You should always lubricate the blade no matter what type of blade it is. We recommend saw blade wax sticks for this purpose, as they are the easiest way to accomplish this. You will also need to take other simple precautions as well, such as clamping the material and wearing protection. For those looking to purchase a circular saw, we recommend Craftsman Circular Saw.
Table Saw. You can also use a table saw to cut through most aluminum. Table saws have plenty of power and precision for most grades of aluminum. If you can get it, choose a blade that is specifically designed for aluminum.
Many companies make these for their table saws, but not all of them do. Aluminum also creates dust, which may be hot from the friction of the blade. You should turn off your dust collection system while cutting aluminum. We prefer the Tacklife Table Saw for most uses. Electric Shears. The top three methods are the best way to cut lots of aluminum in a short amount of time.
They are lightweight and portable, making them perfect for cutting small patterns and getting the details just right. Most electric shears can work on aluminum up to gauge.
This should work for most projects, but it will not be suitable for thicker pieces of aluminum. You will have to cut slowly with electric shears as well, though this can be said for nearly all tools used to cut aluminum. The worst part about these tools is that they rely entirely on your accuracy. We recommend the Genesis GES40 4. Dremel Rotary Tool.
If you need precision overpower, then a Dremel tool is the best option for you. There are a few different ways you can do this. Firstly, you can use a tungsten carbide tip blade to drill small holes and remove small pieces of material. You can also use an attachable saw blade to make cuts.
You have to be careful with this method, but it is doable with the right precautions. This method is best for those who already have a Dremel or who need to cut precisely. We recommend the Dremel Multipurpose Cutting Bit in particular for cutting aluminum. It can also cut through plastic, wood, fiberglass, and other materials, making it a solid bet for most projects.
Pros Precise Plenty of power to cut through aluminum Cons Slow Not best for thicker pieces of aluminum 6. Aviation Snips. For those who are cutting thinner sheets and on a serious budget, a set of aviation snips may be plenty suitable for your needs.
They get the job done, though they are quite slow going. These shears are only going to be as accurate as your hand, however. They require users to be very slow with their cuts. This can be a problem for some people, especially beginners who are a bit more inexperienced. These probably work best for smaller projects. They can cause your hand to fatigue quite quickly. Yellow is usually for straight lines, while green is for cutting to the right, and green is for cutting to the left.
Make sure you wear gloves when using these as well since the metal can be very sharp after it has been cut. Pros Inexpensive Suitable for smaller sheets Cons Only as accurate as your hand Fatigues your hand quickly Only suitable for small projects 7. Utility Knife. If you have no other options, you can cut aluminum with a utility knife. However, it does work.
All you need is a sharp utility knife and a straight edge. Use the knife along some straight edge to score the aluminum on both sides and then snap it apart. As you might imagine, this only really works for some cuts.
However, it is the most economical method if you need to cut straight on a thinner sheet. However, if you need to cut a sheet or two in half, this is a reliable option to try. You will need a utility knife that is strong enough and durable enough to score aluminum. Non-woven discs and wheels are ideal for decorative finishing, satin and antique finishes, final sanding, soft metal finishing and fine burr removal. Power brushes for cleaning also help get the job done quickly without applying excessive pressure that could damage the aluminum.
It is important to use high quality, contaminate-free products and to let the wheel do the work. Applying pressure to increase performance will only lead to additional frustration and compromise quality. Also, a strong, consistent weld begins with proper surface preparation.
The cleaner the seam being welded, the better the weld penetration. For best results always use a product that is designed for use on aluminum. The best products will cut cleanly and smoothly without pitting, gouging or undercutting.
There are several high performance products available to get the job done quickly and efficiently, so always consult your trusted distributor abrasive manufacturer to understand what options are available for the application.
For more information and to view an aluminum solutions guide, please click here. Thanks Rick, for that very informative tip. However, you did not mention which type or types of abrasive material would be suitable for finishing aluminum. Would you care to share? Its interesting to note how you explained that since aluminum is easy to damage, some welding operators use non-woven hand pads or steel wool to finish by hand and minimize potential damage to the part.
My interest in this came around after having a conversation with my brother on industrial aluminum polishing last Tuesday afternoon. I wanted to do know more about and thus, my research led me here. Thanks for all the information! AAG is excited to announce the launch of their new corporate website, aagcnc. Skip to content Supplier Directory Subscribe.
In addition to loading, other common challenges when working with aluminum include contamination and the potential for porosity and oxide inclusions, and achieving the desired finish: Porosity can occur when contaminates from abrasive products release from the wheel and contaminate weld surfaces.
This compromises the structural integrity of the weld. Things You'll Need. Related Articles. Article Summary. Method 1. Use a wood-cutting saw with carbide-tipped blades to cut most aluminum. If possible, choose a saw blade that creates narrow kerfs the notch or slot made by the saw.
Apply cutting lubricants on your blades or bits. This can range from standard oil to saw wax. Since you'll be cutting metal on metal, you want to lubricate it to prevent sparks and slippage. WD is the standard lubricant when cutting aluminum. Apply 5 to 6 small spurts on both the bottom and top halves of the blade. Reduce the diameter of the cutting blade for better results. The cutting speed used for wood is generally going to be too fast to safely cut aluminum. For example, if you use a 10 inch 25 cm saw, you can reduce the blade to 7.
This will slow your cutting speed. If it's not possible to alter blade sizes, consider purchasing equipment with a variable speed router and use the slowest setting. These types of equipment are typically more expensive, but offer a degree of flexibility ideal for cutting aluminum. Use a C-clamp to secure your aluminum piece s. Loosen the bar within the jaw by turning it counterclockwise. Place the clamp upright, with the open end of the jaw facing your working surface and the bottom of the jaw underneath the tabletop.
Place your aluminum into the jaw and tighten the clamp around it by turning the metal rod clockwise. This allows you to cut your aluminum without getting near the blades. Feed the aluminum through the blade, or the blade through the aluminum. Hold the saw firmly with your dominant hand. Apply downward pressure as you move the blade along your metal.
Be sure to work slower than you would with wood. Steady, even pressure is the safest way to go. Remain clear from the kickback zone where recently cut pieces are thrown clear by the power of the saw when cutting. This is usually directly behind the saw. Alternately, you can use a bridge to secure your saw and reduce kickback. Always keep your fingers away from the saw blade.
Retract the blade guard and hold it beside your aluminum piece. Loosen the depth adjustment knob or lever and rotate the base of the saw until the blade is 0. Afterwards, tighten the knob or lever. Use a jigsaw if circular cuts need to be made in the aluminum.
Clamp a guide to your aluminum on both sides of your saw. Position the saw close to the side of the aluminum where you want to begin cutting. Afterwards, lower the blade approximately 0. Push the saw slowly across your aluminum piece by twisting the back of the saw into the direction opposite to the direction you want the blade to move. Always use carbide-tipped blades. Lubricate the blade before using it, and cut slowly. Method 2. Purchase a cold chisel that is 1 size wider than the aluminum.
Use a measuring tape to determine the width of your aluminum. Afterwards, select an appropriate sized chisel. Sharpen your chisel to a to degree bevel using a honing guide. Fit your chisel into your honing guide a tool that clamps onto your tool either from the sides or from above and below and tighten the screws on both sides to keep it in place.
Set the guide to the appropriate angle, and then place the bevel the metal edge of your chisel against a second-cut, medium-coarse file. Hold the guide with both hands and move the chisel back and forth in a thin, figure-eight pattern. When new scratches begin to appear, switch to a fine grit. Wipe the bevel between each grit using a dry, clean cloth.
Place your aluminum piece into your vice and tighten it. Position the piece in the center of the vice's jaws. Make sure that it's tightened firmly in place. Align the chisel with your vice's screw and hammer the aluminum. Hold the chisel tip against the metal—perpendicular to it—with your non-dominant hand. Use a ball-peen hammer to strike the chisel's handle and always cut perpendicular to the jaws of the vice. Continue striking the metal until there is a notch in it.
At this point, you should easily be able to snap it into 2 pieces with your hands. You should be able to cut your aluminum metal piece within 30 seconds. Anything longer and you're probably using the wrong sized chisel, or you need to use a saw.
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