Cutting Aluminium

[fluxcored]

Hi All,

I have to cut 75mm round aluminium stock currently by hand with a hacksaw and am obviously not enjoying it too much.

Referring to this thread - http://www.mig-welding.co.uk/forum/showthread.php?t=85 - where Hitch mentions using a stone/masonry disc. How safe is this method?

Also if memory serves me correctly, Bosch makes aluminium cutting discs but is it safe to use on this thick stock? Worth a try in any case - I'll see what I can get from the hardware this afternoon.

Oh, btw. I've got no bandsaw.

Any suggestions/advice, safety tips will be appreciated.

 

[langy]

I have a DeWalt mitre saw fitted with an ally cutting blade, I reguarly cut 2" & 3" square bar, it slices through like a knife through butter.

 

[fluxcored]

I've tried cutting 20mm thick flat ali bar with my el cheapo Ryobi mitre saw last December and admits to soiling my pants.

Not a fan of that machine probably because it's Ryobi.

But an option that I will look into - thanks Langy, I did'nt know that you get ally blades for these types of saws.

 

[langy]

Bought mine with the blade already in it about 16 years ago, its done a lot of work over the years and still got the same blade !!!
A slight spray of WD40 helps achieve a nice cut.

I've tried cutting 20mm thick flat ali bar with my el cheapo Ryobi mitre saw last December and admits to soiling my pants.

Not a fan of that machine probably because it's Ryobi.

But an option that I will look into - thanks Langy, I did'nt know that you get ally blades for these types of saws.

 

[Big Mick]

A chopsaw with TCT blade will do the job.
http://www.machinemart.co.uk/shop/p...th/power-hacksaws-bandsaws-metal-cutting-saws

But for that money, you could get a cheap bandsaw!

Cheers, Mick.

 

[julieanncharters]

cutting ali with a wood chop saw is fine with the right blade fitted.
typical ali or non ferrous blades have lots of small teeth and no offset .
better Ali blades i have use have tips of teeth rounded not square which seem to give a smoother cut.
you can get em anywhere these days even B&Q
got last one from screwfix

 

[Hitch]

Using a grinder with a stone disc is fine, it doesn't clog up quite as much.
I wouldn't bother doing it like that if there is a better way though. If you have a fair bit to cut, and it will all fit in your saw, a negative raked blade suitable for cutting metal will be a better option. Don't forget goggles whatever way you choose.

 

[fluxcored]

Mick - Agreed. I looked at the Evolution Rage2 saws and can get a small bandsaw for cheaper than that.

Julieanncharters - thx for the description, now I know exactly what to look out for.

 

[fluxcored]

I should have mentioned that a rough cut is fine - I'm cleaning it all up in the lathe afterwards.

Hitch - you are talking about stone cutting discs are'nt you??

 

[Hitch]

Yes, not the diamond ones though The ones that look similar to the metal cutting discs.
The proper ally cutting ones are better mind you.

 

[Shox Dr]

Lubrication is the key to cutting Alloy.

If you only have a grinder;
Use a bar of soap, on a grinding wheel before adding when necessary throughout the cut. Makes a world of difference

 

[fluxcored]

Yes, not the diamond ones though The ones that look similar to the metal cutting discs.
The proper ally cutting ones are better mind you.

Allright, I think I've got a stash somewhere in the garage.

Thx, all - will report back on how it all goes.

 

[morrisguy]

Power hacksaw

You might find an old Power Hacksaw that just needs some TLC . I have two of them I bought cheap , fixed one up and it works well.

Mike in Australia

 

[fluxcored]

You might find an old Power Hacksaw that just needs some TLC . I have two of them I bought cheap , fixed one up and it works well.

Mike in Australia

Hi Mike, I'm actually building one but the going is slow. I'm new to machining and am learning how to turn shafts, pulleys, bushes, etc.

Dr. Shox, I'll make sure that I've got a bar of soap on hand.

 

[fluxcored]

It works really well - cutting with stone cutting disc that is.

The kerf's massive as should be expected and the disc does'nt seem to last very long but that may be due to me using some cheap generic disc.

It produces lots of dust so I would recommend cutting outside and wearing a mask.

I used the soap from the start so I can't say whether it helped or not using the cutting disc. But I made a cut with a hacksaw through 20mm round ali bar and the soap did make a lot of difference. So I am also now a convert of using soap when cutting ali.

Oh and I did find ali blades for a mitre saw locally and it's not that expensive either.

I'm very happy. It's given impetus to some of my projects that's been going slow for some time now.

Thank you all who have taken the time to reply and assist.

Regards.

 

[Wedg1e]

I use a wood bandsaw with 24tpi blade, goes through 12mm alu plate like it was cardboard so it'd do a lot thicker given time.

Dip a paintbrush in paraffin and coat the blade periodically.

 

[fluxcored]

Thx, Wedg1e. Will keep it in mind.

 

[Pete.]

I've cut ally bar with a cheap mitre saw fitted with a standard tipped blade designed for timber. It made a heck of a lot of noise but cut quite nicely.

 

[julieanncharters]

yep if ya not doin a lot a standard cheap chop saw is fine on ali as long as the blade is new.
i'm doin a fair bit so use the proper non ferrous blades as they make a lot less noise and the cut is really clean,

i don't use any wax,soap or anything else as its just more work cleaning it off before tig welding.
elfyn