DIY pendulum saw for metal drawings. How to make a pendulum saw for metal with your own hands? How it works
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A pendulum saw for metal, in fact, is a cutting machine, the tasks of which include: cutting pipes, profiles, metal corners, at various angles. The machine is a rigidly fixed frame, with a pendulum mechanism, which allows cutting to exactly the size and intended angle. Mainly on the market Makita tools are presented, which guarantees high quality and efficiency, but there are also products from lesser-known manufacturers.
Device
The pendulum feeding mechanism of the cutting tool involves a top-down working movement, through mechanical or manual control. One of the advantages the pendulum machine is also a change in the cutting angle, up to 45 degrees from the normal. The working part of the machine is a circular saw; depending on the type, the machine can be single- or double-headed, depending on the number of cutting saws.
The circular saw located on a pendulum mechanism can be driven either manually by an employee or automatically.
The machine is often installed graduated dials, for additional control of cutting accuracy, for example, a Makita LC1230 machine, in this case the cutting angle is changed by turning the handle.
Advantages and disadvantages
When fully equipped, the pendulum saw is absolutely safe and comfortable to use. The dust collector collects abrasive elements and metal particles. The clamp for securing the workpiece holds the part to be sawn and prevents the blade from skewing.
Advantages of pendulum cutting machines:
Disadvantages: the only disadvantage of this type of machines is their high cost in professional performance. Yes, a pendulum saw Makita costs from 10 thousand rubles. But at the same time, Makita tools are most valued by our industrialists. Makita produces power tools and components, the same saw blades, of high quality and different prices, from household models to highly professional equipment.
Assembly saws
A special subtype of pendulum cutting machines is characterized by a simplified design and increased mobility. Assembly machines do not have a mechanism for turning the saw itself and cut the workpiece only along the normal.
The device in this case simplified as much as possible, saw, pendulum, bed. Discs for cutting metal are usually abrasive; carbide is less commonly used.
The drive on a disk, in professional cutting machines, is usually belt driven, this allows you to reduce the load on the engine and avoid sudden jerks.
Due to the lack of hard fastening the pendulum and the workpiece, when working with cutting-off assembly machines, it is necessary to take into account the following nuances:
- Use a clamp to secure the workpiece while cutting.
- At the moment of starting, the torque of the disk gives a strong push to the saw, take this into account.
- When cutting with a mounting machine, a burr is formed on the workpiece, which must subsequently be removed.
Making a pendulum machine with your own hands
To do this, it is enough to make a frame from a channel and an angle; you can use a regular circular saw as a working tool, securing it to the frame.
Open the bed, it’s quite simple to do, install two channels - paws, connecting them in pairs. Weld the base of the pendulum to them. Often, a solid metal plate 12 mm thick is used as the base; in this case, the hole for the saw blade is simply cut or drilled. Need a drilling machine.
After this, you need to make cages for bearings for the pendulum; for this, it is best to contact a turning shop. After turning, welding will be required.
Also, while creating the rotary machine and pendulum parts, you will need a milling machine and a drilling machine.
Don’t forget about the casings; for their manufacture it is best to use sheet metal with a thickness of 0.8–1 mm. Cutting is done according to ready-made patterns, after which it is tacked by spot welding.
During processing and workpieces the following were used:
- Gas cutter, cutting base metal, pendulum and frame blanks.
- Screw-cutting lathe for turning fingers and clips.
- Milling machine for processing the edges of workpieces and milling part of the pendulum parts.
- Drilling machine.
- Welding transformer.
In general, it turns out that the cost of independently manufacturing a frame for a pendulum saw is high; the efforts of an entire mechanical repair shop will be required. In some cases it's worth it, sometimes not. The price is too high.
Sometimes it's easier and more efficient to buy a ready-made tool. This will save time and money.
Cutting tool
As a cutting tool, the saw uses circular saws, abrasive wheels of various diameters and seats. In this case it is necessary See the saw's operating manual; the recommended blade parameters are indicated there. Thus, the Makita LC1230 saw uses a disk with a diameter of 12, with an inch fit, 25.4 mm and a number of teeth of 60 for cutting. This could be a Makita saw blade, 305x25.4x60, for example, Makita B-29393. Discs from other manufacturers that meet the technical specifications can also be used. Cutting is usually done with carbide-tipped discs at the ends of the disc teeth.
Exploitation
Before using the machine must be installed on a raised table or workbench, this is necessary for the comfort of its use. It is also necessary to make room for cutting, carrying material and storing workpieces.
The Makita LC1230 saw is compact; its installation requires a small area, but do not forget about moving the material and workpieces; as a result, the working area of the cutting saw is a rectangle of 2x4 meters. With a material length of 2–3 meters.
Cutting with a pendulum saw is not a difficult task, but nevertheless requires attentiveness and accuracy. Yes, special danger represent sparks and hot metal particles flying from under the saw. Partially, the collar installed on the saw body saves you from them. But nevertheless, we should not forget about personal protective equipment.
Nowadays, there are a huge variety of different tools for cutting metal. Many of them are manual and have a large number of inconveniences. The rest of the tools are considered automated and have large dimensions or a large price category.
To combine business with pleasure, as well as convenience and price, handicraftsmen created a disc cutting machine. Below we will look at everything related to this equipment.
The scope of application of this machine equipment extends to industrial applications and domestic use. Used for cutting various types of metal (steel, cast iron, copper, aluminum, etc.).
Since in everyday life there are a huge number of different metal objects that require minor repairs, this machine becomes extremely necessary. After all, lowering the cutter stand with the cutting disk once will be easier and faster than manually sawing with a hacksaw.
The dimensional characteristics of homemade equipment allow it to be placed under a canopy in the summer, and in winter to be safely placed in a warm garage or workshop.
Tip: To install the frame, it is extremely important to choose a smooth and durable place (concrete slab, thick corners, or concrete support legs of the frame). This is done in order to reduce the possibility of vibration to a minimum during operation.
In production, automated systems are mainly used, which are controlled by an operator via CNC. The goal is mass production of metal products, in the form of cutting pipes of given sizes and various sections, flat rolled metal and much more.
Below we will look at the criteria by which this machine equipment is distinguished.
Classification of cutting machines
All cutting machines are distinguished according to a huge number of criteria. We'll look at the most important ones. So, the main technological criteria:
By type of toolkit
The separation occurs directly on the tool that cuts the metal products. In turn, they are divided into the following subspecies:
Band saws
In this case, a band saw with teeth is used. The belt is made from high-quality high-speed steel. Due to the fact that the cutting tape is thin, there is a saving in material consumption due to the thin cut. Band machines are used in production.
Hacksaws
They are used in small industries, as well as in everyday life. Hacksaw tools can be hand-held (the well-known hacksaw for metal) or an electromechanical machine. In this case, the hacksaw blade is made of various metals (high-speed steel, carbon steel, alloy steel, bimetallic steel). This type is quite easy to operate and is considered a convenient tool.
Disc machines
They belong to the category of indispensable tools. Used throughout the metalworking industry. Using such equipment, high-quality cutting of metal can be carried out even by an unqualified person. In addition to industry, this machine equipment is widely used in everyday life.
By number of cutting edges
Single head
The design has one cutting disc. This type of machine is low-productive of its kind and is capable of performing only one operation.
Double head
Their design uses two “heads” for attaching disks. In this case, one “head” is firmly fixed and motionless. The second has the ability to move in independence in the first. This equipment is considered a high-performance tool.
By type of saw blade feed
Front saw blade feed
The center of the disk moves in a horizontal plane.
Bottom feed
The center of the disk moves from bottom to top along a vertical plane.
Pendulum feed
The center of the cutting disc moves like an arc, from top to bottom.
Vertical feed
The center of the disk moves along a horizontal plane from top to bottom.
By main type
Cut-off saws
This tool is used to cut dimensional pieces of rolled metal. Well suited for small-scale production.
Abrasive - cutting
When working with such equipment, abrasive wheels are used. High-quality cutting of metal residues (burrs) is carried out. Cutting the material into blanks, cutting profile metal at the required angle from 0 to 45 degrees.
Correctly-cutting
Such equipment processes metal produced and supplied on coils (reinforcing steel, metal strip, wire, rods with a profile section). This equipment is equipped with the correct mechanism and automatic unwinding of metal from the reel. The twisted wire enters this mechanism, is straightened over the entire plane and fed into a special receiver for further processing.
Tip: Depending on the material to be cut, you need to select suitable cutting discs. The discs must meet the technical specifications.
Disc machine device
Frame
Or a metal structure that plays the role of the base of the unit.
Pendulum node
This is a kind of metal part made of a metal profile, which looks like the letter “T”. The movable side is mounted on a bracket located on the frame. The movement of the pendulum is carried out by means of bearings, and the return to its original position is carried out by a flexible part (a strong harness or a small spring).
Pipe clamp
The so-called vice, mounted on the bed. They allow you to press the workpiece to give it a stationary position.
Pendulum unit axis
This axis is used to move the disk.
Electrical engine
The heart of the unit. It is he who puts the entire mechanism into action. An asynchronous motor is used for this equipment.
Actuator
A box containing electronics that is connected to the electrical network. On this box there are buttons to turn it on and off.
Wheel protective cover
Steel protection that prevents fragments from the disk from falling directly into the person working on the unit.
Belt guard
Located where the belt makes its movement. This casing is designed to protect a working person from being hit by a belt if it breaks.
Pendulum assembly handle
That part with the help of which pressure is exerted by the cutting disk on the workpiece.
Ground bolt
As with all machines, there is a bolt on the body of the unit that is used for grounding.
Abrasive wheel
Direct cutting disc consisting of various materials.
Sling brackets
(4 units)
bed
This is the area where the main unit of the unit is located.
Adjustable stop
Due to this, the required size of the future product is fixed.
Tip: If your budget is quite modest, then you can use scrap materials to create parts of the unit. If your budget allows, then it is advisable to purchase all the components in the store. This will improve performance and service life.
Manufacturing of a disc cutting machine
Any invention will require certain parts, whether purchased parts or homemade parts. To create a cut-off brainchild you will need the following:
- Metal corner with dimensions No. 24.
- Metal channel No. 10.
- Movable shaft.
- Tubes for making a handle.
- Welding machine.
- Bearings for the pendulum mechanism.
- Electric drive.
- Box for storing electronics.
- On/off toggle switch.
- Starting circuit.
- Winding.
- Electric drill.
- Fastening elements (bolts, screws).
Let's look at the progress of assembling all the equipment:
- First of all, with a grinder, blanks are cut into a frame with dimensions of 400x600x1200 mm.
- Using welding, the frame is assembled from prepared parts.
- A channel is welded over the entire frame. It will give additional strength to the machine and serve as a guide.
- Several vertical supports are screwed onto the channel.
- Next, the next frame is installed, on which the engine and shaft will be located. The frame dimensions should be 400x600 mm.
- A plate intended for the engine is attached to the frame. The best electric motor for these purposes is an asynchronous motor. Its power should be from 1.5 to 3 kW. After installing the engine, it is necessary to connect it to a three-phase network.
- The shaft, flanges, supports with a pulley are made on a lathe.
- Next, the bearings and pulley are installed.
- The box in which the circuit is located is installed in the lower part of the frame.
- A shaft with a sleeve is inserted between the vertical supports. Shaft diameter 12 mm. The gap between the bushing and the shaft should be kept to a minimum.
- On both sides of the bushing, limiters made from pieces of channel are welded.
- An electric motor and a cutting mechanism are installed on a long support beam and on pieces of channel.
- The final step is to install the belt that connects the shaft and the motor.
Based on the above assembly steps, we can conclude that it will be much cheaper to assemble such a unit with your own hands. Moreover, during the assembly process, you yourself adjust the entire mechanism, as they say, for yourself.
The button, which is intended for emergency situations, is connected directly, and the engine is connected through a box with a circuit and an automatic machine.
Tip: If you have assembled such a structure with your own hands at least once, you can easily repair such units. This is because you will know the entire mechanism of such a machine by heart.
Manufacturing a cutting machine based on a grinder
In addition to the classic variation of the cutting machine
There is also a simplified version of the machine using a grinder (angle grinder). In this case, a frame is made into which the second frame is attached to the sleeve. It is on the second frame that the angle grinder is secured using metal fasteners.
In order for the grinder to return to its original position, it is necessary to secure the frame and grinder with a tight rubber band or spring. The frame itself is mounted on a prepared bed or on a large and heavy table. The heaviness of the table will ensure a minimum of vibration. If a frame is being prepared, then it must be mounted on a foundation prepared in advance. Such an invention can serve as a good tool in a home workshop or as an excellent device for cutting metal.
General reviews about the machine
If you search for reviews on the Internet about this unit, you will find only positive reviews. Indeed, such an invention is very convenient in its own way. With its help, you don’t need to suffer with the grinder in your hands, in a bent state. If you choose a cutting tool for certain jobs, then only a disc cutting machine.
Video reviews
Video review of the disc cutting machine:
Video review of a cutting machine using a grinder instead of a disk:
Video review of the assembly of a homemade machine:
Video review of the cutting machine:
An indispensable tool in the home workshop, metalwork shop, and construction site. Many industrial models of these tools are produced, but their price is sometimes unaffordable not only for a private craftsman, but also for a small enterprise. There is a solution - it’s not at all difficult to make a metal cutting machine with your own hands. This requires only certain skills in working with a welding machine, plumbing tools, and some qualifications as an electrician. You also don’t need anything scarce or unavailable for free sale from materials.
To work you will need:
- Bulgarian;
- welding machine;
- drill;
- set of dies, taps, wrenches.
You will have to buy an electric motor with a power of 1.5-2 kW, single-phase or three-phase. In addition, you will need two pulleys, a shaft, bearings 204 or 205, a metal corner, and sheet steel 2-4 millimeters thick. When all this is assembled, the actual production of the machine begins.
You can make the drawings yourself using material from the Internet, or use ready-made ones, such as these. But experience shows that it is best to adapt the drawings to the materials that you have available. As a rule, DIY designs work best when you customize them to fit your needs. Naturally, in this case, certain rules and requirements must be observed that apply to a high-risk tool, such as a cutting disc machine or a pendulum saw, both homemade and industrial.
Most do-it-yourself metal cutting machines are of the pendulum type. more complex to manufacture, but they can be made in a small workshop or metalworking shop. For now, let's focus on the most convenient type of cutting machine - a disk one. The general design can be seen in the video.
It consists of several main components:
- electric motor;
- pendulum;
- drive mechanism;
- cutting disc;
- desktop.
Let's look at them separately.
Engine
Depending on the required power of the metal-cutting machine and the scope of its use, we select the engine power. It should be in the range of 1.5-3 kW. If you plan to use a cutting machine in a home workshop, a small metalworking shop, where cutting profile pipes, fittings, angles or other rolled products is done relatively rarely, and thin-walled metal is used as workpieces, a power of one and a half kilowatts will be enough. For small-scale production, work on a construction site, or the manufacture of frames for any purpose, a more powerful engine will be required.
If you have a three-phase motor with a power of about 3 kilowatts, it can be connected to 220 volts using a star circuit instead of a delta circuit. But it must be taken into account that its power will decrease by 25-30%. The main thing is that the speed indicated on the nameplate will be maintained.
To install on a metal cutting machine, the engine must have a speed of 2500-3000 per minute. This is due to the fact that it is at these speeds that the cutting disc operates optimally.
For a homemade metal cutting machine, circles with a diameter of 300-400 millimeters are used. Here, too, you need to proceed from the needs of production. You shouldn’t chase too large a disk diameter - the farther the working edge is from the center, the less cutting force, and a more powerful engine will be required. The optimal ratio of engine power and disc diameter is 2 kilowatts at three thousand revolutions and 300 millimeters in diameter.
A self-made metal cutting machine must first of all be safe. The cutting discs indicate the maximum number of revolutions at which they can be operated. As a rule, it should not exceed 4400 rpm. If it turns out more, the disk may collapse, which is unsafe. If the number of revolutions is less than 3000, then the cutting speed will be insufficient, and the disk will overheat and wear out. It is these figures that should be taken as the starting point for calculating the power transmission.
Drive unit
It is most convenient to use a belt drive as a drive mechanism. To do this you will have to find two pulleys of the same diameter. One of them is mounted on the motor shaft, the second - on the drive shaft of the cutting disc. The disk shaft is mounted on two bearings. It is best to use the scheme when the drive mechanism is located on the left of the disk mounting cloud. It’s more convenient to work this way, and safety rules are followed. The disc fastening nut will not be at risk of loosening.
To tension the drive belt, the engine is mounted at the rear of the pendulum with 4 bolts located in longitudinal slots. It can shift in the direction of the central axis of the machine (perpendicular to the axis of rotation of the motor shaft) by 5-7 centimeters. This will maintain the required belt tension and prevent it from slipping. It will also be easier to replace the belt if the previous one becomes unusable.
Console (pendulum)
The cantilever part of a metal cutting machine is one of the most important. In addition to the fact that it must be carefully balanced, securely welded in compliance with all the required dimensions, it must also move strictly perpendicular to the work table. The basis for mounting the pendulum are two vertical posts with slots for the pendulum bushing (diameter 10-12 mm). It is best to make them from a steel square of 40x40 millimeters. The height is approximately 80-100 millimeters, but you can calculate your own version.
A bushing shaft is installed horizontally in the holes of the racks, to which a rocker arm is welded, consisting of two levers, the ratio of which is one to three. A platform for installing the electric motor is welded on the short arm. On the long arm there is a cutting wheel drive shaft. The ratio of the lengths of the levers is approximate; it must be calculated so that in the non-working position the weight of the engine outweighs the weight of the assembled saw part (with protective covers). To bring the disk of the switched-on machine into contact with the metal, it is necessary to apply a small but noticeable force.
For ease of operation, a return spring is attached to the bottom of the engine platform, and the upward deflection angle of the pendulum is adjusted by a cable or chain, fixed at one end to the table and at the other end to the bottom of the long lever.
Desktop
The optimal dimensions are 700x1000x900 mm. It is welded from a 25x25 mm corner and covered with a steel sheet 3-4 mm thick, in which slots are made in the rotation zone of the disk. A rotary stop and a clamp with a rotary clamp are fixed on the table. This allows you to cut both perpendicularly and at the required angle. A very interesting version of a homemade machine is shown in the video. Here it is not the workpiece that turns, but the console with the disk and the motor.
Installing a disc-type cutting machine is not particularly difficult for a qualified mechanic. It is important to adhere to some fundamental requirements:
- correctly calculate the disk rotation speed;
- adjust the angle of rotation, it must be strictly perpendicular to the plane of the desktop;
- set the force for feeding the disk into the cutting zone;
- install an emergency stop button on the handle;
- equip the cutting machine with protective covers for the disk and rotating parts.
A metal cutting machine is an indispensable tool in a home workshop, metalwork shop, or on a construction site. Many industrial models of these tools are produced, but their price is sometimes unaffordable not only for a private craftsman, but also for a small enterprise. There is a solution - it’s not at all difficult to make a metal cutting machine with your own hands. This requires only certain skills in working with a welding machine, plumbing tools, and some qualifications as an electrician. You also don’t need anything scarce or unavailable for free sale from materials.
Materials and tools
To work you will need:
- Bulgarian;
- welding machine;
- drill;
- set of dies, taps, wrenches.
You will have to buy an electric motor with a power of 1.5-2 kW, single-phase or three-phase. In addition, you will need two pulleys, a shaft, bearings 204 or 205, a metal corner, and sheet steel 2-4 millimeters thick. When all this is assembled, the actual production of the machine begins.
In this article we will look at the manufacture of a machine based on an electric motor.
You can make the drawings yourself using material from the Internet, or use ready-made ones, such as these. But experience shows that it is best to adapt the drawings to the materials that you have available. As a rule, DIY designs work best when you customize them to fit your needs. Naturally, in this case, certain rules and requirements must be observed that apply to a high-risk tool, such as a cutting disc machine or a pendulum saw, both homemade and industrial.
Most do-it-yourself metal cutting machines are of the pendulum type. Band machines are more complex to manufacture, but they can be made in a small workshop or metalworking shop. For now, let's focus on the most convenient type of cutting machine - a disk one. The general design can be seen in the video.
It consists of several main components:
- electric motor;
- pendulum;
- drive mechanism;
- cutting disc;
- desktop.
Let's look at them separately.
Engine
Depending on the required power of the metal-cutting machine and the scope of its use, we select the engine power. It should be in the range of 1.5-3 kW. If you plan to use a cutting machine in a home workshop, a small metalworking shop, where cutting profile pipes, fittings, angles or other rolled products is done relatively rarely, and thin-walled metal is used as workpieces, a power of one and a half kilowatts will be enough. For small-scale production, work on a construction site, or the manufacture of frames for any purpose, a more powerful engine will be required.
If you have a three-phase motor with a power of about 3 kilowatts, it can be connected to 220 volts using a star circuit instead of a delta circuit. But it must be taken into account that its power will decrease by 25-30%. The main thing is that the speed indicated on the nameplate will be maintained.
To install on a metal cutting machine, the engine must have a speed of 2500-3000 per minute. This is due to the fact that it is at these speeds that the cutting disc operates optimally.
For a homemade metal cutting machine, circles with a diameter of 300-400 millimeters are used. Here, too, you need to proceed from the needs of production. You shouldn’t chase too large a disk diameter - the farther the working edge is from the center, the less cutting force, and a more powerful engine will be required. The optimal ratio of engine power and disc diameter is 2 kilowatts at three thousand revolutions and 300 millimeters in diameter.
A self-made metal cutting machine must first of all be safe. The cutting discs indicate the maximum number of revolutions at which they can be operated. As a rule, it should not exceed 4400 rpm. If it turns out more, the disk may collapse, which is unsafe. If the number of revolutions is less than 3000, then the cutting speed will be insufficient, and the disk will overheat and wear out. It is these figures that should be taken as the starting point for calculating the power transmission.
Drive unit
It is most convenient to use a belt drive as a drive mechanism. To do this you will have to find two pulleys of the same diameter. One of them is mounted on the motor shaft, the second - on the drive shaft of the cutting disc. The disk shaft is mounted on two bearings. It is best to use the scheme when the drive mechanism is located on the left of the disk mounting cloud. It’s more convenient to work this way, and safety rules are followed. The disc fastening nut will not be at risk of loosening.
Drawing of a cutting machine for metal To tension the drive belt, the engine is mounted at the rear of the pendulum with 4 bolts located in longitudinal slots. It can shift in the direction of the central axis of the machine (perpendicular to the axis of rotation of the motor shaft) by 5-7 centimeters. This will maintain the required belt tension and prevent it from slipping. It will also be easier to replace the belt if the previous one becomes unusable.
Console (pendulum)
The cantilever part of a metal cutting machine is one of the most important. In addition to the fact that it must be carefully balanced, securely welded in compliance with all the required dimensions, it must also move strictly perpendicular to the work table. The basis for mounting the pendulum are two vertical posts with slots for the pendulum bushing (diameter 10-12 mm). It is best to make them from a steel square of 40x40 millimeters. The height is approximately 80-100 millimeters, but you can calculate your own version.
A bushing shaft is installed horizontally in the holes of the racks, to which a rocker arm is welded, consisting of two levers, the ratio of which is one to three. A platform for installing the electric motor is welded on the short arm. On the long arm there is a cutting wheel drive shaft. The ratio of the lengths of the levers is approximate; it must be calculated so that in the non-working position the weight of the engine outweighs the weight of the assembled saw part (with protective covers). To bring the disk of the switched-on machine into contact with the metal, it is necessary to apply a small but noticeable force.
For ease of operation, a return spring is attached to the bottom of the engine platform, and the upward deflection angle of the pendulum is adjusted by a cable or chain, fixed at one end to the table and at the other end to the bottom of the long lever.
Desktop
The optimal dimensions are 700x1000x900 mm. It is welded from a 25x25 mm corner and covered with a steel sheet 3-4 mm thick, in which slots are made in the rotation zone of the disk. A rotary stop and a clamp with a rotary clamp are fixed on the table. This allows you to cut both perpendicularly and at the required angle. A very interesting version of a homemade machine is shown in the video. Here it is not the workpiece that turns, but the console with the disk and the motor.
Installing a disc-type cutting machine is not particularly difficult for a qualified mechanic. It is important to adhere to some fundamental requirements:
- correctly calculate the disk rotation speed;
- adjust the angle of rotation, it must be strictly perpendicular to the plane of the desktop;
- set the force for feeding the disk into the cutting zone;
- install an emergency stop button on the handle;
- equip the cutting machine with protective covers for the disk and rotating parts.
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Self-construction of a metal-cutting machine
An example of a homemade machine for precision work When, for some reason, you often have to process metal at home, you come to the understanding that working with an angle grinder is at least inconvenient. Cutting metal is much easier if you have a metal cutting machine. With its help, the cutting line will become ideal, and the established process will go much faster.
But if you think about buying such a machine and look through the prices in the store, you will find that they are very expensive, not every person can afford it. The way out of this situation is to make a metal-cutting machine with your own hands.
Homemade metal cutting machine
Equipment classification
So, let's start with general information about metal-cutting machines. Structurally, they are all united by the presence of an electric motor, transmission and cutting disc. Finding a drawing for the manufacture of such equipment is not a problem. Once you become familiar with how a disc cutting machine works, it won’t be difficult to make the adjustments you need while building it yourself. Now let's look at the main fundamental nuances:
Drawing of a transmission mechanism for a cutting machine 
Cutting equipment is also classified according to the type of saw installation:
- Band machine.
- Abrasive-cutting.
The latter is designed for cutting thick metal fittings, various rods, square profiles and pipes of different diameters. Here you can cut various solid parts and profiles at different angles. The band saw operates on the basis of a closed cutting saw, so it is not a circular saw, the saw moves on pulleys. It’s worth saying right away that it’s easier to build a disk version with your own hands.
Self-production
To build your own disc cutting machine you will need:
Mechanical part of cutting machine - Steel corner.
- Welding machine.
- Bearings.
- Chain.
- On/off button.
- Channel.
- Electric drill.
- Sheet of steel for the work surface.
- Electric motor.
- A box that will contain the electrical component.
Having collected all the necessary materials and tools, you can begin construction. First of all, it is necessary to make the frame of the machine from a steel corner. First, individual elements are cut out from the drawing, they figure out how they will fit together, and then they are welded into a single structure with their own hands.
A guide channel is welded to the top of the frame, which will become the basis of the structure for attaching the cutting element of the equipment. This channel will be used to connect the cutting disc to the motor. At the next stage, vertical posts are attached to the channel, which are secured with bolts.
Now we need to weld another frame. It is made individually - for the specific electric motor that will be used in your machine. When choosing an electric motor, look towards asynchronous motors, as they are more reliable and durable. There is one more point here: the greater the power, the smoother the disk will operate.
Installation of equipment on the frame
Frame made of profile pipes Now you need to connect the working shaft to the electric motor with your own hands. How this will be done is not important, if there are instructions on the drawing, then follow them. If the installation is done correctly, the equipment should operate correctly and reliably.
One more point: if you cannot make any part yourself, then contact a turner for help. He will be able to make you the correct pulley for the belt or flanges for fastening.
It is best to secure the engine to the frame using ordinary bolts and nuts; attach the control panel and a box with an electrical circuit and a switch to the frame next to it.
The channel on which the cutting element is attached must be spring-loaded so that as soon as you release it, it returns to its original position. The most convenient way to secure the spring is with a clamp and bolts.
Pay special attention to the electrical component. There must be an emergency stop button for the machine and a starting chain. In this case, the electric motor must be connected to electricity not directly, but through a box and automatic machine. Switching on and starting the electric motor will be provided by a three-pole starting machine, and the shutdown button is also powered through it.
When completing the final installation with your own hands, do not forget about the protective casing that will protect your eyes from flying sparks.
Making a machine based on a regular grinder
You can also build a cutting machine with your own hands from an ordinary grinder. For example, you have a good, reliable Makita grinder, and you don’t yet need a full-fledged machine, since you will use it from time to time. In this case, just like in the previous version, you need to weld the frame and bed with your own hands, and make a moving part from a pipe or channel to install the grinder.
Cutting machine from an angle grinder Next, you will have to develop a mount for your specific angle grinder. The moving part is also spring-loaded, the technology here is similar. When making such a machine, do not forget that the grinder has such a thing as a reverse blow. This happens when the abrasive disc gets stuck in the workpiece and the grinder shoots back. In this case, fragments of the disk fly in all directions - this can seriously injure the person who is working. Therefore, when building equipment, pay attention to the protective casing if it is not on the grinder.
Collapsible machine from a grinder
Stationary frame-table for attaching an angle grinder Now let's look at another way to make a metal cutting machine from a grinder with your own hands. The benefit of this design is that the machine is dismountable and portable. The tool you will need here is the same as for making a full-fledged machine, which we talked about above.
The drawing will depend on the model of the specific grinder.
The first thing you need to know about such a machine is that it is made on the basis of two frames located on the same axis. Here the lower frame is made in the form of a movable clamp and angle, and the mount for the grinder is made to move along a vertical line.
The spring is also present here - it is needed to return the feed mechanism to its original position. Using a welding machine, you can secure a ruler with a special limiter.
A similar machine is started from a starting pedal, which is connected to the network using a low-voltage relay. Having assembled all the parts, the functionality of the structure is checked at idle. If everything works normally, no mechanisms rub against each other, then such a machine will serve you for a long time.
Considering that you can install various discs on an angle grinder, do not forget about the characteristics of the materials that you plan to cut. And, most importantly, never forget about safety precautions when working with metal-cutting equipment.
Video: Homemade cutting machine from an angle grinder
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Metal cutting machine
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I have long wanted to build an abrasive cutting machine for cutting metal in my workshop. Cutting metal with a grinder is not always convenient. An angle grinder does an excellent job of cutting sheet steel, but cutting off corners and profile pipes evenly with an angle grinder takes a long time and is not always convenient. It is necessary to mark on all sides and cut the workpiece on one side. Cutting is done on the ground in a bent position, holding the workpiece with your foot. Your back gets tired and sparks fly in all directions. And cutting a round pipe evenly is even more difficult and takes longer. It is more convenient to do this on a metal cutting machine, when there is no need to bend over, and the workpiece is securely and safely secured in the machine. It is very convenient to use such a machine to make a canopy from cellular polycarbonate or automatic gates. The machine was made from “what was at hand.” I tell and show you what I got, and you make your own amendments and make the machine even better from “what is at hand.” I do not consider it advisable to describe the entire manufacturing process in detail; I will only focus on the important (in my opinion) points. The manufacturing process must be performed in the following order:
I made the machine in a different sequence and was faced with constant alterations and adjustments, which caused the process to drag on. If I decided to make a machine now, I would do everything in this order. Before I started making the cutting machine, I studied the experiences of other people, from which I realized that:
I installed a 3-phase motor, since I have a 380V voltage in my workshop. If your voltage is 220 V, in this case you will have to install starting capacitors; there is a lot of information on how to do this on the Internet. Next, look at the photographs of the manufacturing process.
 The protective cover lifts up to replace the used disc with a new one. To do this, you need to unscrew just one M8 bolt from above.
 Possibility of adjusting the tilt of the rocker using metal plates. I did not install bearings on this shaft, but simply drilled holes for lubrication on top and plugged them with M6 bolts.  I borrowed the vice for clamping the workpiece from an old factory-made cutting machine, but I had to modify it a little. In this vise, the clamping screw nut can be divided into two halves, which is very convenient when installing and removing the workpiece.  There is no need to create a return mechanism; just change the alignment of the rocker shaft.  Spark arrester. 97 percent of all sparks fall into a removable container. Using a stop bolt (bottom), you can adjust the maximum angle of inclination.
How to calculate the required pulley diameter.We will assume that the cutting disc should rotate at a speed of 3000 rpm. The discs contain information about the maximum permissible rotation speed of 4400 rpm. So you decide for yourself at what speed your disk will rotate, the main thing is that it should not exceed 4400 rpm. To calculate pulley diameters you need to know:
Calculation example: Our engine rotates at a speed of 1500 rpm. The cutting disc should rotate at a speed of 3000 rpm. We have a pulley for the cutting disc shaft with a diameter of 65 mm. What kind of shaft should be on the engine?
How to calculate the length of the drive belt?The following data will be required for the calculation:
Calculation example. We have two pulleys with a diameter of 65mm and 130mm, respectively, their radii are 32.5mm and 65mm. The distance between their centers is variable (in order to tension the drive belt); for an example of calculation, let’s take the length between centers of 500 mm. We count half the circumference of each pulley in millimeters and add to the resulting number two distances from their centers (since the belt passes from one pulley to another and returns back to the first). 32.5mm x 3.14 (Pi) = 102.05mm (half the circumference of the first pulley) 65mm x 3.14 = 204.1mm (circumference of the second pulley) 102.05 + 204.1 + 500 + 500 = 1306 mm (required drive belt length). For a more accurate calculation, you need to take the minimum and maximum length of the distance between centers, choose something in between that suits you.
 This is how the cutting machine turned out!Do the same. Do it even better.Good luck to you!Observe safety precautions when making itand operation! |
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Do-it-yourself cutting machine: design, diagram, manufacturing | Construction portal
Working with a cutting tool, for example, a grinder, many craftsmen understand how much easier it is to cut metal using a simple machine - both the work is more convenient and the cut line is ideal. But when looking at the prices for a cutting machine for metal, even the most primitive used one, there is a desire to make something like this device yourself. There are several ways to make a cutting machine with your own hands, for example, using a grinder or a disc. All designs have their disadvantages or obvious advantages.
Use of cutting machines in everyday life
When working with metal, it is impossible to do without welding, cutting, grinding and other types of processing. The ability to have the simplest machines for woodworking and metal on your farm is a huge help to the home craftsman. In those places where it is difficult to reach for work, for example, cutting off a metal staircase or changing something in the attic structure, you will need a grinder or a circular saw. And cutting equal pieces of reinforcement, rods, small pipes and all kinds of metal workpieces is much easier to do on the working surface of the machine.
The same cutting tank can be used for other purposes to cut aluminum, plastic and other synthetic materials. However, it is not recommended to use metal cutting machines for woodworking purposes. Considering the small size of a household metal-cutting machine and the general simplicity of this design, it will not be difficult to place it on your estate.
To operate the machine, you will need a well-lit area in the yard or garage, an outlet and a flat floor surface. And if it is no longer needed, it can always be taken to the workshop, pantry or utility room until the next use on the farm. Some designs of homemade machines can be assembled and dismantled, the frame or base of the structure will remain intact.
A homemade cutting machine can also not only be used at home, but also rented out in order to recoup the costs of its production - in a word, this is a very profitable device.
Classification of machines
Structurally, all metal-cutting machines combine an engine with a transmission, a cutting disk and the working surface of the machine. There are drawings for a cutting machine on most sites dedicated to various homemade products. Knowing the basic principles of operation of this device, it is easy to make your own adjustments in order to use the materials and mechanisms that are already on the farm.
1. The power of the motor used depends on the expected performance, and it is important to decide on this before making a cutting machine. Most ready-made cutting machines have quite high power - up to 2000 W. Although a machine for domestic use may have smaller parameters, you should not forget that the metal is the same everywhere.
2. To maintain the power of the engine on which the machine will operate, it is important to choose a suitable kinematic transmission method. The most common are belt and friction friction transmission, each method has its own advantages. Gear transmission is gear, worm, chain, but the latter option is the most popular. Belt drive produces the least noise and is most often used on homemade machines, but for more precise machines it is not suitable due to the likelihood of the belt slipping. However, with any machine design, it is important to remember to comply with safety precautions.
3. It is advisable to equip even a homemade machine with a vice - to ensure guaranteed retention of the material being processed. A carbide disc or an abrasive wheel is the choice of the master, depending on what is at hand, as well as on the most frequently performed work.
4. The metal cutting angle parameters can vary from 45° to 90°, but usually cutting is done at a right angle. Not every homemade machine has this advantage.
5.The diameter of the disk determines the height of the piece of metal being cut, but these parameters can be changed. For example, a wide, thin-walled pipe can be rotated while cutting, but it is difficult to secure with a vice. Marking a volumetric metal structure on the working surface of the machine is sometimes also problematic. Cutting machines, in most cases, have a working diameter of up to 400 mm.
6. The total productivity of a manual machine for precise cutting of metal largely depends on the speed of rotation of the disk. The high speed of the machine directly affects the quality of cutting.
7. The weight and dimensions of a homemade machine are determined depending on the material of the general design, which it is advisable to equip the legs with vibration supports.
8. The type of cutting machine also depends on the feed of the cutting tool - pendulum, with bottom or front feed. The disc is fed from above using a pendulum feed.
9. A homemade machine can have 2 cutting heads or one, respectively, there are single-head and double-head options.
The abrasive cutting machine is designed for cutting metal reinforcement, rods, profiles, I-beams, pipes of different diameters, solid parts and profiles at different angles. Works with an abrasive wheel.
A band cutting machine or band saw operates on the principle of a closed metal strip moving on pulleys.
At home, the easiest way is to build a cutting disc machine for metal. There are several ways to make a cutting machine with your own hands, but the simplest method will be the most understandable.
The manufacturing process of a machine based on a cutting disc
To work you will need:
- steel corner,
- channel,
- drill,
- welding machine,
- electric motor,
- bearing pair,
- starting circuit,
- switch,
- coil,
- wooden board or steel sheet for the working surface,
- box to ensure the operation of the electrical circuit.
1. After preparing all the tools, make a frame or a general frame of suitable dimensions, for example, from angle No. 25. The parts of the structure are measured according to the drawing on a cutting machine and cut with a grinder, then welding begins. The finished frame can be placed on vibration-supported legs, which will facilitate the operation of the machine. It is easier to make the legs from the same profile or small diameter tubes.
2. Channel No. 10 is welded to the resulting table, which acts as a guide axis; it will become the basis of the structure for attaching the cutting part of the machine and connecting it to the motor. Next, the main parts are attached to the channel, including two vertical posts secured with bolts.
3. Next, you need to weld another frame from the profiles - this is the base for mounting the electric motor and the main cutting disk. On the other side of the frame, an electric motor with a power of about 1.5-2 kW is fixed. Asynchronous motors are considered the most durable and reliable. The motor will need to be powered from a 3-phase network. We remind you that a higher power engine will provide a more even cut and good speed of metal cutting work.
4. The method of fastening the shaft and the general principle of its connection to the structure are not important. A threading machine, when properly ensuring the supply of revolutions from the electric motor to the rotating shaft, must work reliably. The V-belt will help provide this. Some work can be ordered from a turner (shaft with supports, belt pulley and disk flanges). It is advisable to make the flange projection with a diameter of 32 mm.
5. Next, the support bearings are mounted in the sockets of the upper frame plates on the channel. Bolts and nuts can be used to secure the motor and shaft. Ensuring the operation of the electrical circuit is in a ready-made box with a switch, which is attached to the bottom of the frame.
6. The connection of the racks with a shaft with a diameter of 12 mm is made using a sleeve. To prevent it from slipping, the sleeve and shaft are connected with the smallest gap during a sliding fit. A rocker arm from the channel is welded onto the bushing so that its arm is in a ratio of 1:3.
7. You will need to install a rigid spring near the engine - to ensure return, it will even work from an expander. The springs and chains should be securely secured with bolts.
8. The electric motor is installed on the side of the smaller section of the rocker arm, and the shaft on the larger side. A belt drive will ensure the movement of the shaft.
9. An emergency stop button and a starting circuit are required, while the engine must be connected through a box and a three-pole circuit breaker, and the stop button leads to a direct connection to the network. Connecting the machine will be provided by a three-pole starter that starts the electric motor.
10. Be aware of the sparks that will fly from the disk - provide it with a casing. The work is first checked at idle, and only after making sure that the design is reliable, you can try cutting soft metal, for example, aluminum, in order to correct all inaccuracies. The working surface of the structure can be made of metal or wood and covered with thick plywood; if necessary for work, secure it with a vice.
The manufacturing process of a machine based on a grinder
There are several ways to make a metal cutting machine with your own hands - there are several good videos on this topic.
First way. The simplest device is a frame made of pipe, which will also serve as a comfortable handle. On one side, a transverse strip is attached by welding, on which there should be holes for attaching an angle grinder. The movable shaft will be attached to this base on a piece of angle, the same part can be attached to the floor of the garage or to the desktop. And on the other hand, it is attached to a spring, with the help of which the machine structure can return to its original position. If you attach the grinder correctly, the device will help you cut metal more accurately, freeing up one hand.
Don’t forget about the back impact of the grinder, when the tool is thrown back if the abrasive disc jams. And abrasive fragments from disc destruction can cause serious injury. An angle grinder attached to the machine with a closed casing minimizes such consequences. However, the simplest design does not allow for high-precision cutting, for example, when you need to cut small pieces of steel rod that require further adjustment.
The second way to transform an angle grinder into a cutting machine for metal work. This machine can be made collapsible.
To work you will need:
- welding machine,
- drill,
- steel corner,
- profiled pipe,
- channel,
- spring,
- relay,
- identical bearings,
- pedal,
- bolts,
- wooden board or steel sheet for the work surface.
1. A preliminary drawing or sketch is required, which indicates all the dimensions and necessary details. Ready-made drawings for a metal cutting machine are available on the Internet, but you will still have to make your own adjustments using what is already available on the farm. An easy sketch does not require precise measurements; it is enough to observe the proportions and have an accurate idea of each structural element. And remember that you will have to change the frame to accommodate different sizes of the grinder’s working disk.
2. Two frames on a common axis are the basis of the simplest machine frame, and it is better to weld them from metal. On the lower part it is necessary to weld the fastening, which will consist of a movable clamp and a clamping angle. The part on which the angle grinder will be attached must be made to move vertically relative to the bottom, like a pendulum. You cannot do without a spring; it is needed to return to the starting position. Additionally, secure the ruler with a limiter by welding - for accurate measurements.
3. The start of operation of such a machine will be ensured by a start pedal (button), connected through a low-voltage relay, supplying voltage to the angle grinder. After switching on, the design must be checked at idle speed. If the circle does not touch the casing and rotates freely, then you can use the design in practice - a homemade machine for cutting metal is ready.
4. This design can be collapsible, and other removable disks can be installed on the grinder. When working with other materials, be aware of the characteristics of the materials when cutting them. Remember safety precautions and precautions when performing metal work.
A pendulum saw is a power tool for doing wood and metal work with your own hands. The device provides fast and accurate cutting of workpieces. Many people believe that a pendulum saw and a reciprocating saw are identical units. In fact, there are certain differences between them.
The saw performs reciprocating movements during operation. The saber works exactly the same way.
A cutting pendulum electric saw is a fairly compact machine in size, where the cutting tool is a disk and is mounted vertically on a special pendulum.
The size of the device may vary depending on the model and power. The pendulum provides the ability to raise and lower the cutting blade when working on metal or wood.
The assortment is extensive, which allows the buyer to choose such popular saws as Makita, Zubr, PM 400, etc.
Device Features
Drawing of a typical saw device
- Circular and pendulum saws have approximately the same principle of operation;
- The main difference between the devices is that with a disk cutting tool and the motor are fixed motionless, while with a pendulum device they rise and fall due to the pendulum;
- The cutting pendulum installation provides a high-precision cut at a right angle;
- Additionally, tools such as PM 400, PM 55, Interskol, Zubr, Makita, KD 300, PM 70 and other representatives of the pendulum saw segment are capable of cutting at an angle;
- Often, a cutting system for cutting wood or metal includes an abrasive disc;
- The use of appropriate disks allows you to work efficiently. To process a particular product, you simply need to replace the blade;
- The blade can also be universal, allowing you to cut all kinds of workpieces with one disc;
- A modern cutting pendulum electric saw for cutting workpieces is distinguished by the fact that the cutting blade and disk can be replaced in the shortest possible time. This is what distinguishes the leaders of the segment in the person of PM 70, PM 55, KD 300, Zubr, Makita, Interskol, PM 400, etc.;
- Each cutting tool must be equipped with protection systems. This is because the rotating cutting blade is potentially dangerous;
- By choosing the desired size of the device, you can cut workpieces at home;
- Manufacturers offer both household and industrial models.
Despite its fairly significant advantages, the pendulum cutting saw has several disadvantages.
- For sawing, you have to apply considerable force, as when using a grinder.
- A cutting saw has certain restrictions on the width of the material being cut.
- The device is not characterized by high productivity, therefore it often serves as an auxiliary equipment in factories or in home workshops.
The estimated price of devices for home use is from 12 to 40 thousand rubles.
How it works
To cut materials, you need to know exactly how a pendulum-type electric saw functions.
- A pendulum saw can safely be called a circular saw. Here the circular machine is installed on a special frame;
- The machine operates from the mains;
- Factory models can be equipped with special turntables, due to which the device is used as a miter box. This function cannot be called necessary, but sometimes its relevance is in demand;
- The electric cutting saw received its name due to the fact that the cutting blade is lowered by hand along a pendulum path onto the workpiece, and when the cutting is finished, it rises to its original position;
- Depending on what blade is used, what the size and power of the device are, a factory-made or home-made electric saw can cut metal, wood, tiles, porcelain, plastic, glass, etc.;
- Cutting discs are used to cut metal. They can be borrowed from an angle grinder;
- If it is wood, a circular blade is used.
Reciprocating saw
In home workshops, grinders, circular saws, pendulum saws, and reciprocating saws are widely used. They all have their own design and technical features.
So that you don’t have any problems finding the differences between a pendulum and a reciprocating saw, let’s clarify some things.
- A home reciprocating saw is great for the job;
- Like a pendulum saw, a reciprocating saw can be equipped with special blades for wood or metal, or with universal cutting tools;
- The reciprocating electric saw is distinguished by its reciprocating movements;
- The device is compact in size and can be conveniently used in a home workshop;
- A reciprocating electric saw is an excellent alternative to a hand saw, which has certain limitations and difficulty in operation;
- The main disadvantage that a reciprocating saw has is vibration during operation. Particularly noticeable vibrations occur when working on thick wood or metal.
DIY pendulum machine
When there are various devices on the market and a completely reasonable question arises about the relevance of homemade saws.
A homemade saw usually has a small structure and shaft, and uses a compact attachment assembled with your own hands. You can make the device from a grinder, an electric drill, or just an electric motor.
Some manage to create a worthy alternative to Makita and Zubr saws. Wood and metal cutting on homemade devices is often superior to factory models. To achieve what you want, you will need to select drawings, take a motor from an angle grinder, electric drill or other device, watch a video and photo of a manual for assembling the unit.
- First you need to take an electric motor. The first homemade installation may well be an attachment to an electric drill. Experts advise using an electric motor from a grinder for cutting in a home workshop for a pendulum saw.
- From the angle grinder engine, rotation can be transmitted to the spindle using belt drives. A homemade design based on a V-belt is perfect for these purposes.
- If an attachment to an electric drill is not your option, then build a frame from metal to fix the future pendulum device. Square metal is used.
- On one side, the spindle body is welded to the metal frame, and on the other there will be a platform for installing the grinder engine. Don't forget about the shaft size. Correctly choosing the shaft size is extremely important for the device to turn out correctly. Typically, the shaft size is indicated in the drawings, on the basis of which homemade pendulum saws are assembled.
- Be sure to make a groove in the frame necessary for the passage of the saw's rolling axis. For these purposes, again using a grinder, cut a piece of pipe.
- When welding the frame, make sure that the rolling axis, the grinder motor and the spindle are parallel.
- Consider the issue of a protective casing, which is usually made of sheet metal. A drive handle is installed on the belt casing.