In the past, metalworking was difficult and time-consuming. However, things have changed due to advancements in technology. Metal fabrication has become easier than ever before. Manufacturers use several sheet metal cutting tools and methods to cut and shape the workpiece.
These tools and methods are mainly used to shape sheet metal into various shapes. Knowing these tools and cutting methods is crucial. Do you work in metal fabrication and don’t know about these tools? Worry not! This article will help you understand everything about metal-cutting tools and advanced methods. So, let’s get started!
What is Sheet Metal Cutting?
Before discussing tools and methods, let’s first look at the basics of Sheet Metal Cutting.
Sheet metal cutting is a metalworking process. It involves using a cutter (cutting machine) to cut metal sheets into pieces. Several cutting tools (machines) and methods are available for this job. This process is used to make all sorts of things, from car parts to airplane parts and everything in between.
The tools used for this process vary depending on the type of work needed. For example, if you are cutting small pieces of sheet metal, you must use a handheld shear. If cutting larger sheets, you will use an industrial power shear. Sheet metal is typically used to manufacture electrical, automotive, and medical products.
You can cut sheet metal quickly and easily with the right sheet metal cutting tools. Many different cutting processes are used to cut sheet metal. Each method works differently, and the effectiveness of each cutting tool is also different. So, choosing the right cutter and cutting method is very important.
Some Common Sheet Metal Cutting Tools
There are different cutting tools available in the metal fabrication industry. Each of these tools varies in terms of efficiency and working. Here is the list of the most popular cutters:
- Saws
- Shears
- Tin Snips
- Plasma Cutters
- Angle Grinders
1- Saws
Sheet metal saws are among the most popular cutting tools. They cut through various materials, including galvanized iron, steel, and galvalume metal plates. Sheet metal saws are generally either electric or handheld.
The electric version is ideal for making straight cuts. When cutting sheet metal, keep the material cold. If the material is too hot, it might affect the cutting process. Moreover, you should also wear protective work gloves. This will help protect your hands from the heat and chemicals used during cutting.
2- Shears
Shearing is a mechanical process of cutting metal sheets. They cut in metal sheets or other materials in straight lines. The shearing process is most commonly performed on a shear machine. These machines can be electric, hydraulic, or pneumatic.
Electric machines work using electrical energy. On the other hand, hydraulic machines are old ones that use hydraulic energy through a fluid. Shears are designed for cutting sheets used in the construction and automotive industries. They can be used for cutting metals such as steel or aluminium.
3- Tin Snips
Tin snips are excellent metal sheet cutters for both beginners and experienced metalworkers. What I like about them is that they cut the workpieces without damaging them. This means that they will provide high-quality cuts without deteriorating the sheet.
There are many types of snips available. Each of those snips varies in terms of cutting sheets of specific thickness. Which one you should use depends on your needs. I recommend you choose ones designed to handle the metal thickness you are cutting.
Some models of snips are designed to cut in straight lines. At the same time, some others are created to cut in curves. These are made of any alloy and come in different shapes and sizes. They’re an excellent choice to cut metal without using power tools.
4- Plasma Cutters
Plasma cutters are powerful tools that can cut metal sheets of any thickness. They blow heated gas (plasma) on the metal to create a cut. The plasma melts the metal sheet, and the gas removes or blows away the molten material. Generally, metal sheet cutters are slow, and their precision is not ideal.
However, these plasma cutters cut the material at a very high speed. It increases efficiency, especially when you are cutting to make complex shapes. Some plasma cutters are small and handheld. These are suitable options for small-scale workshops. On the other hand, some high-end plasma cutters are also available and are suited for professional scale.
5- Angle Grinders
Angle grinders are tools that cut the material and can create curves or angles. Apart from cutting, they also perform grinding and offer excellent polishing of edges. They use a spinning disc that rotates and cuts the metal sheet. What makes this cutting tool stand out is its flexibility. How? Spinning discs of different types are available.
Each type is particular in its functionality and cutting. So you can change the disc and get the functionality you desire from these tools. For example, you can easily slice a metal sheet with a slicing disc on these cutters. Similarly, a specific grinding disc will help smooth the sheet’s edges.
Sheet Metal Cutting Methods
In the section above, I discussed various cutting tools. Each is very specific in its role and usability. However, there are a few metal sheet-cutting methods. Each is unique and specific in its workings.
1- Sheet Metal Laser Cutting
Sheet metal laser cutting is a great way to create clean, straight cuts. This process is excellent for cutting intricate details and getting a beautiful finish. What I like about this method is its contactless thermal process. This means the heat source is a laser. A laser beam is typically focused through a high-quality lens on the work zone.
After amplification, the beam exits through a series of mirrors. The narrowest part of the focused beam is only about 0.0125 inches (0.32 mm) in diameter. While laser cutting has many benefits, it also has some disadvantages.
- First, the heat generated by the process can warp and distort parts.
- The laser can also be susceptible to back spatter, damaging the focusing optics.
- Another disadvantage is the oxidized layer left on the cut surface.
- Also, while laser cutting offers excellent speed and accuracy, it is not the cheapest method.
- It requires expert machinists with professional skills. It is recommended that you do not use this method if you are a newbie.
2- Waterjet Cutting
This cutting method uses a high-pressure stream of water to cut the metal sheets. Many professional fabricators use this cutting process due to its precision. The process is less expensive, less wasteful, and eco-friendly than other methods.
Water jet cutting produces high-quality parts with smooth edges. This process has several benefits, including.
- Cost-effectiveness
- High cutting accuracy
- Efficiency & Adaptability
- Versatile and highly flexible
It is possible to cut various materials with precision water jet cutting. Common materials include steel, aluminum, plastics, rubber, wood, and foam. It is also suitable for cutting holes, tight radii, and irregular shapes. The waterjet cutting procedure is also eco-friendly. How? Because it does not generate toxic fumes or greenhouse gases. Moreover, it does not require post-processing or secondary finishing.
3- EDM Cutting
Unlike laser or plasma cutting methods, EDM uses high-voltage sparks to cut metals. This process produces ultra-precise components. It is also used in the aerospace, medical, and tool industries. It is becoming a standard method for creating production parts.
EDM uses a special wire called an electrode. The electrode is made of a conductive metal, such as brass, graphite, or copper. A servo motor is guided in the desired path to ensure the electrode does not touch the workpiece. Electrical discharge machining is a newer method of metal processing.
It has the following benefits:
- It is error-proof and highly reproducible.
- It is more effective for machining tough materials.
- It is also a good process for thin machining materials.
- It can produce fine features, small apertures, and internal cuts.
- The process also requires little bulk heating, leaving no residual stresses.
The process allows for a smooth surface finish. Moreover, you can also use it for drilling through hard or complex geometries. The dielectric fluid, usually deionized water, helps remove material left behind. It can also control the amount of heat produced during the process.
4- Plasma Cutting
Plasma cutting uses hot plasma to cut through metal. It is beneficial for metals that conduct electricity. Plasma cutting on sheet metal is an excellent way to cut through medium and thick metal gauges. This type of cutting is ideal for machining large sheet metal parts.
Some prominent benefits of the plasma cutting method are as follows:
- It produces a sharper edge compared to oxy-fuel cutting.
- It has fewer on-the-job injuries than other metal-cutting methods.
- It produces accurate, smooth cuts. Moreover, it is also more portable
- It can be used with CNC machines, which provide accuracy and repeatability.
The plasma-cutting system uses advanced CAM software to analyze part drawings. It identifies the best lead-ins and outs during analysis, allowing it to optimize the cutting parameters. This improves accuracy and increases throughput. It also affects the cost of operating the cutting machine and the quality of the cut part.
Plasma cutters are used in various industries, including automobiles and aerospace. Fabricators cut and shape large sheets to make consoles and enclosures. They are also helpful for tubing, brackets, and tube assemblies.
Things to Consider When Cutting Sheet Metal
Cutting metal sheets is not an easy job. Small mistakes can result in imperfection in the cutting process. Moreover, cutting metal can also pose serious safety issues for the operators. Let’s discuss the key considerations you should look for when cutting metal sheets:
1- Use Appropriate Safety Gear
Using personal protective equipment ensures your safety while cutting sheet metal. It also helps prevent accidents outside of the actual cut. Safety equipment for cutting sheet metal includes:
- Face Mask
- Safety Gloves
- Safety Glasses
- Protective Footwear.
Each piece of equipment must be properly sized and always ready to use. Moreover, you should avoid wearing loose clothes. Wearing pieces of jewelry that could get tangled in the machinery is not recommended. Additionally, you must wear a fire-resistant apron. Leather shoulder covers should be worn for overhead welding operations.
2- Choose the Right Blade for the Right Material
Choosing the right blade for any specific material is key. It can make a considerable difference in the overall efficiency and quality of the job. However, choosing the wrong blade can also cause the workpiece to warp, bend, or shatter. I recommend you select a blade that matches the material, the type of saw, and the cutting job.
There are three types of blades designed for metal cutting: toothed, slicing, and regular-tooth. Teeth per inch (TPI) is an essential measure of the blade’s aggressiveness. A fine blade has more teeth per inch than a coarse blade. If you’re cutting thin sheet metal, a fine blade with a TPI over 18 is necessary.
A high-speed steel blade is the best choice for cutting soft, non-ferrous metals like aluminum. Carbon steel is another good choice for softer materials. A hardback blade is the best choice if you’re cutting thicker lines. However, a hybrid blade can also be helpful. Hybrid blades have a mid-range tooth count. These blades create clean cuts while reducing vibration.
3- Choose Correct Hand Tools for Metal Sheet Fabrication
If you’re cutting sheet metal, you’ll need to select a metal-cutting tool suitable for the job. For example, if you are cutting thick, corrugated metal, you’ll need to use a saw or compound snips. Alternatively, you can use a cut-off tool for thinner metal.
Therefore, you must know the capabilities of each cutting tool. This helps assess the tool’s compatibility with specific materials you are working on. Remember, choosing the wrong tools will result in inefficient cutting and shaping of the material. Always ensure you wear safety glasses and a face mask, no matter which tool you use.
Frequently Asked Questions
What is the best tool for cutting sheet metal?
Different tools are available for metal sheet cutting. Most include saws, shears, snips, and plasma cutters.
What are the methods of metal cutting?
Shearing, laser cutting, and plasma cutting are the best methods for cutting metal. The best method depends on the metal. There is no one fit (method) for all metal sheets and materials.
What cutting tools are used for sheet metal?
There are many metal sheet cutting tools used in metal fabrication. Each of those tools varies in terms of its working and efficiency. Here is the list of some popular tools:
Conclusion
The right cutting tools and techniques are key to a successful sheet metal project. Some cutting methods are more effective for specific applications than others. Knowing which is right for your work can be a money and time-saver. You can cut sheet metal in various ways.
Sometimes, you must use hand tools to achieve the best results. In other cases, you may need to use a power tool. Using a power tool can be a much more efficient method of cutting sheet metal. We also provide reliable metal fabrication services. You can contact us for the best advanced solutions related to your project.