A metal cutting machine is useful for any workshop. It is required during construction work and in the metalwork shop. The market offers a wide variety of machines, but not all of them are affordable. For home workshops, the way out of this situation will be a homemade metal cutting machine. To manufacture it, you will need certain skills in working with a welding machine and plumbing tools. It will require a metal cutting unit from a master and the skills of an electrician.
Required tools and materials
In order for the future machine to reliably perform its functions, you will need a simple set of tools:
- drill;
- Bulgarian;
- taps;
- welding apparatus;
- spanners;
- dies.
An additional engine will be required. The optimal option is a 2 kW motor. It is recommended to purchase single-phase or three phase motors for such machines.
The necessary elements of the future unit are:
- sheet steel 3 mm thick;
- bearings 204;
- 2 pulleys;
- metal corner;
Any homemade mechanism need to be customized according to your requests and drawings. The master pays special attention to safety precautions. When working with cutting units, a particularly vulnerable part of the body is the hands, which can easily be damaged by neglecting simple rules work safety.
Disc cutting machines
In practice, craftsmen make machines of three types: belt, pendulum, disk. The first type is the most difficult to make in a home workshop. The best option It is considered a disk type metal cutting machine.
These units include:
- cutting disc;
- pendulum;
- Desktop;
- Electrical engine;
- drive mechanism.
For a standard workshop, the sufficient power of the engine used is 1.5 kW. The power of the electric motor depends on the type of metal used. If metal with thin walls is used during operation, then a power of 1.5 kW will be sufficient for such an engine. To carry out frequent work cutting pipes from profiles, you will need a 3 kW unit.
An important indicator of the engine is the number of revolutions it makes in the process of cutting a metal part. The recommended speed is at least 3000 per minute. At low motor speeds, the cutting disc is not able to operate optimally.
Particular attention must be paid to the diameter of the circle used. Experts advise choosing circles with a diameter of 300-350 mm with an electric motor power of 2 kW. With the specified parameters, the recommended engine speed is 3000-4400 rpm. As the indicator increases, the circle is destroyed, and at low speeds it quickly overheats and wears out.
What to pay attention to
The choice of drive mechanism matters. A belt drive does this job well. To make it you will need 2 pulleys of the same size. The first pulley is fixed on the drive shaft of the cutting wheel, the second on the electric motor shaft. The shaft is mounted on two bearings.
To prevent the belt from slipping and maintain the necessary tension, it is necessary to secure the electric motor in the rear part of the pendulum. Fastening is done with 4 bolts.
The pendulum has its own separate requirements. It should be:
- balanced;
- well cooked;
- move perpendicular to the desktop.
The pendulum is mounted on two vertical posts. Each post has slots into which a bushing with a diameter of 11 mm is inserted. The stands are made of a metal square measuring 40*40 mm. Optimal height- 90 mm.
Desktop Design Requirements
The cutting unit must have a work table optimal sizes. The required parameters are: 701*1000*900 mm. The table is welded from a corner measuring 25*25 mm, after which it is covered with a steel sheet having a thickness of 3 mm. Slots are made in advance in the sheet at the point where the circle rotates.
It is fixed at the workplace with a rotary clamp and a rotary stop. Such a homemade mechanism allows you to cut products at an angle and perpendicularly.
Any cutting machine for metal requires compliance with a number of conditions during its installation:
- adjustment of the rotation angle is required (its location must be perpendicular to the surface of the desktop);
- the master needs to protect his hands from damage by installing covers around the disk and rotating elements;
- it is important to calculate the rotational speed of the circle in advance;
- equip the handle with an emergency stop button, which, when pressed by hand, instantly stops the operation of the entire mechanism;
- Place the wheel feed force in the cutting zone.
Procedure for making your own machine
Any machine with which it is possible to cut metal is assembled according to the following scheme:
- Preparation protective covers, intended for installation on the drive belt;
- installing a motor using a drive belt as a connecting part between the motor and the shaft;
- manufacturing a shaft for attaching a pulley and a cutting disc to it (the unit is assembled and mounted on a pendulum, which is the upper part of the structure);
- manufacturing a shaft for mounting a pendulum on it;
- manufacturing a machine frame on which the metal for processing and a spark catcher are supposed to be mounted;
- the pendulum is fixed on the frame;
- electrical wiring is installed;
- The device is launched in test mode to check the build quality.
Features of the assembly of the device based on the grinder
In the workshop it is possible to assemble a homemade cutting machine for metal based on a grinder. Tools and materials required:
- start relay;
- some profile pipes with square or rectangular cross-section;
- control pedal;
- metal sheet for desktop;
- spring;
- metal corner;
- two bearings.
Machine start relay
Unlike a disk-type machine, the operation of such a device has a more accurate result. The assembly process is very similar to the disk assembly, but has a number of features:
- frame parts are manufactured;
- a hinge joint is installed on the pendulum arm;
- a bracket is made in the shape of the letter “P”, in which holes are made for mounting the grinder gearbox;
- strips with clamps are made, due to which the grinder is secured to the pendulum;
- welding the clamp, bracket and cutting tool(an alternative would be to use threaded connection for installation of the specified elements);
- pressing into bearing supports;
- pressing bearings onto the shaft from both sides;
- welding the pendulum on the edge of the working platform with a mandatory distance of 0.5 cm from the edge;
- installation of an angle grinder and a protective casing;
- installation of the return spring.
After installing all structural elements, the machine is started in trial mode. Additionally, you will need to fit the groove under the tool and install supports with which the metal being processed is secured.
On final stage The work machine is covered with enamel. It will protect the unit from adverse effects rust.
When working with an angle grinder, the master must protect his hands and eyes from the effects of sparks. Any work is carried out wearing protective gloves and a mask.
Today, the industry produces many types of pendulum saws, which differ in purpose, functionality and configuration. Due to such differences, inexperienced craftsmen have difficulty choosing a tool to effectively perform the work that arises in front of them.
To avoid such problems and understand which model should be chosen for use in a private workshop or in living conditions, you should familiarize yourself with the key characteristics that should be taken into account when choosing such a unit.
What are pendulum machines?
The classic version of this equipment is a compact portable machine equipped with a disk-type cutting tool. The design features of the saws allow you to quickly change cutting discs depending on the material you have to work with. The design of pendulum machines uses a lever system, with the help of which it is possible to make deep and extended cross-cuts not only at a straight line, but also at an arbitrary angle in the range specified by the manufacturer.
Unlike other varieties This type of power tool allows you to create very precise cross cuts in any materials. Thanks to this feature, when using this equipment, it is possible to ensure higher quality of work and accuracy when final assembly elements. Pendulum machines provide the ability to quickly change the angle of inclination of the cutting device in two planes and securely fasten it with special clamps.
Today, the construction market offers many different models of such equipment. They differ from each other not only in cost, but also in technical characteristics. If you turn to practical experience applications various devices, then we can conclude that the most suitable for performing most of the work that arises for home craftsmen is a pendulum Makita saw.
Despite the fact that it costs slightly more than its competitors, this is compensated by its longer service life, which it demonstrates even in conditions of active use. This tool attracts consumers with advantages such as versatility, performance, accuracy and safety in use.
An important point is that to operate it requires a regular household power supply with a voltage of 220 V. This power tool also has a lot of other positive qualities- high mobility, no difficulties in transportation, the ability to ensure productive work even in the most difficult conditions.
Pendulum type machine design
If you take a closer look at the internal equipment of pendulum saws for wood, they use the same operating principle as saws with a circular blade. These two types of power tools differ only in that during operation pendulum saws the cutting blade makes it spin special device, while in the disk version the blade is in a stationary position.
With this type of saw you can easily perform precise and clean cut at right angles. There are models that allow you to make cuts at other angles in an inclined position cutting disc.
If there is a need to cut metal or hardwood, you can install an abrasive disc on the machine. Depending on the nature of the work facing the master you can use removable disks various shapes. Circular blades for universal use are also available for sale, with which you can create cuts in parts made of different materials.
Every saw must have safety mechanisms designed to reduce the risk of injury from a rapidly rotating cutting blade.
This type of power tool has a number of disadvantages:
- During hand sawing, you have to exert significant physical effort, which forces you to take frequent breaks.
- The cutting model of the machine is only suitable for sawing workpieces of limited thickness.
- similar machines are no different high performance, therefore they are most often used as additional equipment or used for domestic purposes.
How it works
This type of cutting equipment belongs to the category of circular cutting machines. In its design, the cutting disc is mounted on a special frame, and the power source for the machine is the electrical network. The presence of the word “cutting” in the name indicates that the cutting disk is lowered during cutting, and after the end of the working cycle it returns to its original position.
With the help of a powerful cutting blade, you can make cuts in a wide variety of materials - not only metal and wood, but also tiles, plastics, glass and porcelain. For working with wood The machine can be equipped with a blade used in circular saws.
How to choose
Select a pendulum machine for the home handyman not an easy task. To do this, you need to pay attention to the performance characteristics that various models don't always match.
engine's type
Modern pendulum machines can be equipped with two types of electric motors:
- collector;
The first type is highly powerful, but has a serious drawback due to the fact that it uses carbon brushes, which have an extremely short service life. Asynchronous Models more durable and do not create much noise during operation. However, this type of motor is limited by the type of pendulum machines they can be installed on.
Cutting width
When studying various models of pendulum machines, you should also pay attention to such a characteristic as the width of the cut, which depends on the design features of the machine and the operating characteristics of the saw blade. The larger the diameter of the cutting wheel, the wider the cut.
A feature of some pendulum machines is that the cutting wheel can only rotate in a vertical plane. However, if necessary, you can purchase more universal device, equipped with horizontal guides that allow the saw blade to move forward and backward.
When choosing between models with and without guides, provided that they use saw blade of the same diameter, it is best to give preference to the first, since it can provide a much larger maximum cutting width.
Electrodynamic brake
If equipped pendulum machine This system is used, the saw blade will stop almost instantly immediately after pressing the corresponding button. Models equipped with an electrodynamic brake are safer to operate.
Maintaining cutting blade speed
A saw that is able to maintain stable rotation rates of the cutting blade, regardless of the load level, is not only able to provide higher work efficiency, but also save time on its implementation. This function will be especially relevant for novice craftsmen. Experienced specialists are unlikely to be able to evaluate it, since during the work they select the optimal speed by changing the level of pressure on the saw.
Laser pointer
With this device you can easily determine the cutting line. Some models of pendulum cutting machines may produce a certain level of vibration during operation, which can throw off the pointer. This will ultimately require the technician to re-adjust it from time to time. Because of this significant drawback, such mechanisms are very rarely used in powerful productive machines.
Amateur or professional instrument
Judging by their intended purpose, both types of equipment are designed to perform the same tasks. The difference between professional pendulum-type machines and amateur ones lies only in the quality of assembly, the materials used and the possibility of continuous operation for a long period of time. Conventional models intended for use in domestic conditions have a smaller margin of safety and do not have a very precise fit of structural components, but they outperform their professional counterparts due to their lower price.
Price
When choosing a pendulum machine, many consumers, among others important characteristics attention is also paid to trademark. Depending on the manufacturer, pendulum machines may have similar performance characteristics, but at the same time differ significantly from each other. The fact is that each company, when producing such equipment, uses various materials, own technology and assembly options. This can ultimately affect the price of the cutting machine.
Also, the cost of a saw for cutting metal depends on the fame and vocation of the manufacturer. There may be situations where professional machines are not famous brand will be offered at the same price as equipment from a famous brand, which has a more budget option. Likewise, a saw blade from a reputable brand can cost the same as an inexpensive miter saw.
However, of course, when choosing a pendulum saw for metal, the price for this equipment from internationally recognized brands, for example, Makita, will be higher than for machines from little-known companies.
How to make it yourself
It is not necessary to spend significant amounts of money on purchasing an expensive pendulum cutting machine. Every master can make such a tool with his own hands. The basis for a pendulum saw for metal can be a regular electric drill, grinder or electric motor. Even with minimal knowledge and skills in working with the tool, you can easily assemble homemade unit, which will not be inferior in power and performance to factory models.
Before you start making such a power tool with your own hands, it won’t hurt you to first familiarize yourself with the drawings and instructions for assembling the machine. During operation, you must adhere to the following algorithm:
If you are interested in purchasing professional tool for long-term operation, we advise you to choose from machines from reliable and trusted manufacturers. You should not buy cheap devices made in China. And it will do an excellent job of performing a small amount of work in domestic conditions. hand saw for metal chain.
It is no coincidence that pendulum cutting saws are popular among professionals and amateurs. After all, this equipment has a lot of advantages, among which the most relevant for consumers are versatility, high accuracy and processing performance, and safety. All this makes such machines one of the most attractive for home craftsmen who need a simple tool to perform a small amount of work.
Of course, it is necessary to select this equipment with special care, paying attention not only to the price, but also to the key performance characteristics, as well as the manufacturer. If necessary, you can even try to make such a machine with your own hands, especially since this will require the most accessible tools and materials, minimal knowledge and experience in working with the tool. The main thing is to choose suitable drawing and carefully study the order of doing the work and follow it exactly.
Nowadays, there are a huge variety of different tools for cutting metal. Many of them are manual and have a large number of inconveniences. The rest of the tools are considered automated and have large dimensions or a large price category.
To combine business with pleasure, as well as convenience and price range, craftsmen created a disc cutting machine. Below we will look at everything related to this equipment.
The scope of application of this machine equipment extends to industrial applications and domestic use. Used for cutting various types metal (steel, cast iron, copper, aluminum, etc.).
Since in everyday life there are a huge number of different metal objects that require minor repairs, this machine becomes extremely necessary. After all, lowering the cutter stand with the cutting disk once will be easier and faster than manually sawing with a hacksaw.
Dimensions homemade equipment allow you to place it under a canopy, in summer time, and in winter it can be safely placed in a warm garage or workshop.
Tip: To install the frame, it is extremely important to choose a smooth and durable place (concrete slab, thick corners, or concrete support legs bed). This is done in order to reduce the possibility of vibration to a minimum during operation.
In production, automated systems are mainly used, which are controlled by an operator via CNC. The goal is mass production of metal products, in the form of cutting pipes of given sizes and various sections, flat rolled metal and much more.
Below we will look at the criteria by which this machine equipment is distinguished.
Classification of cutting machines
All cutting machines are distinguished according to a huge number of criteria. We'll look at the most important ones. So, the main technological criteria:
By type of toolkit
The separation occurs directly on the tool that cuts the metal products. In turn, they are divided into the following subspecies:
Band saws
IN in this case used band-saw with teeth. The belt is made from high-quality high-speed steel. Due to the fact that the cutting tape is thin, there is a saving in material consumption due to the thin cut. Apply band machines in production.
Hacksaws
They are used in small industries, as well as in everyday life. Hacksaw tools can be hand-held (the well-known hacksaw for metal) or an electromechanical machine. In this case, the hacksaw blade is made from various metals (high speed steel, carbon steel, alloy steel, bimetallic steel). This type is quite easy to operate and is considered a convenient tool.
Disc machines
Belongs to the category indispensable tools. Used throughout the metalworking industry. Using such equipment, high-quality cutting of metal can be carried out even by an unqualified person. In addition to industry, this machine equipment is widely used in everyday life.
By number of cutting edges
Single head
The design has one cutting disc. This type of machine is low-productive of its kind and is capable of performing only one operation.
Double head
Their design uses two “heads” for attaching disks. In this case, one “head” is firmly fixed and motionless. The second has the ability to move in independence in the first. This equipment is considered a high-performance tool.
By type of saw blade feed
Front saw blade feed
The center of the disk moves in a horizontal plane.
Bottom feed
The center of the disk moves from bottom to top along a vertical plane.
Pendulum feed
The center of the cutting disc moves like an arc, from top to bottom.
Vertical feed
The center of the disk moves along a horizontal plane from top to bottom.
By main type
Cut-off saws
This tool is used to cut dimensional pieces of rolled metal. Well suited for small-scale production.
Abrasive - cutting
When working with such equipment, abrasive wheels are used. High-quality cutting of metal residues (burrs) is carried out. Cutting material into blanks, cutting profile metal for required angle from 0 to 45 degrees.
Correctly-cutting
Such equipment processes metal produced and supplied on coils (reinforcing steel, metal strip, wire, rods with profile section). This equipment is equipped with the correct mechanism and automatic unwinding of metal from the reel. The twisted wire enters this mechanism, is straightened over the entire plane and fed into a special receiver for further processing.
Tip: Depending on the material to be cut, you need to select suitable cutting discs. The discs must meet the technical specifications.
Disc machine device
Frame
Or a metal structure that plays the role of the base of the unit.
Pendulum unit
This is a kind of metal part made of a metal profile, which looks like the letter “T”. The movable side is mounted on a bracket located on the frame. The movement of the pendulum is carried out by means of bearings, and the return to its original position is carried out by a flexible part (a strong harness or a small spring).
Pipe clamp
The so-called vice, mounted on the bed. They allow you to press the workpiece to give it a stationary position.
Pendulum unit axis
This axis is used to move the disk.
Electrical engine
The heart of the unit. It is he who puts the whole mechanism into action. An asynchronous motor is used for this equipment.
Actuator
A box containing electronics that is connected to electrical network. On this box there are buttons to turn it on and off.
Wheel protective cover
Steel protection that prevents fragments from the disk from falling directly into the person working on the unit.
Belt guard
Located where the belt makes its movement. This casing is designed to protect a working person from being hit by a belt if it breaks.
Pendulum assembly handle
That part with the help of which pressure is exerted by the cutting disk on the workpiece.
Ground bolt
As with all machines, there is a bolt on the body of the unit that is used for grounding.
Abrasive wheel
Direct cutting disc consisting of various materials.
Sling brackets
(4 units)
bed
This is the area where the main unit of the unit is located.
Adjustable stop
Due to it, it is fixed right size future product.
Tip: If your budget is quite modest, then you can use scrap materials to create parts of the unit. If your budget allows, then it is advisable to purchase all the components in the store. This will improve performance and service life.
Manufacturing of a disc cutting machine
Any invention will require certain parts, whether purchased elements or homemade parts. To create a cut-off brainchild you will need the following:
- Metal corner with dimensions No. 24.
- Metal channel No. 10.
- Movable shaft.
- Tubes for making a handle.
- Welding machine.
- Bearings for the pendulum mechanism.
- Electric drive.
- Box for storing electronics.
- On/off toggle switch.
- Starting circuit.
- Winding.
- Electric drill.
- Fastening elements (bolts, screws).
Let's look at the progress of assembling all the equipment:
- First of all, with a grinder, blanks are cut into a frame with dimensions of 400x600x1200 mm.
- Using welding, the frame is assembled from prepared parts.
- A channel is welded over the entire frame. It will give additional strength to the machine and serve as a guide.
- Several vertical supports are screwed onto the channel.
- Next, the next frame is installed, on which the engine and shaft will be located. The frame dimensions should be 400x600 mm.
- A plate intended for the engine is attached to the frame. The best electric motor for these purposes is an asynchronous motor. Its power should be from 1.5 to 3 kW. After installing the engine, it is necessary to connect it to a three-phase network.
- The shaft, flanges, supports with a pulley are made on a lathe.
- Next, the bearings and pulley are installed.
- The box in which the circuit is located is installed in the lower part of the frame.
- A shaft with a sleeve is inserted between the vertical supports. Shaft diameter 12 mm. The gap between the bushing and the shaft should be kept to a minimum.
- On both sides of the bushing, limiters made from pieces of channel are welded.
- An electric motor and a cutting mechanism are installed on a long support beam and on pieces of channel.
- The final step is to install the belt that connects the shaft and the motor.
Based on the above assembly steps, we can conclude that it will be much cheaper to assemble such a unit with your own hands. Moreover, during the assembly process, you yourself adjust the entire mechanism, as they say, for yourself.
The button, which is intended for emergency situations, is connected directly, and the engine is connected through a box with a circuit and an automatic machine.
Tip: If you have assembled such a structure with your own hands at least once, you can easily repair such units. This is because you will know the entire mechanism of such a machine by heart.
Manufacturing a cutting machine based on a grinder
In addition to the classic variation of the cutting machine
There is also simplified version machine using a grinder (angle grinder). In this case, a frame is made into which the second frame is attached to the sleeve. It is on the second frame that the angle grinder is secured using metal fasteners.
In order for the grinder to return to its original position, it is necessary to secure the frame and grinder with a tight rubber band or spring. The frame itself is mounted on a prepared bed or on a large and heavy table. The heaviness of the table will ensure a minimum of vibration. If a frame is being prepared, then it must be mounted on a foundation prepared in advance. Such an invention can serve as a good tool in a home workshop or as an excellent device for cutting metal.
General reviews about the machine
If you look for reviews on the Internet about this unit, you will only find positive reviews. Indeed, such an invention is very convenient in its own way. With its help, you don’t need to suffer with the grinder in your hands, in a bent state. If you choose a cutting tool for certain jobs, then only a disc cutting machine.
Video reviews
Video review of the disc cutting machine:
Video review of a cutting machine using a grinder instead of a disk:
Video review of the assembly of a homemade machine:
Video review of the cutting machine:
A pendulum saw for metal, in fact, is a cutting machine whose tasks include: cutting pipes, profiles, metal corners, at various angles. The machine is a rigidly fixed frame, with a pendulum mechanism, which allows cutting to exactly the size and intended angle. Mainly on the market Makita tools are presented, which guarantees high quality and efficiency, but there are also products from lesser-known manufacturers.
Device
The pendulum feeding mechanism of the cutting tool involves a top-down working movement, through mechanical or manual control. One of the advantages the pendulum machine is also a change in the cutting angle, up to 45 degrees from the normal. The working part of the machine is a circular saw; depending on the type, the machine can be single- or double-headed, depending on the number of cutting saws.
Circular saw located on pendulum mechanism can be driven either manually by an employee or automatically.
The machine is often installed graduated dials, for additional control of cutting accuracy, for example, a Makita LC1230 machine, in this case the cutting angle is changed by turning the handle.
Advantages and disadvantages
When fully equipped, the pendulum saw is absolutely safe and comfortable to use. The dust collector collects abrasive elements and metal particles. The clamp for securing the workpiece holds the part to be sawn and prevents the blade from skewing.
Advantages of pendulum cutting machines:
Disadvantages: the only disadvantage of this type of machines is their high price in a professional manner. Yes, a pendulum saw Makita costs from 10 thousand rubles. But at the same time, Makita tools are most valued by our industrialists. Makita produces power tools and components, the same saw blades, High Quality And different prices, from household models to highly professional equipment.
Assembly saws
A special subtype of pendulum cutting machines is characterized by a simplified design and increased mobility. Assembly machines do not have a mechanism for turning the saw itself and cut the workpiece only along the normal.
The device in this case simplified as much as possible, saw, pendulum, bed. Discs for cutting metal are usually abrasive; carbide is less commonly used.
The drive on a disk, in professional cutting machines, is usually belt driven, this allows you to reduce the load on the engine and avoid sudden jerks.
Due to the lack of hard fastening the pendulum and the workpiece, when working with cutting-off assembly machines, it is necessary to take into account the following nuances:
- Use a clamp to secure the workpiece while cutting.
- At the moment of starting, the torque of the disk gives a strong push to the saw, take this into account.
- When cutting with a mounting machine, a burr is formed on the workpiece, which must subsequently be removed.
Making a pendulum machine with your own hands
To do this, it is enough to make a frame from a channel and an angle; you can use a regular circular saw as a working tool, securing it to the frame.
Open the bed, it’s quite simple to do, install two channels - paws, connecting them in pairs. Weld the base of the pendulum to them. Often a solid piece is used as a base. metal plate 12 mm thick, in this case the hole for the saw blade is simply cut or drilled. Need a drilling machine.
After this, it is necessary to make cages for bearings for the pendulum; for this, it is best to contact a turning shop. After turning, welding will be required.
Also, while creating the rotary machine and pendulum parts, you will need a milling machine and a drilling machine.
Don’t forget about casings; for their manufacture it is best to use sheet metal 0.8–1 mm thick. Cutting is done according to ready-made patterns, after which it is tacked by spot welding.
During processing and workpieces the following were used:
- Gas cutter, cutting base metal, pendulum and frame blanks.
- Screw-cutting lathe for turning fingers and clips.
- Milling machine for processing the edges of workpieces and milling part of the pendulum parts.
- Drilling machine.
- Welding transformer.
Overall it turns out that the price self-made the frame for the pendulum saw is large, the forces of an entire mechanical repair shop will be required. In some cases it's worth it, sometimes not. The price is too high.
Sometimes it's easier and more efficient to buy a ready-made tool. This will save time and money.
Cutting tool
The saw uses as a cutting tool circular saws, abrasive wheels of various diameters and seats. In this case it is necessary See the saw's operating manual; the recommended blade parameters are indicated there. Thus, the Makita LC1230 saw uses a disk with a diameter of 12, with an inch fit, 25.4 mm and a number of teeth of 60 for cutting. This could be a Makita saw blade, 305x25.4x60, for example, Makita B-29393. Discs from other manufacturers that meet the technical specifications can also be used. Cutting is usually done with discs carbide tipped at the ends of the disc teeth.
Exploitation
Before using the machine must be installed on a raised table or workbench, this is necessary for the comfort of its use. It is also necessary to make room for cutting, carrying material and storing workpieces.
The Makita LC1230 saw is compact; installation requires small area, but we must not forget about the movement of material and workpieces, as a result work zone cutting saw is a rectangle of 2x4 meters. With a material length of 2–3 meters.
Cutting with a pendulum saw is not a difficult task, but nevertheless requires attentiveness and accuracy. Yes, special danger represent sparks and hot metal particles flying from under the saw. Partially, the collar installed on the saw body saves you from them. But nevertheless, we should not forget about personal protective equipment.
Working with a cutting tool, for example, a grinder, many craftsmen understand how much easier it is to cut metal using a simple machine - both the work is more convenient and the cut line is ideal. But when looking at the prices for a cutting machine for metal, even the most primitive used one, there is a desire to make something like this device yourself. There are several ways to make a cutting machine with your own hands, for example, using a grinder or a disc. All designs have their disadvantages or obvious advantages.
Use of cutting machines in everyday life
When working with metal, it is impossible to do without welding, cutting, grinding and other types of processing. The ability to have the simplest machines for woodworking and metal on your farm is a huge help to the home craftsman. In places where it is difficult to reach to carry out work, for example, cutting metal staircase or change something in the design of the attic, you will need a grinder or a circular saw. And cutting equal pieces of reinforcement, rods, small pipes and all kinds of metal workpieces is much easier to do on the working surface of the machine.
The same cutting tank can be used for other purposes to cut aluminum, plastic and others. synthetic materials. However, it is not recommended to use metal cutting machines for woodworking purposes. Considering the small size of a household metal-cutting machine and the general simplicity of this design, it will not be difficult to place it on your estate.
To operate the machine, you will need a well-lit area in the yard or garage, an outlet and a flat floor surface. And if you don’t need it, you can always take it to the workshop, pantry or utility room before the next use on the farm. Some designs of homemade machines can be assembled and dismantled, the frame or base of the structure will remain intact.
A homemade cutting machine can also not only be used at home, but also rented out in order to recoup the costs of its production - in short, this is a very profitable device.
Classification of machines
Structurally, all metal-cutting machines combine an engine with a transmission, a cutting disk and the working surface of the machine. There are drawings for a cutting machine on most sites dedicated to various homemade products. Knowing the basic principles of operation of this device, it is easy to make your own adjustments in order to use the materials and mechanisms that are already on the farm.
1. The power of the motor used depends on the expected performance, and it is important to decide on this before making a cutting machine. Most off-the-shelf cutting machines have quite high power- up to 2000 W. Although a machine for domestic use may have smaller parameters, you should not forget that the metal is the same everywhere.
2. To maintain the power of the engine on which the machine will operate, it is important to choose a suitable kinematic transmission method. The most common are belt and friction friction transmission; each method has its own advantages. Gear transmission is gear, worm, chain, but the latter option is the most popular. Belt drive produces the least noise and is most often used on homemade machines, but for more precise machines it is not suitable due to the likelihood of the belt slipping. However, with any machine design, it is important to remember to comply with safety precautions.
3. Even homemade machine It is advisable to equip it with a vice - to ensure guaranteed retention of the material being processed. Carbide disc or abrasive wheel- the choice is up to the master, depending on what is at hand, as well as on the most frequently performed work.
4. The metal cutting angle parameters can vary from 45° to 90°, but usually cutting is done at a right angle. Not every homemade machine has this advantage.
5.The diameter of the disk determines the height of the piece of metal being cut, but these parameters can be changed. For example, a wide, thin-walled pipe can be rotated while cutting, but it is difficult to secure with a vice. Mark volumetric metal structure on the working surface of the machine, sometimes it can also be problematic. Cutting machines, in most cases, have a working diameter of up to 400 mm.
6. The total productivity of a manual machine for precise cutting of metal largely depends on the speed of rotation of the disk. The high speed of the machine directly affects the quality of cutting.
7. The weight and dimensions of a homemade machine are determined depending on the material of the general design, which it is advisable to equip the legs with vibration supports.
8. The type of cutting machine also depends on the feed of the cutting tool - pendulum, with bottom or front feed. The disc is fed from above using a pendulum feed.
9. A homemade machine can have 2 cutting heads or one, respectively, there are single-head and double-head options.
The abrasive cutting machine is designed for cutting metal fittings, rods, profiles, I-beams, pipes of different diameters, solid parts and profiles at different angles. Works with an abrasive wheel.
A band cutting machine or band saw operates on the principle of a closed metal strip moving on pulleys.
At home, the easiest way is to build a cutting disc machine for metal. There are several ways to make a cutting machine with your own hands, but the simplest method will be the most understandable.
The manufacturing process of a machine based on a cutting disc
To work you will need:
- steel corner,
- channel,
- drill,
- welding machine,
- electric motor,
- bearing pair,
- starting circuit,
- switch,
- coil,
- wooden shield or steel sheet for the work surface,
- box to ensure the operation of the electrical circuit.
1. After preparing all the tools, make a frame or a general frame of suitable dimensions, for example, from angle No. 25. The parts of the structure are measured according to the drawing on a cutting machine and cut with a grinder, then welding begins. The finished frame can be placed on vibration-supported legs, which will facilitate the operation of the machine. It is easier to make the legs from the same profile or small diameter tubes.
2. Channel No. 10 is welded to the resulting table, which acts as a guide axis; it will become the basis of the structure for attaching the cutting part of the machine and connecting it to the motor. Next, the main parts are attached to the channel, including two vertical racks, secured with bolts.
3. Next, you need to weld another frame from the profiles - this is the base for mounting the electric motor and the main cutting disk. On the other side of the frame, an electric motor with a power of about 1.5-2 kW is fixed. They are considered the most durable and reliable asynchronous motors. The motor will need to be powered from a 3-phase network. We remind you that the engine more power will provide a more even cut and good speed performing metal cutting work.
4. Shaft mounting method and general principle its connection to the structure is not important. A threading machine, when properly ensuring the supply of revolutions from the electric motor to the rotating shaft, must work reliably. The V-belt will help provide this. Some work can be ordered from a turner (shaft with supports, belt pulley and disk flanges). It is advisable to make the flange projection with a diameter of 32 mm.
5. Next, the support bearings are mounted in the sockets of the upper frame plates on the channel. Bolts and nuts can be used to secure the motor and shaft. Ensuring the operation of the electrical circuit is in a ready-made box with a switch, which is attached to the bottom of the frame.
6. The connection of the racks with a shaft with a diameter of 12 mm is made using a sleeve. To prevent it from slipping, the sleeve and shaft are connected with the smallest gap during a sliding fit. A rocker arm from the channel is welded onto the bushing so that its arm is in a ratio of 1:3.
7. You will need to install a rigid spring near the engine - to ensure return, it will work even from an expander. The springs and chains should be securely secured with bolts.
8. The electric motor is installed on the side of the smaller section of the rocker arm, and the shaft on the larger side. A belt drive will ensure the movement of the shaft.
9. An emergency stop button and a starting circuit are required, while the engine must be connected through a box and a three-pole circuit breaker, and the stop button leads to a direct connection to the network. Connecting the machine will be provided by a three-pole starter that starts the electric motor.
10. Be aware of the sparks that will fly from the disk - provide it with a casing. The work is first checked for Idling, and only after making sure of the reliability of the design, you can try cutting soft metal, for example, aluminum, in order to correct all the inaccuracies. work surface The structures can be made of metal or wood and covered with thick plywood; if necessary for work, secure them with a vice.
The manufacturing process of a machine based on a grinder
There are several ways to make a metal cutting machine with your own hands - there are several good videos on this topic.
First way. The simplest device is a frame made of pipe, which will also serve as a comfortable handle. On one side, a transverse strip is attached by welding, on which there should be holes for attaching an angle grinder. The movable shaft will be attached to this base on a piece of angle, the same part can be attached to the floor of the garage or to the desktop. And on the other hand, it is attached to a spring, with the help of which the machine structure can return to its original position. If you attach the grinder correctly, the device will help you cut metal more accurately, freeing up one hand.
Don’t forget about the back impact of the grinder, when the tool is thrown back if the abrasive disc jams. And abrasive fragments from disc destruction can cause serious injury. An angle grinder attached to the machine with a closed casing minimizes such consequences. However simplest design does not make it possible to perform high-precision cutting, for example, when you need to cut small pieces of steel rod that require further adjustment.
The second way to transform an angle grinder into a cutting machine for metal work. This machine can be made collapsible.
To work you will need:
- welding machine,
- drill,
- steel corner,
- profiled pipe,
- channel,
- spring,
- relay,
- identical bearings,
- pedal,
- bolts,
- wooden board or steel sheet for the work surface.
1. A preliminary drawing or sketch is required, where all dimensions and necessary details. Ready-made drawings for a metal cutting machine are available on the Internet, but you will still have to make your own adjustments using what is already available on the farm. An easy sketch does not require precise measurements; it is enough to observe the proportions and have an accurate idea of each structural element. And remember that you will have to change the frame under different sizes working disk of the grinder.
2. Two frames per common axis- the basis of the simplest machine frame, and it is better to weld them from metal. On the lower part it is necessary to weld the fastening, which will consist of a movable clamp and a clamping angle. The part on which the angle grinder will be attached must be made to move vertically relative to the bottom, like a pendulum. You cannot do without a spring; it is needed to return to the starting position. Additionally, secure the ruler with a limiter by welding - for accurate measurements.
3. The start of operation of such a machine will be ensured by a start pedal (button), connected through a low-voltage relay, supplying voltage to the angle grinder. After switching on, the design must be checked at idle speed. If the circle does not touch the casing and rotates freely, then you can use the design in practice - a homemade machine for cutting metal is ready.
4. This design can be collapsible, and other removable disks can be installed on the grinder. When working with other materials, be aware of the characteristics of the materials when cutting them. Remember safety precautions and precautions when performing metal work.