One of the most common metalworking operations is cutting. It is a technological process during which sheet or high-quality billets are divided into parts of the desired format. Modern types of metal cutting allow you to perform this operation with high accuracy and minimal scrap.
Manual mechanical cutting methods
The most affordable and widespread approach to cutting metal billets is still the use of hand tools. And in the domestic sphere, and in construction use all kinds of carvers, guillotines, and sometimes grinders. Disk cutters on the frame effectively cope with strips of metal, and with pipes, as well as with fittings. It is enough to firmly fix the cutter platform to the floor surface and carry out work operations with the handle. Especially for sheet metal processing , a machine guillotine is used. Its principle of operation is generally similar to the cutter - the master is required to perform similar manipulations, but the mechanics of influencing the workpiece itself are different due to the design of the cutting part.
Manual types of mechanical cutting of metal with the use of electrical fillings are rarely used due to the low level of security. Such methods include the already mentioned grinder (angle grinder) and a circular saw, for which special disks will be required. Both options in compliance with safety rules can be used in cases of transverse cuts, in the processing of pipes, angles and channels. But to achieve high quality in both cases will not work.
Industrial mechanical cutting
At the level of professional in-line processing within the production, of course, manual cutting methods are not used. Today, metalworking enterprises widely use band saws, consisting of a body with a supporting part, a high-power electric motor up to 1-1.5 kW and a band saw that is mounted on pulleys. The average cutting speed on such a machine reaches 100 mm / min while maintaining high precision edge processing. Moreover, the latest mechanical types of metal cutting actively use electronic means of automation and programming operations. This provides a more detailed adjustment of operating parameters, makes it possible to simulate cutting parameters, process the same edges and form a curly cut according to computer graphic templates.
Industrial Impact Cutting
The method is implemented by equipment such as a guillotine, but not in the manual aforementioned version, but with electromechanical, hydraulic and pneumatic drive systems. The operator is only required to lay the workpiece (usually a sheet) on the desktop and fix it with clamping guiding elements. Next, the employee presses the button through the remote control or control panel, after which a special knife hits the technological hole, cutting through the laid detail. The principle of force is determined by the drive used. The guillotine type of metal cutting with hydraulics, for example, is considered the most powerful, allowing you to accurately deal with 6 mm sheets. In electromechanical models, the emphasis is on the implementation of automatic feeding of blanks, which positively affects productivity.
Plasma cutting technology
This group of metal processing methods involves the use of a plasma high-temperature jet formed by gas mixtures. The technology has been used for several decades, but only in recent years it has been possible to achieve tangible optimization in terms of the organization of the process, saving performers from the need to use gas cylinders and bulky equipment.
Modern types of plasma cutting of metal include the use of compact and ergonomic plasma cutting machines that generate a high-temperature electric arc. Under the action of ionized gas flows, a metal melt is formed. The method is quite effective, but requires high power to maintain temperatures of the order of 20,000-25,000 ° C. With these modes, you can count on the following cutting thickness indicators:
- Alloyed and carbon steel alloys - up to 50 mm.
- Copper - up to 80 mm.
- Cast iron - up to 90 mm.
- Aluminum - up to 120 mm.
According to experts, plasma cutters justify themselves with high-precision processing of workpieces with a thickness of up to 100 mm. Thicker products are more appropriate to cut in other ways, which will be discussed below.
Laser cutting technology
One of the methods of high precision cutting, which also allows engraving. To date, the following types of lasers are used for metal cutting:
- Universal. They can cut, in addition to metal, plastic, wood and composite materials.
- Fiber. The laser is generated by a fiber optic optical filling that provides high cutting speed with minimal material loss. By the way, the width of the cut line can be up to 0.1 mm.
- CNC models. The regulatory framework is based on numerical control.
- Industrial models. They focus not only on the quality of cutting, but on power and performance. Such machines can handle up to 10 tons of billets per day.
One of the few drawbacks of all types of laser cutters is the restrictions on use in relation to certain types of metals. This primarily applies to titanium and aluminum, but depending on the characteristics, some of the high alloy alloys may not be allowed.
Thermal metal cutting
A fairly extensive group of methods that are widely used in industries, in construction and in the household. The most effective types of metal thermal cutting are based on a combination of the principles of laser and plasma processing. The emphasis is on a balanced combination of the power of temperature exposure and the accuracy of optical radiation. The technology is implemented by thermal cutting machines, which, depending on the functionality, can also perform figured cutting and engraving operations, chamfer and process ends.
Oxygen cutting of metal
The method is based on the high-temperature effect of a welding arc, which is formed during the combustion of a gas-oxygen mixture. Unlike conventional gas, thermal and plasma processing methods, this method requires preliminary heating of the part and only then the gas-oxygen stream enters the case, accurately forming a cut line on the target surface. The quality of work will largely depend on which tool is used. At the moment, there are several signs of the separation of cutters for oxygen cutting of metal by type:
- Appointment - for manual or automatic cutting.
- Type of fuel - on acetylene, on substitute gases or liquid fuel.
- Type of cutting - separation, surface, flux.
- The principle of operation is non-injector or injector.
- The level of oxygen pressure is high or low.
- The type of mouthpiece is multi-nozzle or slotted.
Waterjet cutting
A very technological and productive method of processing various materials, thanks to which metal blanks can be cut with a thickness of about 300 mm. The main means of action in this case is a water jet supplied under high pressure at a level of 6000 bar. For its supply, diamond, ruby and sapphire nozzles with an outlet diameter of up to 0.1 mm are used. Almost all types of metal cutting in this way involve mixing sand abrasive particles (usually pomegranate sand). There are also techniques using fine metal sand that can be reused. As for productivity, according to average estimates, waterjet plants provide cutting of metal with a thickness of 100 mm at a speed of about 20 mm / min.
Conclusion
Cutting metal with certain parameters may be required both by construction or manufacturing enterprises, and by an ordinary private trader. Such problems can also be solved in different ways, but it is far from always possible to use specialized equipment. Therefore, there is a separate type of activity - metal cutting with the possibility of additional processing. Prices for such services are on average 500-700 rubles / m with a workpiece thickness of 70 to 100 mm. You can do it yourself if you are talking about small volumes and there is a grinder or a mechanical cutter at hand. At least, such equipment is quite affordable for the same home master.