How to cut an aluminum profile, barrel: cutting with a miter saw

Hacksaw for metal

When finishing buildings during the construction process, specialists come to the rescue with a miter saw, with which they can cut a sheet of metal. However, it is not always appropriate to use a power tool. For a gentle approach, choose a manual device such as a simple and reliable hacksaw.

There are special blades designed for cutting soft and non-ferrous metals Source Farpost.ru

Cutting aluminum sheets that do not have a large cross-section has several disadvantages, namely:

an inconvenient work format, during which the specialist is forced to simultaneously fix the profile and perform movements. Because of this, the quality of the product decreases;
during the cutting process, the material loses its original shape;
manual processing takes longer than machine processing.

How to cut a drywall profile at home

When installing frames for walls, ceilings or partitions, you need to cut a profile for gypsum boards. Craftsmen use hand and electric tools. Let's find out what is better to cut.

Using tools, you can quickly and smoothly cut a profile of the desired size. Return to contents

Full contents of the material

Types of tools

An affordable cutting method that most people use is metal scissors. In addition to them they use:

a hacksaw with fine teeth for metal;
guillotine machine, a device for cutting profiles for drywall;
a jigsaw with a special file;
grinder with cutting disc;
small circular saw.

Metal scissors

The tool is convenient and easy to work with aluminum. Sheets of metal are pre-marked.

The disadvantages of working with scissors include:

the need for training before finishing metal cutting. A person without experience will not perform the action exactly along the marking lines;
Due to the structural features of the profile, there is a high probability of deformation of the product or an uneven cut.

There are special cutting shears for aluminum, but they are not suitable for cutting profiles; you should give preference to the classic version Source Artem-tools.ru

Features of cutting aluminum with a grinder

For example, to cut a sheet product or any aluminum workpiece with a large thickness, kerosene is dripped onto the working seam.
Read more: Brief review of panasonic cs e12rkdw cu e12rkd

Cutting aluminum is not only difficult, but also unsafe! Especially when using a high-power grinder. Due to the viscosity of aluminum, the disc will get stuck, and the tool will try to pull out of your hands.

And this will not happen immediately, but only when the cut reaches a certain depth. And this may come as a surprise to an inexperienced tool user. And in general, cutting with a disk stuck in the metal will not be easy.

One of my friends once had a job delivered to him and needed to saw an aluminum tank with a grinder. “It’s a piece of cake,” he thought—cutting aluminum, there’s nothing easier!

The disk constantly got stuck, stuck in this metal. The grinder tried to jump out of my hands. Cutting was a pain, it went very slowly. Various abusive thoughts did not leave my head. )))

So what to do? I got to work - I need to do it! So several hours of hard work passed. An old man passing by came to the rescue.

Seeing the torment, he began to try to give advice, but advice is sometimes difficult to accept, especially when his nerves are already at their limit. After all, the work, which seemed simple at first, was already pretty exhausting. Therefore, the first reaction to advice is the desire to send him to hell.

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

Electric jigsaw

To cut metal with such a tool, the following prerequisites must be met:

Using a saw for metal products.
Reliable fixation of the workpiece.

If you deviate from these rules, the quality of the product will suffer. This is explained by the fact that wood saws are designed for softer materials, and unsuccessful fastening of aluminum can move the product out of place during the cutting process. The result will be a deformed product with an uneven cut.

Metal files have a more frequent tooth and are highly durable Source Oriontfmarket.ru

Correct use of the tool

When you start sawing any part using an angle grinder, you should adhere to these rules.

When cutting metal, you need to hold the grinder firmly, with both hands.
The wheels can be changed only after they have completely stopped rotating and cooled down to an acceptable temperature, disconnecting the power tool from the power supply.
Do not place the working tool on the ground or table (do not let it out of your hands).
It is required to periodically stop for about 5 minutes to rest and allow the disk to cool.
It is necessary to constantly monitor the condition of the cutting wheel, preventing it from being pinched by the edges of the workpiece being cut.
Do not leave the tool plugged in unattended.
Use only discs of the correct size as specified in the operating instructions for the device you are using.
It is better to do the work on a flat surface so that the body position is stable.
Make sure that the power cord is kept away from the rotating circle, sharp edges, and objects heated above 100 degrees.
Movements not directly related to cutting must be performed only with the power tool turned off.
You need to position yourself on the side or behind the tool, doing the work with your own hands so that parts of the body are not in the cutting plane.

When cutting metal with a grinder is finished, you should wait until the disk stops completely and disconnect the power cord of the tool from the mains. Afterwards, it is recommended to ensure that there are no signs of fire. When cutting materials, a right-handed person should correctly hold the handle of the device in the area of the on/off button with his right hand. The left hand is placed on the handle screwed into the body of the power tool from above.

As for the question of which direction—toward or away from you—the disk of a switched-on angle grinder should rotate, there is no definite answer. The operating instructions indicate that the first option is correct. This is due to the fact that the resulting sparks fly away in the direction opposite to the operator, without causing harm. Also, fragments of the circle will fly in that direction if it breaks into pieces.

But if the rotating disk jams towards itself, the tool will fly off towards the worker. For this reason, many specialists prefer to cut metal so that the circle rotates “from itself”. A power tool torn out of your hands will fly in the opposite direction. This reduces the likelihood of injury, and clothing, shoes and gloves will protect the user from flying sparks.

Grinder (angle grinder)

This power tool cuts metal smoothly and quickly. However, in the case of aluminum, the softness of the metal must be taken into account. When cutting sheet material, it is necessary to cut the profile without rough influence, since aluminum forms unwanted work hardening on the grinding machine wheel.

Metal discs for angle grinders are marked in blue Source Festima.ru

The disadvantages of working with an angle grinder include the following:

Metal processing can only be done by an experienced craftsman. Otherwise, the cut line will be crooked and inaccurate;
there is a high probability of the part burning;
To improve the quality of work, it is necessary to use a device for securing the workpiece. Craftsmen use a vice, but it is recommended to fix the part on a stand. Such a clamp, even in specialized stores, is rare.

There are many more advantages to using a grinding machine:

large selection in stores;
a wide price range allows you to choose a budget model;
the specialist performs the work without strain;
high speed;
high-quality cutting line;
Correct use of add-ons for working with different metals will ensure reliable operation of the tool over a long period.

How to cut an aluminum barrel

SC MetOptTrading LLC not only sells high-quality rolled aluminum, but also carries out its processing: production of profiles according to customer drawings, cutting and cutting of aluminum slabs and sheets.

We process materials of any marking using modern high-tech equipment, which guarantees an impeccable result while maintaining all the performance characteristics of the metal.

The quality of our work meets Russian and international standards.

What's special about aluminum bending?

Basically, two methods are used for bending aluminum sheet material:

Air or free
Sensor.

Free way. This is the air gap between the hammer drill and the metal sheet. This method is the most widely used today.

During the bending process, if there is no air gap between the punch and the walls of the mold and the aluminum sheet is tightly compressed, this method is called sizing. This technique is quite old and is used for the softest materials or for making complex shapes of products.

Free bending of aluminum has a number of advantages over the calibration method, namely:

A higher degree of flexibility, therefore, without changing the punch and shape, you can get different bending angles of the sheet profile;
Less effort is required to carry out deformation;
You can bend sheets of greater thickness;
Relatively low cost of equipment.

The disadvantages of the free method include:

Low accuracy of bending angle of thin-walled metal sheets;
The accuracy of the repetition of the shape depends on the physical properties of the material;
Poor applicability for complex configuration operations.

Which brands can be bent and which cannot?

Thus, there are several main types of rolled aluminum sheets, which can differ significantly from each other in their physical properties and deformation capabilities. So, the most common types:

Fired , it has the letter M in the designation, it is the softest grade, so it is perfectly susceptible to deformation, but at the same time easily shrinks and breaks under excessive stress.
Semi-finished products The fifth is called H2 and has more rigid properties than the M grade, also deforms well and can withstand bending of more than 90 degrees at a time. At the same time, due to its increased rigidity, it retains its shape well and prevents the formation of dents, which is why it is often used as a facing material.
Cropped , Class designation contains one letter N. Hardening. It is a method of imparting increased strength to sheet steel by cold welding. To do this, an aluminum sheet is additionally rolled between two shafts on a special machine. This grade bends well at angles up to 90 degrees and is able to withstand significant loads on its surface.
Hardened , or naturally aged, is typically denoted by the letter T. It is a fairly hard aluminum, so it is more demanding to machine because it flexes when bent at a cold 90 degree angle. It is used for the manufacture of parts and assemblies that operate under high loads.

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The main types of aluminum sheet metal alloys can be organized as follows:

Technical alloys of grades 1105 and VD1 have a relatively low specific gravity of the sheet and are easily bent without problems.
Aluminum-magnesium alloys are designated with the letters AMG. They are made of aluminum alloy with the addition of magnesium and manganese. The AMG grade has acid-resistant properties and bends well, so it is mainly used for the production of containers and tanks, as well as parts for boats and boats.
Food alloys of grades A5 and AD are produced with cages, half-cells or annealed marks.
AMC alloys are specifically designed for the production of complex curved parts such as automotive radiators and the like.
Dural is marked with the letter D. It is a high-strength grade, the main difference of which is its high resistance to external influences. Dural practically cannot be bent, so it is used only in the manufacture of parts by stamping.
Particularly strong class B aviation alloys are bent using special stamping and pressing technology. They are used in the production of highly loaded parts in the automotive and aircraft industries.

Plasma or laser cutting machine

The plasma cutter is a professional equipment. Plasma metal processing is a modern working method. This technology ensures high quality and precision of the aluminum cutting line.

There are compact “garage” versions of plasma cutters that have a relatively reasonable price Source Ngsdo.ru

Among the disadvantages of a laser cutting machine are:

impossibility of use outside industrial sites;
significant price of equipment, reaching seven-figure sums;
high noise level during operation.

The advantages of a plasma cutter include:

the maximum achievable level of cut line quality;
speed of work completion, reaching several minutes;
The specialist’s responsibilities are limited to setting up the machine, and all functions are performed by the installation.

Cutting with an angle grinder

The devices are known as “grinders”. It’s worth noting right away that cutting aluminum with a tool is difficult, since it has a soft, viscous structure. But processing the material is still possible, it just requires specific actions.

For example, when cutting thick aluminum sheets, kerosene is dripped onto the cut site so that the cutting disc does not get stuck in the metal. You also need to buy a circle suitable specifically for aluminum; otherwise, the efficiency and safety of work will be reduced.

Aluminum is a special material with specific properties, so the cutting technology is chosen differently than for the same steel. The choice of processing method, process control, and correct setting of initial parameters (when working with automated installations) are important for the user. Mistakes are unacceptable - plastic and tough aluminum will not forgive a miscalculation.

If you know other effective ways of how and with what to cut aluminum, share your knowledge in the discussion about the material.

Source

A circular saw

The tool performs the functions of a regular saw, but is more powerful. Modern equipment has a number of advantages:

possibility of cutting in any part of the product;
the cut is made lengthwise, across or at an angle of up to 45°;
selection of rotation speed depending on the thickness of the metal;
high processing speed;
long service life of disks with the right choice.

To work with metal, it is recommended to use a machine with an all-metal body Source 999.md
The disadvantages of a circular saw include:

the purchase of equipment is not justified in case of one-time use;
large dimensions;
the price of a saw varies widely.

Industrial cutting of aluminum profile

Plasma cutting.

Plasma equipment for cutting aluminum profiles allows you to obtain ideal cut quality. To process aluminum with a plasma cutter, you should choose hydrogen, argon, or nitrogen - inactive gases - as plasma-forming gases.

VT-metall offers services:

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

Compressed air is also suitable for cutting aluminum workpieces, but only if they are no thicker than 70 mm. Nitrogen-argon mixture is not suitable for cutting aluminum.

Cutting aluminum using pure nitrogen is quite acceptable if the workpiece is no thicker than 20 mm. To cut aluminum blanks, the thickness of which reaches 100 mm, you will need a mixture of nitrogen and hydrogen.

A mixture of argon and hydrogen is optimal for working with aluminum; it is suitable for cutting aluminum workpieces of considerable thickness - over 100 mm. To ensure stability of the plasma arc, mixtures with a hydrogen content of no more than 20% should be used.

Waterjet cutting.

Waterjet equipment for cutting aluminum profiles allows you to obtain products with a high-quality cut and average edge roughness.

Metal losses when using this technology are minimal. Waterjet cutting is not accompanied by heating of the workpiece; it is fire and explosion-proof.

Cutting occurs due to the action of a narrowly directed jet of water under high pressure. Abrasive grains are added to the water, the composition and size of which may vary depending on the parameters of the material being processed and the working conditions.

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

Using waterjet cutting of aluminum profiles, you can obtain parts of complex shapes, cutting them with high precision. So it is possible to efficiently perform even such difficult operations as the formation of bevels, internal radii and even sharp corners.

Waterjet cutting is safe for the environment, since during operation there is no formation of harmful chemicals and microparticles that pollute the air. To process large batches of profiles, a waterjet machine with computer numerical control (CNC) is used. The operator only supervises the equipment, which independently cuts the aluminum profile in a given mode, according to the established program.

Guillotine cutting.

A guillotine is a forging and pressing installation. There are three options for such installations: guillotines operating in manual, mechanical and hydraulic modes.

A mechanical guillotine operates on the principle of a kinematic chain, while a hydraulic guillotine operates using a working fluid.

Manual guillotines make it possible to easily cut thin sheets of aluminum using a lever-spring mechanism.

Mechanical guillotines are connected to a power source.

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

A very precise cut is ensured only by stationary hydraulic guillotines equipped with rear rulers.

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

Circular Saw

This type of equipment is designed for cutting thin aluminum profiles.

The disadvantages of such a saw are:

impressive dimensions;
the price of mid-level equipment reaches 50,000 rubles.

The advantages of a circular saw include:

cutting metal at an angle;
processing of large parts;
saw blades can be bought at any hardware store;
high quality cut;
speed of metal processing.

Pendulum (miter) saw

This tool is similar to previous saws. The difference lies in the use of an abrasive disc. For utility work in a garage or home, a pendulum installation best meets the stated requirements.

Pendulum miter saws for metal are slightly different from woodworking versions Source Tehnoteca.ru

Most saws have a large working surface on which metal can be processed up to 68 mm deep at 90° and up to 50 mm at 45°.

Cutting aluminum profile with hand tools

All cutting technologies are divided into two groups:

Using hand and compact power tools.
Using industrial equipment (discussed in the appropriate section).

The first group includes profile cutting using tools such as:

hacksaws for metal;
metal scissors;
jigsaws;
Bulgarians;
saws.

Let us dwell in more detail on the features of each method.

Hacksaw for metal.

Not everyone has a miter saw; often you have to use something less complex. A hacksaw belongs to the category of simple tools; it can be used to cut thin aluminum profiles and sheet aluminum. Work order: starting to cut from the edge, move to the back side, and finally saw the side parts.

Advantages:

the tool is lightweight;
easy to use;
cheap;
It is as effective as a jigsaw.

Flaws:

low cutting speed;
deformation of the profile is possible;
Accuracy is not guaranteed since the workpiece must be held.

We recommend articles on metalworking

Steel grades: classification and interpretation
Aluminum grades and areas of their application
Defects in metal products: causes and search methods

Metal scissors.

It’s also a very simple tool, it’s even easier to work with than a hacksaw: you need to apply a mark and cut the metal along it.

Advantages:

cutting is not as slow as when using a hacksaw;
the tool is cheap;
an experienced craftsman with good scissors can achieve good results.

Flaws:

on the edges of the workpiece it is easy to leave the marking line and the cutting will go crookedly, in this case you can also bend the workpiece or even ruin it;
In order to cut the aluminum profile exactly according to the markings, you will have to practice well on unnecessary scraps before starting work.

Jigsaw.

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

Advantages:

It is easier to work with an electric tool than with a hand one;
Excellent cutting quality is achieved: no bevels or burrs;
cutting is much faster;
the right fabric can be used many times;
This is the cheapest power tool in the group under consideration.

Flaws:

the need for reliable fixation of the workpiece (otherwise it will “lead” during the work process).

Angle grinder.

The grinder is a tool that can do a lot. Excellent cutting of aluminum profiles. Of course, cutting wheels are not used for cutting, but rather cutting wheels. It is necessary to choose thin tooling to reduce metal loss. It is important to remember to protect your eyes and skin from sparks.

Advantages:

fast cutting with excellent cut quality;
An angle grinder is relatively inexpensive;
minimum effort from the master;
Aluminum cutting equipment lasts a long time.

Flaws:

possible burning of the workpiece;
it is extremely difficult for an inexperienced craftsman to make an even cut;
To achieve high cutting accuracy, it is better to fix the grinder in a special rack, which is sold separately and is not always available in stores (if it is not available, a vice can help).

A circular saw.

It does the same job as a hand saw, but is significantly more powerful.

Circular features:

cutting along, across and at an angle;
the ability to start cutting the profile from any side;
the saw beeps or automatically turns off when overheated (modern saws);
Speed mode selection available.

Advantages:

discs for working on metal are durable;
speed of work;
maneuverability;
cutting of aluminum profiles at an angle of up to 45 degrees is available;
The cost of a circular saw is close to that of miter saws for cutting aluminum.

Flaws:

powerful models of saws are bulky and heavy, which complicates the work;
purchasing a saw for cutting aluminum profiles is justified only for large volumes of work;
the cost of the saw depends on the maximum permissible cross-section of the profile being cut, for example, the Evo 180 hand saw, when cutting vertically, cuts a box-shaped aluminum profile up to 56 mm, and if cutting is done at an angle of 45°, it copes with a cross-section up to 35 mm; such a saw costs almost 25,000 rubles

Circular Saw.

As an example, consider the Yilmaz KY 305 tabletop sawing machine . This is a machine for cutting aluminum profiles of small cross-section with thin walls. Can be used both in a small workshop and in production. In any case, operator participation is required.

The machine is equipped with a mechanical clamp for fixing the workpiece. You can select 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).

Advantages:

the machine cuts larger workpieces than a circular saw (up to 130x65 mm);
works quickly and with high accuracy;
cutting at a given angle is possible;
availability of equipment for profile cutting (300 mm disc).

Flaws:

high price, on average 40,000–50,000 rubles;
The machine is quite large and heavy.
Miter (pendulum) saw.

Its design is similar to the saws described above. It differs in that it is equipped not with an all-metal, but with an abrasive saw blade. This is the best saw for cutting aluminum profiles in small (non-industrial) quantities. It has the following features:

cuts aluminum profiles across, lengthwise, and with a bevel;
the design allows the operator to do without much physical effort, you only need to gently press the handle;
the workpiece is firmly fixed in the clamps;
Long profiles can be cut;
There are models comparable in cost to similar circular saws, but superior in functionality.

Consider, for example, the characteristics of the Makita LF 1000 miter saw. It gives a cutting depth of up 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 cutting width is up to 210 mm. The saw produces up to 2,700 rpm. Its power is 1,650 W, weight is 32 kg. Spacious work desk.

The cost of such a saw is about 60,000 rubles. So it makes sense to buy this trimmer only if you plan to use it constantly, otherwise this purchase will not pay off.

How to cut correctly?

Cutting aluminum products is carried out step by step:

Using a tape measure, markings are applied to the metal part.
Determining the right angle will help to trim the profile laterally.
According to the marks, the product is bent, along which an incision is made.
When working with a profile intended to strengthen a frame structure, the unevenness of the ribs is taken into account. Using scissors, this part of the part is made smooth. Workpieces up to a meter long are cut without using fixation in a vice.
Work with small parts begins with preliminary cutting, maintaining an angle of 45°. At the first stage, the required length is cut, then the angle is marked, and then cutting is carried out.

When cutting metal, the first priority is not the speed of work, but safety precautions Source Waysi.ru

Compact equipment overview

Let's look at the main features of the most popular compact devices with which you can cut aluminum profiles.

Jigsaws

To cut an aluminum profile, you can also use an electric jigsaw. This is a very convenient and compact tool that many home craftsmen have in stock.

Before getting down to work, it makes sense to make sure that the device has an appropriate saw for metal parts. Wood blades can easily cut aluminum, but the quality of the cut will not be the highest. The cutting process itself begins from the rear, after which the side edges are sawed one by one.

Let's find out what strengths jigsaws demonstrate.

Electrical equipment significantly simplifies any work, especially when compared with manual devices.
The quality of the cut made with a jigsaw can be almost perfect. There will be no burrs, bevels or other possible defects.
The work will not take much time.
There is the possibility of repeated use if you choose the right file.
A jigsaw will cost much less than other similar devices for cutting aluminum profiles.

The tool in question does not have a large number of serious shortcomings. However, the craftsman will need to ensure that the workpiece is fixed as firmly and reliably as possible. Otherwise, during cutting, it may “lead” under the influence of the jigsaw.

Plasma, laser, milling systems

Plasma and laser machines are the ideal solution if you want to cut metal as quickly and efficiently as possible. True, such options are not suitable for home use. Plasma cutter and laser machine belong to the category of professional equipment. Such equipment can be found at various large enterprises.

Such equipment has the following positive characteristics:

cutting aluminum with a laser or plasma machine will only take a couple of minutes;
the master only needs to set up professional equipment, and all other work is done by the machine;
The quality of the cut with such equipment will be the highest.

The disadvantages include:

the high cost of such high-quality equipment;
it is not possible to use such equipment at home or in a garage;
Laser and plasma machines make a lot of noise during operation.

We should also talk about modern milling machines. Such equipment must be correctly configured by the operator to work with aluminum. This requirement is explained by the high softness and ductility of the specified material.

It is also equally important to set low speed rates for milling equipment (from 5000 to 9000 per minute). You will first need to drop a little kerosene onto the area where the cut will be made.

Feeding the workpiece here should be as careful as possible, otherwise the machine’s cutter can be damaged. The pros and cons of a milling machine are similar to those of a laser and a plasma cutter, but the quality of processing parts is slightly less qualitative.

Often different types of saws are used to cut metal. Let's learn about the characteristics of the most popular options.

Circular. Similar to a hand tool, but with more power. A circular saw can be used to make longitudinal, transverse and oblique cuts (for example, at an angle of 45 or 90 degrees). Modern technology can eliminate overheating by turning off at the right moment. This is a durable, reliable and practical device, maneuverable, and reduces work time.

Disk. Many models of circular saws are capable of cutting very large workpieces. The tool itself may have very small dimensions. A circular saw can be used to make corner cuts. The accuracy of the work here is as high as possible. True, a saw with a special disc in its design will cost a pretty penny.
Trimming. In many ways similar to a circular saw. Can cut lengthwise, straight, or at an angle. The workpiece is firmly fixed in special clamps. A miter saw can be used to cut long aluminum profiles.