Drilling large holes is not a problem if you use the right tool. For example, such work may be necessary to secure a channel or metal corner. The easiest way is to use an electric drill, but it takes a lot of effort to get a hole with a diameter of, for example, 15 mm. To drill a large diameter hole in metal, special tools and core drilling technology are used.
Creation features
During drilling, it must be taken into account that the crown or stepped cone nozzle must be selected in such a way that it has a smaller diameter than the hole being created.
Using various tools it is also necessary to take into account their features. For example, when reaming with conical products, even edges are obtained.
Drill attachments
There are several attachments for drills that make the process easier and make big hole smooth:
- Drilling guide. Such a device is a housing in which there are several guide bushings for drills of different diameters. The material used to make the bushings is harder than drill bits, so you don't have to worry about the tool tipping to the side while drilling and widening the hole.
- Drill guide. Such a product allows you to fix the tool so that during drilling it does not deviate to the side. In the absence of such a product, the tool may move to the side, which will lead to the creation of an uneven edge. It can also be fixed at an angle. But when drilling metal products this is usually not required.
- Drill stand. A similar DIY product can be an inexpensive replacement drilling machine, as it allows you to more comfortably carry out the work. The fixed tool, when using the rack, moves along the bar with the help of a lever. In this case, displacement is completely excluded, since the workpiece to be drilled is securely held due to the presence of a clamp.
Using these products, you can greatly facilitate the process of drilling metal products.
Feature of deep holes
To drill into metal deep hole It is best to use a lathe. During this process, cooling must be carried out. In this case, the chips must be forcibly retracted. Periodically, the tool is removed from the workpiece to remove chips.
When working without specialized devices, you should not sink the nozzle by more than 2/3 of its length. Water must be used for cooling during operation. If the work is done in several approaches, a change in the angle is not allowed.
Features of Large Diameter Holes
This procedure is more complex than deep drilling. Cutting work is carried out either using a crown or using a cone drill. Crowns for metal are similar to products for concrete and drywall. The difference lies only in the material used to create the cutting edge.
Also, drilling can be done with standard products in several stages. To do this, first use a small diameter nozzle. Then a larger instrument is selected.
Most convenient way is the use of cone drills. Such devices allow you to drill a hole in one go. big size. To do this, the tool is simply recessed into the material.
Drilling without the hassle
During operation, you can use a nozzle of a small section, as well as a used grinding wheel for a grinder. It is important to remember that it must have a smaller diameter than the hole being created.
Before carrying out work on the workpiece, a circle is marked for the hole, and the second circle will be less than the first by a distance equal to the diameter of the drill used. After that, 2 holes are marked in opposite places of the circle. From them it is necessary to retreat 3 mm and outline the places for drilling. Thus, drilling occurs along the entire drawn circle. If necessary, some areas will have to be processed with a chisel. As a result, jagged edges will be created, which will then need to be turned. It is important to ensure that during the work there is no increase in the circumference, i.e., do not expand the planned diameter.
Cone drill
The described types of drills are made from tool steel. Shanks of such products can be hexagonal and cylindrical. The cutting edge removes all burrs, so the edge is smooth. At the end of the drill head there is a sharpened tip that allows pre-drilling of the material.
Using these products you can:
- to create cuts with a diameter of up to 30 mm;
- forget about uneven edges;
- carry out boring of various diameters without changing the nozzle.
With step drills, cuts of various diameters can be made in sheet steel up to 4 mm thick. Unlike a simple cone drill, when using such products, the drilled diameter is fixed.
The disadvantages include:
- the need to use a tool with low speed and high torque;
- sensitivity to even small distortions.
Despite these shortcomings, this nozzle allows you to conveniently work with metal plates, quickly drilling circles of the desired diameter.
Crown for metal
Metal processing is a complex process, so such work is usually done using specialized equipment. To do work in living conditions, core drills can be used.
Such products allow you to make the edges round and centered. In this case, a standard drill is used for drilling. Products consist of several parts:
- crown;
- centering nozzle;
- product shank;
- screws needed for fixing.
When using a core drill, the speed of work is increased up to 10 times. Also, the advantages include the ability to accurately drill in the range from 1.2 to 15 cm.
Thus during drilling it is not necessary to make centering. It is also worth noting that such drills have a higher wear resistance compared to spiral drills.
Before starting work, a center drill is installed in the center of the circle, after which drilling is carried out. After that, the drill is retracted and the work is carried out by the crown.
Hole press
One of the most common methods is punching with a special press. It happens like this:
- First, the workpiece is placed on the press table and gripped by several clamps.
- The metal is then moved under the punching tool. At this stage, there is an additional fixation of the material with the help of a clamping ring.
- At the last stage, penetration occurs with the help of a punch.
The revolver can have several nozzles of different diameters, which allows you to quickly create holes of different diameters. Such equipment is usually not used for working with metal in a domestic environment.
If the work is planned to be done at home, you should choose universal tool. This will allow you to easily process metal without worrying about purchasing additional parts. The presented video will acquaint you with the technology of the process in detail.
Metal is the material that the angle grinder (angle grinder) was originally designed to work with. Now, with its help, reinforcing bars, various metal sheets, pipes of various diameters, brick, concrete, stone, tile and other building materials are cut. Due to the presence of a variety of nozzles, the grinder also allows you to polish and grind the surfaces of products. Cutting metal with a grinder is one of the main, most frequent work. To reduce the likelihood of injury, it must be performed correctly, with strict observance of the requirements of general and personal safety.
Bulgarian belongs to the category relatively hazardous power tools. You can get injured from a scattered disc or a tool that has fallen out of your hands. In both cases, the danger is associated with the high speed of rotation of the device's electric motor.
To improve the efficiency of the grinder, expand its functionality, in practice, such accessories:
- tripods;
- clamps.
Their use allows to improve the quality of sawing metal blanks, to increase the accuracy of the process. Also, working conditions are improving from a safety standpoint, and its productivity is increasing.
The use of additional devices allows you to use the tool as a machine tool designed to perform different types works.
In order to secure the cutting process as much as possible, you should work on metal with an angle grinder in compliance with a number of rules. They are conditionally divided into preparatory and main (working) activities.
Before starting cutting, it is necessary to carry out a number of manipulations.
If possible, the sawn material should be securely fixed in advance, for example, in a vice, in order to remove possible accidental movements. Do not hold workpieces in your hands or between your knees.
Proper tool operation
When you start sawing any part with an angle grinder, you should follow these rules.
- When cutting metal, hold the grinder firmly with both hands.
- Wheels can only be changed after they have completely stopped rotating and cooled down to an acceptable temperature by disconnecting the power tool from the mains.
- Do not put a working tool on the ground or a table (do not let go of it).
- Required intermittently for about 5 minutes stop for rest and keep the disk 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 a plugged-in tool unattended.
- Use discs only right size specified in the operating instructions for the device you are using.
- Better work done on a flat surface to keep the body in a stable position.
- Make sure that the power cord is away from a rotating circle, sharp edges, objects heated to more than 100 degrees.
- Movements not directly related to cutting should only be carried out with the power tool turned off.
- It is necessary to be located on the side or behind the tool, doing the work with your own hands so that the parts of the body are not in the plane of the cut.
When the cutting of the metal with the grinder is completed, you should wait until the disc stops completely, disconnect the power cord of the tool from the mains. After that, it is recommended to make sure that there are no signs of fire. When cutting materials, right-handedly hold the handle of the device in the area of the on / off button right hand. Left hand at the same time, it is located on a handle screwed into the body of the power tool from above.
It is unacceptable to perform work using a grinder in a very tired state, or while under the influence of alcohol, psychotropic or narcotic drugs.
As for the question of which direction - towards itself or away from itself - the disk of the included angle grinder should rotate, there is no unequivocal answer here. V operating instructions indicates that the first option is correct. This is due to the fact that the resulting sparks fly off in the opposite direction from the operator, without causing harm. Also, fragments of the circle will fly in that direction if it shatters into pieces.
But in the case when a jamming of the disk rotating “on itself” occurs, the tool will fly off into the working one. For this reason, many experts prefer to cut metal so that the circle rotates “away from itself”. The power tool torn from the 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.
Cutting sheet metal grinder
To cut metal of different types and thicknesses, use appropriate cut-off wheels of different thicknesses and diameters. The algorithm for cutting sheets is as follows.
- For cutting with a grinder, sheet metal is pre-laid on a flat surface.
- Mark with chalk (marker) the exact dimensions of the cut fragments on the surface of the sheet.
- Sawing is carried out along the marked lines, without changing the angle of the initial inclination of the disk to the working surface, so that it does not jam and break the power tool.
If there are no skills in sawing sheet metal with a grinder, it is recommended that you first practice on soft material This will give you a feel for how the instrument works.
It must be taken into account that the lower near segment of the disk cuts the metal more effectively.
When cutting a sheet of metal, to obtain a quality result, you should take into account such recommendations.
- Cutting space required for better cooling pour water, which will also increase the life of the circle.
- It is worth starting cutting metal only when the disk is rotating: you cannot turn on the tool if the stationary circle is in contact with the surface of the workpiece.
- To cut tin (thin sheet metal) or cut out various geometric shapes, it is more convenient to use small, worked out circles("stubs").
- You should not press the grinder with significant effort: cutting should occur almost exclusively under the own weight of the angle grinder.
- If the cutting wheel stops in the slot (when the power tool is turned off), then work can only be resumed after it has been removed.
If sawing the sheet is slow, you should change the working head. Excessive load on the angle grinder when cutting metal will lead to its overheating or jamming of the rotating circle.
Cutting a round hole in metal with an angle grinder
In practice, it is often necessary to cut a circle in metal, and only an angle grinder is available from the tools. But it is quite enough for this purpose. The algorithm of actions is the following.
- A circle is drawn with a compass on the metal surface or according to a pre-made paper (cardboard) template with chalk or a marker.
- Holding the grinder at an angle to the surface of the sheet, a preliminary marking cut of the metal is performed along the marked contour, making short movements with the disk (sawed in small segments).
- Then, moving the nozzle in the same way, deepen the slot until it is completely cut out.
Need to cut along the outer contour of the circle so as not to reduce the size of the circle. If its diameter is small, then they cut, touching the metal with a disk point by point (without longitudinal movement of the nozzle). A round hole will turn out with an oblique cut, as well as with some minor flaws (they depend on the skill of the worker). After it, if necessary, processed.
The whole process of cutting a round hole in sheet metal via special device shown in video:
Features of working with thick metal, copper, cast iron, aluminum
When it is required to cut thick metal into separate fragments, it is recommended to additionally perform the following steps:
- constantly cool the area of contact of the metal with the disk using cold water due to strong heating of the slot;
- make all cuts only in a straight line;
- different curvilinear contours should be cut in separate straight segments of small length, while removing unnecessary parts;
- it is necessary to completely cut the workpiece in several approaches, with each subsequent deepening of the slot;
- if it is required to cut corners, I-beams, channel bars, rails, then each of their structural parts is sawn separately.
Cutting cast iron, stainless steel, as well as non-ferrous metals such as aluminum and copper, is carried out using special circles designed to work with these materials. All the necessary information information about discs is contained in the labeling of these products, applied on their side. At the same time, the circles differ in the composition of the fillers:
- in some, the additive is a heavy-duty material that can cut alloy steel;
- others use soft binders.
Cutting stainless steel with conventional metal discs is prohibited, because they contain substances that lead to accelerated corrosion of the cut point. Aluminum and copper are very tough non-ferrous metals. They are cut with a grinder, pouring kerosene slot formed by the disc. It is necessary to follow the rules fire safety.
Cutting pipes from different metals is a demanded operation during repair and construction work. It is necessary to cut off the products during the installation of sewer and heating systems, water lines. In this direction, the grinder copes well with various tasks. Disks for work are selected according to the material from which the pipe is made.
Application of angular grinder give a chance:
- cut pipes at different angles, for example 45 and 90 degrees;
- cut products of large diameter;
- evenly cut profile (rectangular or square) pipes;
- to make longitudinal cutting of tubular blanks;
- sawing cast iron pipes;
- cut thin-walled tubes.
If you need to cut a large diameter pipe, then using a grinder allows you to do this work without significant cash costs. But at the same time, labor productivity is small, and the risks are considerable. When long pipes lie on supports, they only saw off hanging parts. If you cut in the center, the cutting edges will pinch the cutting wheel, which will lead to jamming of the tool and possible injury.
Specialists not only cut pipes from different materials at the right angles, but also cut holes in them of the required shapes. Work with profile and round blanks is carried out in a similar way, with the obligatory observance of safety regulations.
Cutting pipes at different angles
It is necessary to cut round and shaped pipes at an angle of 45 and 90 degrees when laying various communications. In any case, it is necessary to saw off the pipe evenly so that the elements that need to be connected are connected to each other as tightly as possible.
Rez at an angle of 45 degrees cylindrical pipes are carried out as follows:
- take a regular square paper sheet;
- fold it exactly diagonally;
- wrap the pipe with this template;
- a future cut line is applied with chalk or other marking device;
- remove the template;
- clamp the workpiece in a vise;
- cut off the marked pipe fragment.
When applying the template, either of the two short sides of this triangle must be parallel to the central axis of the pipe.
When to cut at an angle of 90 degrees, pipes are simply wrapped in a circle (cylindrical) or around the perimeter (profile) with a sheet of paper. After that, mark the cut line. You can also mark the profile pipe very simply using a regular square.
If it is necessary to cut at an angle of 45 and 90 degrees a significant number of profile pipes, appropriate templates are made from this material, only with a larger section. This allows you to perform the required measurements only once. At the same time, a construction square or a protractor is used for the initial marking. When the template is made, cut blanks are inserted inside it, marking the cut lines. Then sawing is done.
Templates are also made for other angles. This method improves labor efficiency.
Features of cutting cast iron and thin-walled pipes
Cast iron is brittle material . To saw through cast iron pipe grinder, act in the following sequence:
- mark the cut line;
- put under the pipe wooden block who will serve as her support;
- make a cut along the contour with a depth of several millimeters;
- insert a chisel into the recess made;
- according to the instructions, they hit hard and sharply with a hammer.
After the impact, the pipe will split along the cut line. Its edges will be fairly even. If necessary, they are further processed.
To perform longitudinal sawing of the pipe, it is also important precise marking. For its application, various devices are used, for example, a construction thread (“beat”). The entire sawing process should be done carefully, slowly, so as not to stray from the marked line.
Thin-walled pipes are one of the varieties of this kind of products. They are often made of non-ferrous metals: copper or aluminum. Cutting them is difficult. In this case, circles for the grinder should be used corresponding to the material of the workpiece.
Sawing thin-walled tubes must be done very carefully, because they can easily be deformed even by applying a slight load.
To reduce the likelihood of bending the part being cut, various loose fillers are poured inside it, for example, ordinary cleaned sand.
Cutting profiled sheets and metal tiles
Quite often, in practice, one has to face the need to cut a profile sheet or metal tile. These materials are made of steel, which is coated with zinc and polymer protective layers, painted.
Regarding the possibility of using a grinder for cutting them, they speak different opinions. The installation instructions say that the profiled sheet cannot be sawn with an angle grinder. To do this, you need to use other tools. But they need to be purchased, which is not always justified by the amount of work to be done, and also requires additional financial investments. When there is no tool other than an angle grinder, before sawing with a grinder, you should know the possible Negative consequences.
- If you cut a metal tile or a corrugated board grinder, then the protective coating in the saw cut area and a little near it will be destroyed, and the cut edge will begin to rust.
- The material is out of warranty.
- Flying sparks can spoil not only the appearance of the rest of the sheet (burn through the paint), but also damage the polymer coating.
- The cut edge may be torn.
All the considered negative consequences can be minimized if you cut the corrugated board or metal tile with a grinder, observing the following recommendations:
- perform all work immediately before installation;
- treat sections with anti-corrosion compounds;
- cover the cut edges with a primer and paint;
- use discs for metal minimum thickness(up to 1 mm);
- to keep the edges neat, you need to cut pretty quickly;
- carefully sand the torn edges.
Before sawing, as usual, carry out sheet layout.
If you need to cut a square, then do this:
- draw it on the surface of the sheet;
- cut the material along the marked contour with a grinder;
- at the end, carefully cut out each corner.
Circles or other shapes are cut out, working in the same way.
The use of a grinder for cutting metal tiles and profiled sheets facilitates the work. It becomes more convenient to perform it, because you can adjust the sheets to size directly on the roof.
In order for the metal tile or profiled sheet to remain under warranty, you should measure the object and order the factory cutting of the sheets. You can also try to choose a material with such dimensions that cutting is not required.
Cutting metal with a grinder is cheap, practically affordable and quite effective method sawing it. In this case, appropriate discs without defects should be used for each material. Not only the quality of the result obtained, but also your own health will depend on this. Be sure, when sawing metal, it is required to follow safety rules and use tools personal protection. It should always be remembered that when working with an angle grinder, any shortcomings and inattention can result in injury. Therefore, you need to work carefully and carefully.
Any design, whether in your home or in production, involves working with metal.
Often, during the operation of this material, the question may arise: how to cut a circle in metal?
It deserves attention, because from the choice the right tool and technology directly depends on the complexity of the process of performing work and the quality of its result.
Methods for cutting a circle from thin metal
metal circles
Metal can be thin or thick and strong, so a variety of tools are used to cut it.
The choice of materials and cutting technology also depends on what diameter the circle is needed and how even it should be.
Jigsaw application
If there is a need for a perfectly even circle, you can use an electric jigsaw to cut it.
The work is carried out in several stages:
- First, the thickness of the metal is determined and the appropriate saw blade for the electric jigsaw is selected.
- Before cutting a circle in metal with a jigsaw, the outline of the circle to be cut is outlined on the working plane.
- With the help of a drill and a drill (with a diameter of eight to ten millimeters), a hole is cut out from which work will begin.
- A jigsaw saw blade is placed in the resulting slot and cutting continues according to the intended drawing.
Cutting with this tool does not take much time and effort. Moreover, using a jigsaw, you can get a circle with perfect edges. But this tool is used only for working with metal of minimum or medium thickness (for example, 2 - 3 mm).
The use of grinders
The grinder is used in working with metal of small thickness. Form with this tool round hole possible by following this step by step advice:
- Before cutting a circle in metal with a grinder, marking is carried out so that its contours are clearly visible.
- Along the entire length of the intended drawing, short segments are cut through the angle grinder disk, which will eventually connect.
- The figure will look more like a polyhedron than a circle. Therefore, after cutting is completed, the product is processed and cleaned until the edges are sufficiently even and smooth. For processing, you can also use the grinder. If the circle has a wide diameter, you can grind the contours with a large disk.
When processing a cut circle with a grinder, you should be careful that the disk is inside the hole and, at the same time, is located in the same plane with the work sheet.
Cutting a circle in thick metal
Cutting a circle with a grinder
In order to outline the exact contours of the figure that will be cut out of metal, you should use a ruler, a marking compass and a marker.
First, using a ruler, the required width of the compass connector is set so that it matches the required diameter of the circle.
Then the center point of the circle is determined on the metal plane.
Contours are drawn from it with the help of a compass.
So that during the robots they are clearly visible, they should be drawn with a marker.
Cutting torch application
A circle in metal of medium thickness can be cut with a gas cutter. The work takes place in several stages:
- The contour of the circle is outlined.
- The tool burner ignites.
- Burning flame is adjustable.
- Gently and slowly, the torch is carried out according to the drawn drawing.
With this method, you can cut a hole in the metal, which has a width of about four or five millimeters.
Welding Machine Application
Welding machine
If there is no gas cutter in your home arsenal, you can use a welding machine.
It needs to be adjusted to high level current.
Then a burning arc is substituted for the contour and held on it until a hole is formed.
Then you just need to slowly lead it along the drawing until you get an even circle.
But the most important thing is to correctly adjust the power of the tool.
For example, if metal is used with a thickness of about four millimeters, a device operating at a power of about 150 amperes is needed. If the metal is thicker, the power of the tool will be greater.
To speed up the process, it is better to use thin electrodes. However, they burn out quickly and need to be replaced. Because of this, there will be a need for frequent heating of the metal, since it will have time to cool down during the replacement of the electrode.
How to cut an even circle from metal with a cutter is shown in the video:
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How to cut a circle out of metal in 2018
People working with metal quite often have to deal with the need to cut a round blank from a metal sheet. In production, this problem is solved simply - with the help of oxygen-gas, plasma or laser cutting. For each type of these operations, specialized equipment is required, which there is no reason to have in private use. Therefore, in the conditions of private workshops, a circle of metal is cut out in different ways - taking into account the available equipment. 
- - gas cutting equipment;
- - welding machine;
- - angle grinder;
- - electric drill with a set of drills;
- - grinder;
- - manual lever scissors;
- - core;
- - marking circle.
- - gas cutter;
- - welding machine;
- - angle grinder;
- - electric drill;
- - center punch;
- - drill Ø4-5 mm;
- - marker;
- - ruler;
- - marking circle.
- - the cloth;
- - drawing;
- - graph paper;
- - ruler;
- - pencil;
- - scissors;
- - roller knife;
- - cardboard;
- - tape measure;
- - calculator.
Draw a circle on the workpiece. To do this, you can use an ordinary compass, but if its radius is too small, you can create a similar device. Carefully drive the nail into the workpiece and fasten the rope with the pin to it. The length of the rope should be equal to the radius of the circle being drawn. Instead of a rope, you can use a strip of cardboard or a wooden plank. After finishing the marking, securely fix the workpiece in a vise or simply fix it in a certain position. Depending on the type of material, select a suitable blade for the electric cutter and install it in the device. Connect the instrument to the network. Fasten the rod that comes with the hacksaw to the center of the circle. Attach the electric saw to the workpiece, fix the sole on the surface of the product with auxiliary screws. Start sawing along the marked line. For making holes of small diameter (up to 10 cm), a drill saw is suitable. With the help of a cutting tip, it cuts into a tree and makes an initial hole. Sawing is done using the cutting edge of the tool. Before cutting a hole, select a suitable nozzle and install it securely in the saw. A hacksaw works well for making holes in wood. Its interchangeable blades make it possible to work with almost any material. However, it should be noted that the cutting depth is limited by the arc of the jigsaw, so cutting a circle further than 40 cm from the edge of the workpiece becomes almost impossible. When cutting, guide the blade as carefully as possible to prevent distortions. Otherwise, the canvas will be damaged. When using a conventional hacksaw to make a hole, you must first drill a hole from which the cut will begin. When working with an electric hacksaw, it is enough to bring the tool to the workpiece with a slight forward inclination. The tool will automatically make the correct hole. How to cut a circle out of metal in 2018 www.kakprosto.ru
How to cut various materials with a grinder
An angle grinder, which everyone calls a grinder, can not only grind, but also cut various materials using special circles. But in order to skillfully use these opportunities, it is necessary to have knowledge and experience.
Many people have a grinder, but most people do not know how to use it correctly and how to hold it. This leads not only to marriage at work, but also to serious injuries. The grinder is a rather dangerous power tool.
The circle must be installed with the pattern up and clamped with a special nut.
The person with the leading right hand holds the grinder by the handle with his right hand. In this case, the circle should be located on the left side of the machine, and the protective cover should cover it from above. The rotation is so that during the cutting sparks fly to the worker. If the circle jams at the grinder and the grinder breaks out of her hands, then she will go not to the carver, but in the opposite direction.
The left hand holds the machine by the handle, which is screwed into a threaded hole on the body. There are several of them for special use cases, but the correct position of the handle is only the top one.
This position of the machine requires the use of protective equipment. To protect the eyes and the exposed part of the face, these are goggles, and even better - a protective mask. To protect exposed parts of the body from sparks and small fragments during the cutting process, it is necessary to wear a suit made of dense material.
How to cut straight
To cut something evenly with a grinder, you must perform correct markup. For example, before cutting a piece of pipe, it is necessary to mark the size with a marker or thin chalk. Then we take a sheet of paper with a smooth edge and wrap the pipe on the mark. We will get a paper pipe on top of a metal one. The border of the paper will be the exact path along which to saw off part of the pipe.
For these purposes, you can also use construction tape, which makes it easier to wrap the pipe and secure it. Draw a cutting line along the edge of paper or tape. We remove the paper, heal the pipe in a vise and cut it with a grinder.
In this way, you can cut a corner, profile or sheet. Do not just forget that during cutting you can not change the position of the machine. Skewed wheel will cause jamming or breakage. Do not press too hard on the circle, especially the thin one. The deformation is immediately reflected by the curvature. The machine must itself eat into the material, it only needs to be held.
The evenness of the cut depends on correct selection circle. It is difficult to achieve a smooth trajectory by cutting off part of a thick-walled pipe with a thin circle.
How to cut a circle with a grinder
Sometimes it is necessary to cut a circle on a sheet of metal, but there is no tool other than a grinder. To do this, mark the circle in the selected area with a white marker or thin chalk. The cutting line should be on the outside of the circle so as not to reduce it.
We install the grinder not perpendicular to the sheet, but at an angle. Moreover, the grinder will lean towards the center of the circle. At low speed, we make a preliminary contour cut. Both the contour and the main cut must be made in short movements, moving the position of the circle along the contour.
You can do the same with other materials. To cut a circle in a tile under a pipe with a grinder, you need to make markings on the back of the tile. Then take the grinder and make cuts along the chord inside the marked circle at a distance of 4-5 mm from one another.
Then the tile is turned at a right angle, and cuts are made perpendicular to the former. During cutting, pieces of the tile will crumble, but inside the outlined circle. The remaining cloves can be ground with a grinder first from the front side.
Naturally, the cut will be oblique, with an extension to the back. But this edge can be gradually captured with pliers and crumbled. At the end of the operation, the back side of the hole is ground. It will require accuracy, attention and patience.
How to cut tiles and porcelain stoneware with a grinder without chipping
To avoid chipping while cutting tiles, it must be moistened with water. This will timely reduce the temperature, which is the cause of the destruction. In this way, you can not only cut the tile, but also cut out the necessary fragments. Another way is to use a cutting wheel on the stone. Such a circle does not give cracks and chips. 
The situation with porcelain stoneware is a little more complicated. Porcelain stoneware is slightly thicker ordinary tiles and stronger than her. Manual tile cutter very quickly blunts, without reaching the result. Therefore, porcelain stoneware can be sawn around the stone.
We make a contour incision along the drawn cut line. Then another, third. As long as the uncut thickness of the material is less than the cut. We shift the porcelain stoneware tile to the edge of the table and break it with a sharp, but not very strong movement.
How to saw without dust
Any dust is harmful to human health. During repair or construction, it settles everywhere. Cleaning it up afterwards is both time consuming and quite difficult. But the main thing is that it cannot be removed from the body. In order to work without dust, you need to make a small and inexpensive fixture for a grinder. 
This device is very similar to a medical dropper. In normal plastic bottle with a volume of 1.5 - 2.0 liters we start a tube from a dropper. We leave only the regulator on it. In the protective cover of the grinder, we make a hole along the diameter of this tube. We insert another similar tube into this hole.
We connect these two tubes, pour water into the bottle and open its supply to the circle. After the first approximate cut, we regulate the water supply, which should extinguish all the dust released during cutting.
With such a device, concrete, brick and many other materials can be processed, which, when destroyed, emit a large amount of dust.
How to saw or cut with a grinder
Various materials behave differently during processing with a grinder. Some immediately overheat and break, others are deformed, others do not want to be processed at all. It is difficult to know all the intricacies of working with an angle grinder, but practice requires knowing at least something.
We cut paving slabs, tiles, porcelain tiles
For cutting paving slabs grinder will need a special circle with a diamond notch. A marking is made on the tile, and an incision is made along this marking to almost half the radius of the circle. If the grinder is with a large circle, then in one pass you can cut the tile immediately to the full depth. The main thing is that it should not be more than the radius of the circle. If the radius of the circle is insufficient, then the tile is turned over and a counter cut is made.
Tiles without chips are better processed with a stone cut-off wheel. A line is applied to the tile along which a contour cut is made. Then the depth gradually increases. When the cut part becomes larger, the tile is placed on the edge of the table and broken along the line. Irregularities and roughness can then earn extra money.
Porcelain stoneware is well processed around for stone. Cutting technology is no different from cutting technology tiles.
We cut wood with a grinder
Compared to others building materials wood has always been and remains the most malleable in processing. For the grinder, the production of a wide variety of discs for cutting wood has been launched.
The most common disc, the look of which we have long been accustomed to on a circular saw. main feature the selection of such a disk is that the calculated speeds of the grinder and disk must match. Only in this case, it turns out to cut smoothly and without burning wood.
Such a blade easily cuts wood in any direction, but traditionally prefers to cut across. It is easy to cut not only raw wood, but also tree knots. It is convenient to dissolve the boards into bars or planks. For a large amount of such work, the grinder must be fixed permanently. You get a complete analogy of a circular saw.
Pressed wood materials of any density are also processed very simply. And if you need to cut wood panel with stuffed nails, then a disc is produced for such work. He is not afraid of meeting with nails. This versatile disc is made from tungsten carbide by Bosh. The Bosh Carbide Wheel is marked. Available in sizes 76, 115 and 125 mm.
Bulgarian for brick, concrete, concrete ring
Brick and concrete cutting is done with special stone cutting wheels. Brick is easy to cut, the main thing is to fix it correctly before cutting and do not use your foot as a clamp.
Almost no problem cutting concrete slab or concrete. But the concrete ring creates some problems. Not concrete itself, but embedded in it steel reinforcement. The circle in the grinder is under heavy load during concrete, and the reinforcement harms it.
To shorten the ring by a certain amount, a cut is made from the outside of the ring. Then the cut-off part is broken with a sledgehammer, and the protruding reinforcement is cut in a circle for metal.
Decking, metal and sheet metal
The grinder was originally intended for cutting and grinding metal, so cutting any metal is her element. For sheet metal of different thicknesses, we select a circle of a certain thickness, select the rotation speed and perform a cut along the drawn lines. On the way to extreme point cut, you need to drown the grinder a little so that the cut border does not have a bevel.
Using this technology, you can cut out various geometric shapes from a sheet of metal. To cut a square or rectangle, you need to draw the dimensions on the sheet. We set the circle of the grinder beyond the border of the square and make a cut in the metal. When all four sides are cut, cut out the corners.
It does not cause difficulties cutting corrugated board. The cut starts from any edge or in the middle, if required. The only remark is when cutting thin metal with reverse side a torn cut is formed. To avoid injury and for the cleanliness of the work, it is better to grind this cut.
Cutting grinder pipes and gas cylinders
Large diameter pipe gas cylinder are no exception in the work of the grinder. A large diameter pipe can be thought of as a sheet of metal. The difficulty is cutting a cylinder in which a trace of gas or condensate remains. It is very dangerous with a possible explosion.
To secure the cutting of the cylinder, it is necessary to unscrew the valve. This is difficult to do, because over time the thread grows together tightly. In this case, it is necessary to weld the cylinder for the stand, which is located in its lower part, to a massive slab or frame.
On a welded cylinder, it is easier to unscrew the valve. Water is poured into the vacated hole until it overflows, and then they start cutting with a grinder. Cutting a cylinder is no different than cutting a large diameter pipe.
glass cutting
For an angle grinder, there are no problems when cutting glass. For this operation, you can use the cheapest circle for ceramics. A light contour cut is made, and then it deepens. The cut glass is laid out on the edge of the table and broken.
Cutting glass pipes with a grinder can be considered using the example of cutting a conventional glass bottle. The bottle is placed in an extended vise or placed between two wooden bars. Turning it a little, they make a cut with a grinder. The bottle is rotated until the unnecessary part simply disappears.
How to cut slate without a grinder
If there is no grinder, then you can cut the slate sheet using a conventional hacksaw. Better for these works fit a hacksaw with fine teeth and a small divorce. In extreme cases, you can use hacksaw blade from a hacksaw, and just a knife.
The main thing is to correctly distribute the forces and load on the sheet in order to avoid chips and breakage of the slate. wave slate it is somewhat more difficult to cut, and it is easy to cut a sheet of flat sheet slate with any tool.
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How to cut metal with a grinder, cut round holes, cut pipes, cut profiled sheets
Metal is the material that the angle grinder (angle grinder) was originally designed to work with. Now, with its help, reinforcing bars, various metal sheets, pipes of various diameters, brick, concrete, stone, tile and other building materials are cut. Due to the presence of a variety of nozzles, the grinder also allows you to polish and grind the surfaces of products. Cutting metal with a grinder is one of the main, most frequent works. To reduce the likelihood of injury, it must be performed correctly, with strict observance of the requirements of general and personal safety.
Preparation for work as a grinder for metal
Bulgarian belongs to the category of relatively dangerous power tools. You can get injured from a scattered disc or a tool that has fallen out of your hands. In both cases, the danger is associated with the high speed of rotation of the device's electric motor.
To increase the efficiency of the grinder, expand its functionality, in practice use such additional devices:
Their use allows to improve the quality of sawing metal blanks, to increase the accuracy of the process. Also, working conditions are improving from a safety standpoint, and its productivity is increasing.
The use of additional devices allows you to use the tool as a machine tool designed to perform different types of work.
In order to secure the cutting process as much as possible, you should work on metal with an angle grinder in compliance with a number of rules. They are conditionally divided into preparatory and main (working) activities.
Before starting cutting, it is necessary to carry out a number of manipulations.
If possible, the sawn material should be securely fixed in advance, for example, in a vice, in order to remove possible accidental movements. Do not hold workpieces in your hands or between your knees.
Proper tool operation
When you start sawing any part with an angle grinder, you should follow these rules.
- When cutting metal, hold the grinder firmly with both hands.
- Wheels can only be changed after they have completely stopped rotating and cooled down to an acceptable temperature by disconnecting the power tool from the mains.
- Do not put a working tool on the ground or a table (do not let go of it).
- It is required to periodically stop for about 5 minutes to rest, and for 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 a plugged-in tool unattended.
- Use only discs of the correct size as specified in the instruction manual for the device you are using.
- Work is best done on a flat surface so that the position of the body is stable.
- Make sure that the power cord is away from a rotating circle, sharp edges, objects heated to more than 100 degrees.
- Movements not directly related to cutting should only be carried out with the power tool turned off.
- It is necessary to be located on the side or behind the tool, doing the work with your own hands so that the parts of the body are not in the plane of the cut.
When the cutting of the metal with the grinder is completed, you should wait until the disc stops completely, disconnect the power cord of the tool from the mains. After that, it is recommended to make sure that there are no signs of fire. When cutting right-handed materials, it is correct to hold the handle of the device in the area of the on / off button with your right hand. At the same time, the left hand is located on the handle screwed into the body of the power tool from above.
It is unacceptable to perform work using a grinder in a very tired state, or while under the influence of alcohol, psychotropic or narcotic drugs.
As for the question of which direction - towards itself or away from itself - the disk of the turned-on grinder should rotate, there is no definite answer here. The operating instructions indicate that the first option is correct. This is due to the fact that the resulting sparks fly off in the opposite direction from the operator, without causing harm. Also, fragments of the circle will fly in that direction if it shatters into pieces.
But in the case when a jamming of the disk rotating “on itself” occurs, the tool will fly off into the working one. For this reason, many experts prefer to cut metal so that the circle rotates “away from itself”. The power tool torn from the 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.
Cutting sheet metal grinder
To cut metal of different types and thicknesses, use appropriate cut-off wheels of different thicknesses and diameters. The algorithm for cutting sheets is as follows.
- For cutting with a grinder, sheet metal is pre-laid on a flat surface.
- Mark with chalk (marker) the exact dimensions of the cut fragments on the surface of the sheet.
- Sawing is carried out along the marked lines, without changing the angle of the initial inclination of the disk to the working surface, so that it does not jam and break the power tool.
If there are no skills in sawing sheet metal with a grinder, it is recommended that you first practice on a delicate material - this will give you the opportunity to feel the work of the tool.
It must be taken into account that the lower near segment of the disk cuts the metal more effectively.
When cutting a sheet of metal, to obtain a quality result, you should take into account such recommendations.
- To improve cooling, it is necessary to water the sawing place with water, which will also increase the life of the circle.
- It is worth starting cutting metal only when the disk is rotating: you cannot turn on the tool if the stationary circle is in contact with the surface of the workpiece.
- To cut tin (thin sheet metal) or cut out various geometric shapes, it is more convenient to use small, worked out circles (“stubs”).
- You should not press the grinder with significant effort: cutting should occur almost exclusively under the own weight of the angle grinder.
- If the cutting wheel stops in the slot (when the power tool is turned off), then work can only be resumed after it has been removed.
If sawing the sheet is slow, you should change the working nozzle. Excessive load on the angle grinder when cutting metal will lead to its overheating or jamming of the rotating circle.
Cutting a round hole in metal with an angle grinder
In practice, it is often necessary to cut a circle in metal, and only an angle grinder is available from the tools. But it is quite enough for this purpose. The algorithm of actions is the following.
- A circle is drawn with a compass on the metal surface or according to a pre-made paper (cardboard) template with chalk or a marker.
- Holding the grinder at an angle to the surface of the sheet, a preliminary marking cut of the metal is performed along the marked contour, making short movements with the disk (sawed in small segments).
- Then, moving the nozzle in the same way, deepen the slot until it is completely cut out.
You need to cut along the outer contour of the circle so as not to reduce the size of the circle. If its diameter is small, then they cut, touching the metal with a disk point by point (without longitudinal movement of the nozzle). A round hole will turn out with an oblique cut, as well as with some minor flaws (they depend on the skill of the worker). After it, if necessary, processed.
The whole process of cutting a round hole in sheet metal using a special tool is shown in the video:
Features of working with thick metal, copper, cast iron, aluminum
When it is required to cut thick metal into separate fragments, it is recommended to additionally perform the following steps:
- constantly cool the area of contact of the metal with the disk with cold water due to the strong heating of the slot;
- make all cuts only in a straight line;
- different curvilinear contours should be cut in separate straight segments of small length, while removing unnecessary parts;
- it is necessary to completely cut the workpiece in several approaches, with each subsequent deepening of the slot;
- if it is required to cut corners, I-beams, channel bars, rails, then each of their structural parts is sawn separately.
Cutting cast iron, stainless steel, and non-ferrous metals such as aluminum and copper is carried out using special wheels designed for working with these materials. All the necessary information about the discs is contained in the labeling of these products, applied on their side. At the same time, the circles differ in the composition of the fillers:
- in some, the additive is a heavy-duty material that can cut alloy steel;
- others use soft binders.
Cutting stainless steel with conventional metal discs is prohibited, because they contain substances that lead to accelerated corrosion of the cut point. Aluminum and copper are very tough non-ferrous metals. They are sawn with a grinder, pouring kerosene into the slot formed by the disk. In this case, fire safety rules must be observed.
Cutting pipes from different metals is a demanded operation during repair and construction work. It is necessary to cut off the products during the installation of sewer and heating systems, water lines. In this direction, the grinder copes well with various tasks. Disks for work are selected according to the material from which the pipe is made.
The use of an angle grinder makes it possible to:
- cut pipes at different angles, for example 45 and 90 degrees;
- cut products of large diameter;
- evenly cut profile (rectangular or square) pipes;
- to make longitudinal cutting of tubular blanks;
- sawing cast iron pipes;
- cut thin-walled tubes.
If you need to cut a large diameter pipe, then using a grinder allows you to do this work without significant cash costs. But at the same time, labor productivity is small, and the risks are considerable. When long pipes lie on supports, only the hanging parts are sawn off. If you cut in the center, the cutting edges will pinch the cutting wheel, which will lead to jamming of the tool and possible injury.
Specialists not only cut pipes from different materials at the right angles, but also cut holes in them of the required shapes. Work with profile and round blanks is carried out in a similar way, with the obligatory observance of safety regulations.
Cutting pipes at different angles
It is necessary to cut round and shaped pipes at an angle of 45 and 90 degrees when laying various communications. In any case, it is necessary to saw off the pipe evenly so that the elements that need to be connected are connected to each other as tightly as possible.
A cut at an angle of 45 degrees of cylindrical pipes is carried out as follows:
- take a regular square paper sheet;
- fold it exactly diagonally;
- wrap the pipe with this template;
- a future cut line is applied with chalk or other marking device;
- remove the template;
- clamp the workpiece in a vise;
- cut off the marked pipe fragment.
When applying the template, either of the two short sides of this triangle must be parallel to the central axis of the pipe.
When it is necessary to cut at an angle of 90 degrees, the pipes are simply wrapped in a circle (cylindrical) or around the perimeter (profile) with a sheet of paper. After that, mark the cut line. You can also mark the profile pipe very simply using a regular square.
If it is necessary to cut at an angle of 45 and 90 degrees a significant number of profile pipes, appropriate templates are made from this material, only with a larger section. This allows you to perform the required measurements only once. At the same time, a construction square or a protractor is used for the initial marking. When the template is made, cut blanks are inserted inside it, marking the cut lines. Then sawing is done.
Templates are also made for other angles. This method improves labor efficiency.
Features of cutting cast iron and thin-walled pipes
Cast iron is a brittle material. To cut a cast-iron pipe with a grinder, proceed in the following sequence:
- mark the cut line;
- put a wooden block under the pipe, which will serve as a support for it;
- make a cut along the contour with a depth of several millimeters;
- insert a chisel into the recess made;
- according to the instructions, they hit hard and sharply with a hammer.
After the impact, the pipe will split along the cut line. Its edges will be fairly even. If necessary, they are further processed.
Accurate marking is also important in order to perform longitudinal sawing of the pipe. For its application, various devices are used, for example, a construction thread (“beat”). The entire sawing process should be done carefully, slowly, so as not to stray from the marked line.
Thin-walled pipes are one of the varieties of this kind of products. They are often made of non-ferrous metals: copper or aluminum. Cutting them is difficult. In this case, circles for the grinder should be used corresponding to the material of the workpiece.
Sawing thin-walled tubes must be done very carefully, because they can easily be deformed even by applying a slight load.
To reduce the likelihood of bending the part being cut, various loose fillers are poured inside it, for example, ordinary cleaned sand.
Cutting profiled sheets and metal tiles
Quite often, in practice, one has to face the need to cut a profile sheet or metal tile. These materials are made of steel, which is coated with zinc and polymer protective layers, painted.
There are different opinions about the possibility of using a grinder for cutting them. The installation instructions say that the profiled sheet cannot be sawn with an angle grinder. To do this, you need to use other tools. But they need to be purchased, which is not always justified by the amount of work to be done, and also requires additional financial investments. When there is no tool other than an angle grinder, before sawing with a grinder, you should be aware of the possible negative consequences.
- If you cut a metal tile or corrugated board with an angle grinder, then the protective coating in the saw cut area and a little near it will be destroyed, and the cut edge will begin to rust.
- The material is out of warranty.
- Flying sparks can spoil not only the appearance of the rest of the sheet (burn through the paint), but also damage the polymer coating.
- The cut edge may be torn.
All the considered negative consequences can be minimized if you cut the corrugated board or metal tile with a grinder, observing the following recommendations:
- perform all work immediately before installation;
- treat sections with anti-corrosion compounds;
- cover the cut edges with a primer and paint;
- use discs for metal of minimum thickness (up to 1 mm);
- to keep the edges neat, you need to cut pretty quickly;
- carefully sand the torn edges.
Before sawing, as usual, mark sheets.
If you need to cut a square, then do this:
- draw it on the surface of the sheet;
- cut the material along the marked contour with a grinder;
- at the end, carefully cut out each corner.
Circles or other shapes are cut out, working in the same way.
The use of a grinder for cutting metal tiles and profiled sheets facilitates the work. It becomes more convenient to perform it, because you can adjust the sheets to size directly on the roof.
In order for the metal tile or profiled sheet to remain under warranty, you should measure the object and order the factory cutting of the sheets. You can also try to choose a material with such dimensions that cutting is not required.
Cutting metal with a grinder is a cheap, practically affordable and quite effective way to saw it. In this case, appropriate discs without defects should be used for each material. Not only the quality of the result obtained, but also your own health will depend on this. Be sure, when sawing metal, it is required to follow safety rules and use personal protective equipment. It should always be remembered that when working with an angle grinder, any shortcomings and inattention can result in injury. Therefore, you need to work carefully and carefully.
A hole in the metal will need at least one of the indicated devices: a grinder, a drill, an electric welding machine or a gas cutter. Each of these tools has its own advantages and is used depending on the size of the hole and the thickness of the metal. If the question is how to cut a large diameter round hole, then a gas cutter is best suited for this. But first you need to mark the hole with a compass. The contour should be made very clear so that it can be clearly seen even under the sparks of a grinder or a welding machine.
After the hole is marked, the torch of the gas cutter should be lit. Next, you need to properly adjust its torch and make the cut itself. Move the cutter smoothly and at the same pace as the metal is cut. It's certainly not as difficult as drilling a hole in glass, but you still have to be careful. And if there is no gas cutter, then you can use an electric welding machine. True, this method is limited by the power of the apparatus and the thickness of the metal. The power of most of them is enough for 3-4 mm metal. Well, the cutting process itself boils down to the fact that you first need to install a welding dock, then light an arc and then burn through the metal according to the markup.
But how to drill a hole in metal, if not, neither gas burner, no welding machine? In this case, a grinder (angle grinder) can come to the rescue. However, it should be noted that it can only be used when the hole is not less than the cutting circle of the grinder, and the thickness of the metal does not exceed 3 millimeters. In addition, making a round hole at once will not work, because you have to make many short cuts along the contour of the circle. Even with their minimum length, it will still form not a circle, but a polygon. Therefore, after the operation is completed, you will have to trim the shape of the circle with a file.
Another way to drill a large hole is to use a drill. The advantage of this method is that the drill is a very common tool and it will not be difficult to get one. The disadvantage is that this method is the most laborious. Its essence lies in the fact that along the entire line of the contour, the metal is drilled through with many holes. It should not be forgotten that since the drill has a certain thickness, you need to mark another hole, the diameter of which should be reduced by the diameter of the drill. And then drill along a smaller contour. The same method can be used if you need to solve the problem of how to drill a hole in the wall.
You will need
- - gas cutting equipment;
- - welding machine;
- - angle grinder;
- - electric drill with a set of drills;
- - grinder;
- - manual lever scissors;
- - core;
- - marking circle.
Instruction
Mark the center of the circle on the steel sheet so that it is spaced from the edges of the sheet at a distance slightly greater than the radius of the circle. Place the leg of the marking compass in the trace of the core and draw on a circle of the required diameter.
The most common and technologically advanced method is cutting metal using a gas cutter. To make the circle clearly visible, circle the outline drawn with a compass with a marker or chalk. Light the torch, adjust the flame and cut metal around the designated circle. Theoretically, the thickness metal, which can be cut with a gas cutter, is 250–300 mm. In practice, such thicknesses are extremely rare.
You can cut a circle from a steel sheet with . Strike the welding arc at any point on the marked circle and hold the electrode in place until a hole is burned through the plate. After that, start melting the edge of the hole by passing the electrode along the drawn circle. Low-power welding machines operated by private owners can have a relatively small thickness - a maximum of 4-5 mm. The edges from cutting are uneven and melted, and the cut blank has an irregular shape, which must be brought to the point of processing on a lathe or manually on a grinding wheel.
A simple, but rather time-consuming operation is cutting a circle with a grinder. Cut in the sheet on all sides of the drawn circle lines that are tangential to it. The greater the number of cut lines, the closer the shape of the cut figure approaches a circle. But in any case, it will not be a circle, but a polygon, which will have to be brought to a circle on a grinding machine.
A circle metal thicknesses up to 3-4 mm can be cut with manual lever scissors. First, cut out a square with a circle inscribed in it, then cut the workpiece from all sides, running the scissor blades along the lines tangent to the circle. The shorter the length of the tangents and the greater their number, the less work will be required when turning the workpiece on a grinding machine.
The most time-consuming way to cut a circle is to drill holes around its perimeter. But sometimes, in the absence of other options, you have to resort to this method. From the same center from which the original circle was drawn, draw another one with a diameter greater than the diameter available by the diameter of the drill that will be used for drilling (usually 4-5 mm). Perform punching along this circle in such a way that the recesses from the core are separated from each other by a distance of the diameter of the drill. Drill holes in the punched places around the entire perimeter of the circle. Knock out a circle from the sheet with a hammer or sledgehammer, process it along the outer diameter on a grinding machine.