Cutting Metals

Option 1: Hacksaw

The Hacksaw is the most commonly used method of cutting metal in the school workshop. The main points to note when choosing a Hacksaw are :

1) Make sure it has a good blade (no blunt or missing teeth)

2) Choose an appropriate blade (Fine teeth for hard metals Coarse teeth for softer metals)

3) Make sure the blade is fitted correctly (teeth should point forward)

4) Make sure the blade is tight.

Grip the Hacksaw as shown in the picture above and saw with an even downward force.

Hacksaw

Keep the cut as close as possible to the vice.

Too Far

Hacksaw

If the blade overheats during use try applying a little oil.

As shown in the picture on the left one of the apparent disadvantages of using a Hacksaw is the limited depth of cut.

This can be overcome by turning the blade through 90 degrees.

(As shown below)

Hacksaw

Hacksaw

By turning the pins at both ends of the Hacksaw it is possible to use the Hacksaw for much deeper cuts.

Blade clamp turned through 90 degrees

Hacksaw cutting beyond apparent maximum depth

Option 2: Junior Hacksaw

The Junior Hacksaw is used for cutting small sections

The main points to note when choosing a Junior Hacksaw are :1) Make sure it has a good blade (no blunt or missing teeth)

2) Make sure the blade is fitted correctly (teeth should point forward)

Junior Hacksaw

The Junior Hacksaw is used for cutting small section metals and is used with one hand as shown in the picture on the left.

Option 3 Tinsnips

Tinsnips are used to cut sheet metal. They can be used in your hand “like scissors” but it’s easier to use them fixed in the vice as shown to the right

Option 4: Guillotine

The Guillotine or Bench Shears are primarily designed for cutting sheet metal (up to 4.8mm thick). However they can also be used to cut round or square section metal (up to 12.7mm diameter)

Handle

Blade

Locking Pin

GuillotinePupils should be aware of the following Hazards

Closing movement between shearing surface and other parts can result in trapping and serious injury.Sharp edges on cut material can cause cuts. (When carrying large sheets of metal wear gloves)Lack of space around the guillotine can lead to the operator being pushed by passers by.Slippery floor surface or loose items around the machine can cause slips that result in contact with moving parts.Manual handling of sheet metal can present a hazard. Conditions of use.

Only one person is allowed to use this equipment at a time.

Guillotine

The Guillotine or Bench Shears are primarily designed for cutting sheet metal (up to 4.8mm thick). Remember to keep your fingers well away from the blade.

Guillotine

The Guillotine can also be used to cut bar up to 12.7mm in diameter. To do this the bar is fed through the shear hole. (This is the only way to cut bar on the Guillotine. If you try to cut bar in the normal fashion you will damage the cutters)

Shear Hole

Option 5

Gabro Guillotine

The Gabro Guillotine is designed for cutting sheet metal (up to 1.6mm thick). The main advantage to this guillotine is it’s ability to cut accurate strips from sheets of steel

Gabro GuillotinePupils should be aware of the following Hazards

Closing movement between shearing surface and other parts can result in trapping and serious injury.Sharp edges on cut material can cause cuts. (When carrying large sheets of metal wear gloves)Lack of space around the guillotine can lead to the operator being pushed by passers by.Slippery floor surface or loose items around the machine can cause slips that result in contact with moving parts.Manual handling of sheet metal can present a hazard. Conditions of use.

Only one person is allowed to use this equipment at a time.

The Fence can be set to any size between 0 and 165mm

Fence

Guard

Gabro Guillotine

Although the Gabro Guillotine does cut accurate strips due to the cutting action there is more waste material produced.

Waste Notch

Gabro Guillotine

The End