vertical band saw:
Pros:
quiet
long blade life
good for curves


Cons:
cost
throat depth


Dry cut saw:
Pros:
Fast
good for all but hard materials
blade life

Cons:
Loud
lots of chips
cost

Plasma cutter:
Pros:
fast
cut any conductive material
accurate
consumable life

Cons:
Cost
need compressed air
messy
loud


Oxy fuel:
Pros:
portable
cut/heat/weld(with acetylene)


Cons:
Cost
heat affected zone
sparks
learning curve

 

[Ign]

I've found a use for virtually every tool under the sun to cut metal except the gimmicky dual cut saws (basically an angle grinder with two blades that spin opposing with carbide tipped teeth). Those things ****.

And whenever possible I prefer the smooth action of rotary (this could easily include bandsaws) to the violent back and forth of reciprocating. Reciprocating has its place but it's rarely my first choice.

You could also add sheetmetal tools like handheld shears (power or manual) and nibblers (air or electric as some of the 110V units are capable of impressive plate thickness).

 

[matt_i]

I'd like to suggest adding a cold saw (like Bewo, Scotchman, Kzoo, MEP, etc) and hydraulic machinery like the ironworker.

(There are mechanical ironworkers but these are scary machines....)

For sheetmetal there are throatless shears (like a Beverly) jump/stomp shears, hand shears, nibblers of many styles.

 

[AJ.]

You could add Tin Snips to your list, very useful metal cutting tools.

Cheers Andrew

 

[dadsEH]

So where is waterjet on yer list.?

 

[Seppala]

Hammer and chisel

 

[flushcut]

Air nibbler, shears, laser, punch press

 

[flushcut]

You forgot to mention the massive column of super-heated sparks coming off the plasma cutter.