It is much easier, safer and more comfortable to perform the process of cutting metal and metal structures using machine tools than using hand tools and tools. But not every amateur can make a quality machine.
This is the reason why many prefer to design such mechanisms with their own hands, using what is in everyday life, for example, saws or grinders.
Why are cutting machines needed?
Summer cottages always require minor repairs: replace a dilapidated greenhouse rack, make a fence for land plot from metal, repair a garden wheelbarrow or cart - cutting metal at a right angle or with a bevel is always needed. Make blanks for any metal products easier and more quickly due to the machine.
With the help of cutting machines, you can cut any materials: steel, cast iron, copper. Cutting is done at 45º and 90º angles. You can make products from pipes of all diameters with your own hands. As a rule, cutting mechanisms are used for cutting semi-finished products into fixed lengths.
Metal equipment can also be used for processing other materials, while eliminating the operation of the cutter. machine made with my own hands, compact, it is possible to install it under a canopy, and in winter time rearrange it to working room.
You need a flat and hard surface with lighting. A similar corner can be found on the site of any structure. All-welded and collapsible equipment designs are used. In order to reduce manufacturing costs, the device can be periodically given to neighbors for temporary use.
Cutting machine device
Any work that is associated with metal or wood requires a cutting process, for which special cutting equipment is used. The application of this device is incredibly extensive: from everyday needs and life, to large plants and factories.
It should be noted that machines of this type are mechanisms that will allow you to perform transverse cutting of metal.
Cutting machines can cut parts from any type of metal: from copper and PVC profiles, to large steel billets. Semi-finished products can be cut under straight and sharp corners. Using a cutting machine, it is possible to cut pipes of large and medium diameters.
The most important mechanism of the apparatus, its "soul", is an electric motor and a working body - a cutting wheel, which are connected to each other by means of gear or belt drives. Each of these types has its own merits. For example, belt inherent easy running, resistant to various types of loads, less noisy. It can be mounted even on a massive cutting machine.
The gear train is oversized, and due to this feature it is suitable for a miniature home-made cutting unit. Therefore, in the process of buying a cutting mechanism, you need to look at the type of gear used.
Almost any type of machine is equipped with abrasive wheels, but sometimes there are mechanisms on which a carbide disc is installed. Moreover, all such metal saws are equipped with a vice that securely fixes the product or semi-finished product.
Video: homemade cutting machine from a grinder.
Homemade cutting machine for metal: manufacturing instructions
The machine, which is made by one's own hands, has an undeniable advantage: it is made to the requirements of a particular master and products planned for further production. For work you will need:
- 24th corner;
- 10th channel;
- pipes;
- welder;
- rolling bearings;
- electric drive;
- capacity for mounting the electrical circuit;
- start toggle switch;
- starting circuit;
- winding;
- drill.
Assembly progress:
- From the corner No. 24 and using the angle grinder, cut the blanks onto the frame with your own hands, its dimensions are 400x600x1200 mm;
- Using a welding machine, workpieces are welded together;
- Channel No. 10 is welded as a guide, which at the same time will give strength to the entire structure.
- Using screws, two vertical supports are fixed to the channel;
- Using pipes, make a frame 400x600 mm for subsequent mounting of the electric drive and shaft at the required angle;
- On the "tail" part of the frame there is a plate with a fixed electric motor. It is advisable to use an asynchronous motor, as it is unpretentious. Depending on the future destination, you can give preference to the motor, the power of which will be in the range of 1.5 ... 3 kW and perform “powering” from three-phase network. If it is possible to use only a 1-phase network, select a motor 1/3 more power than the calculated value, it is connected using capacitors;
- With help lathe, make the shaft and flanges, pulley and supports. The flange must protrude 30.32 mm.
- Install the support bearings and pulley;
- The installation of the box with the wiring diagram is carried out directly in the lower area of the frame.
- A 12 mm shaft is attached between the racks, on which the sleeve is put on. The distance between the shaft and the sleeve must be kept as small as possible and a sliding fit must be ensured.
- A rocker arm from the 10th channel (L = 800 mm) is welded onto the bushing using a welding machine, the ratio of the arms of the rocker arm is 1 to 3. Its stroke is limited by a chain.
- An electric motor is installed on the area of the short section of the rocker, and a cutting mechanism is installed on the long component.
- A belt drive is laid from the electric motor to the shaft.
Capacity price for electrical circuit, made by hand, will be slightly lower compared to those bought in hardware store. To extend the power supply to the equipment, you need a three-pole circuit breaker, from which power is supplied to the electric motor, an emergency shutdown button and a starting circuit.
The emergency button is connected directly, the electric motor is connected using a box and an automatic machine. This will ensure complete safety and electrical protection of the equipment you have made.
Based on the foregoing, making a cutting mechanism with your own hands is not only cheaper, but also more practical, since in the process of its manufacture you yourself adjust its parameters and adjust it for its future work.
Also, having done such a procedure once, you can repair such equipment without any problems. Moreover, if necessary, you can earn money by making cutting equipment with your own hands.
Video: do-it-yourself homemade cutting machine for metal.
Cutting machine for metal is useful for any workshop. It is required for construction work and in the locksmith shop. The market offers a wide variety of machines, but not all of them are affordable. For home workshops, a home-made metal cutting machine will be the way out of this situation. For its manufacture will require certain skills to work with welding machine and locksmith tools. It will require a cutting unit for metal from the master and the skills of an electrician.
Necessary tools and materials
In order for the future machine to reliably perform its functions, you will need a simple set of tools:
- drill;
- Bulgarian;
- taps;
- apparatus for welding;
- spanners;
- dies.
An additional engine is required. The best option is a 2 kW motor. It is recommended to purchase single-phase or three-phase motors for such machines.
The necessary elements of the future unit are:
- sheet steel 3 mm thick;
- bearings 204;
- 2 pulleys;
- metal corner;
Any home-made mechanism must be customized to fit your needs and drawings. The master pays special attention to safety. When working with cutting units, the hands are a particularly vulnerable part of the body, which are easy to damage, neglecting simple rules work safety.
Disc cutters
In practice, craftsmen make three types of machines: tape, pendulum, disk. The first type is the most difficult to make in the home workshop. The best option is a disk-type metal cutting machine.
These units include:
- cutting disc;
- pendulum;
- Desktop;
- Electrical engine;
- drive mechanism.
For a standard workshop, the power of the motor used is 1.5 kW. The power of the electric motor depends on the type of metal used. If metal with thin walls is used during operation, then a power of 1.5 kW for such an engine will be enough. For frequent work for cutting pipes from a profile, you will need a 3 kW unit.
An important indicator of the engine is the number of revolutions that it makes in the process of cutting a metal part. The recommended number of revolutions is at least 3000 per minute. At low motor speeds, the cutting disc is not able to work optimally.
Particular attention must be paid to the diameter of the circle used. Masters advise choosing circles with a diameter of 300-350 mm with an electric motor power of 2 kW. With the specified parameters, the recommended number of engine revolutions is 3000-4400 rpm. With an increase in the indicator, the circle is destroyed, and at low speeds, it quickly overheats and is erased.
What to look out for
The choice of drive mechanism matters. This task is well handled by a belt drive. For its manufacture, you will need 2 pulleys that have the same size. The first pulley is fixed on the drive shaft cutting wheel, the second - on the motor shaft. The shaft is mounted on two bearings.
To prevent the belt from slipping and maintaining the necessary tension, it is necessary to fix the electric motor in the back of the pendulum. Fasteners are made on 4 bolts.
The pendulum has its own separate requirements. It should be:
- balanced;
- well brewed;
- move perpendicular to the desktop.
The pendulum is mounted on two vertical posts. Each rack has slots where a bushing with a diameter of 11 mm is inserted. Racks are made of a metal square 40*40 mm in size. Optimal Height- 90 mm.
Design desktop requirements
The cutting unit must have a working table optimal sizes. The required parameters are: 701*1000*900 mm. The table is welded from a corner measuring 25 * 25 mm, after which it is covered with a steel sheet having a thickness of 3 mm. Slots are made in advance in the sheet at the point of rotation of the circle.
At the workplace, it is fixed with a swivel clamp and a swivel stop. A similar home-made mechanism allows you to cut products at an angle and perpendicularly.
Any cutting machine for metal requires compliance with a number of conditions during its installation:
- adjustment of the angle of rotation is required (its location must be perpendicular to the surface of the desktop);
- the master needs to protect his hands from damage by installing casings around the disk and rotating elements;
- it is important to pre-calculate the rotational speed of the circle;
- provide the handle with an emergency stop button, which, when pressed by the hand, instantly stops the operation of the entire mechanism;
- Place the wheel feed force in the cutting area.
Procedure for self-manufacturing of the machine
Any machine with which it is possible to cut metal is assembled according to the scheme:
- preparation of protective covers intended for installation on a drive belt;
- installation of the motor using a drive belt as a connecting part between the motor and the shaft;
- production of a shaft for fixing a pulley and a cutting disc on it (the assembly is assembled and mounted on a pendulum, which is the upper part of the structure);
- production of a shaft for mounting a pendulum on it;
- manufacturing of a machine frame, on which it is supposed to fix metal for processing and a spark catcher;
- the pendulum is fixed on the frame;
- electrical wiring is installed;
- the device is launched in test mode to check the build quality.
Features of the assembly of the apparatus based on the grinder
In the conditions of the workshop, it is possible to assemble a home-made cutting machine for metal based on a grinder. You will need tools and materials:
- starting relay;
- several profile pipes with a square or rectangular section;
- control pedal;
- sheet of metal for the desktop;
- spring;
- metal corner;
- two bearings.
Machine Start Relay
Unlike a disk-type machine, the operation of such an apparatus has a more accurate result. The assembly process is very similar to the disk assembly, but has a number of features:
- frame parts are made;
- a swivel is arranged on the pendulum lever;
- a bracket is made in the shape of the letter “P”, in which holes are made for mounting the grinder gearbox;
- strips with clamps are made, due to which the angle grinder will be fixed on the pendulum;
- welding clamp, bracket and cutting tool(an alternative would be to use threaded connection for the installation of these elements);
- pressing into bearing supports;
- pressing bearings on the shaft from both sides;
- welding of the pendulum on the edge of the working platform with a mandatory indent from the edge by 0.5 cm;
- installation of a grinder and a protective casing;
- return spring installation.
After installing all the structural elements, the machine starts in trial mode. Additionally, you will need to adjust the groove for the tool and install supports with which the metal being processed is attached.
On final stage works the machine is covered with enamel. It will protect the unit from the adverse effects of rust.
When working with a grinder, the master needs to protect his hands and eyes from exposure to sparks. Any work is carried out in protective gloves and a mask.
For cutting metal, in our time, there is a huge variety of various tools. Many of them are manual and have a large number of inconveniences. The rest of the toolkit is considered automated and has large dimensions, or a large price category.
To combine business with pleasure, as well as convenience and price category, needlework masters created a disc cutting machine. Below we will consider everything related to this equipment.
The scope of this machine equipment extends to industrial area applications and for domestic use. Used for cutting different kind metal (steel, cast iron, copper, aluminum, etc.).
Since in everyday life there are a huge variety of different metal objects required minor repairs, this machine becomes extremely necessary. After all, once lowering the cutter stand with the cutting disc will be easier and faster than manually sawing with a hacksaw.
Dimensions homemade equipment allow you to place it under a canopy, in the summer, and safely place it in a warm garage or in the workshop in winter.
Tip: It is extremely important to choose a smooth and stable place to install the bed (concrete slab, thick corners, or concrete support legs bed). This is done in order to reduce the possibility of vibration to a minimum during operation.
Mainly used in production automated systems controlled by the operator through the CNC. The goal is the mass production of metal products, in the form of cutting pipes of given sizes and various sections, flat metal products and much more.
Below we will analyze by what criteria these machine tools are distinguished.
Classification of cutting machines
All cutting machines are distinguished by a huge number of criteria. We will analyze the most important ones. So, the main technological criteria:
By type of tool
Separation occurs directly on the tool that cuts metal products. In turn, they are divided into the following subspecies:
Band saws
In this case, it is used band-saw with teeth. The belt is made from high quality high speed steel. Due to the fact that the cutting belt is thin, material consumption is saved due to the thin cut. Apply tape machines in productions.
Hacksaw
Used in small industries, as well as in everyday life. A hacksaw tool can be manual (everyone knows a hacksaw for metal) and an electromechanical machine tool. In this case, the hacksaw blade is made of various metals (high speed steel, carbon steel, alloy steel, bimetal steel). This type is quite easy to operate and is considered a handy tool.
Disc machines
Belong to the category indispensable tools. Used throughout the metalworking industry. On such equipment, it is possible to carry out high-quality cutting of metal even to an unskilled 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 inefficient in its kind and is capable of performing only one operation.
Two-head
In their design, two "heads" are used for mounting disks. In this case, one "head" is in a firmly fixed and motionless state. The second has the ability to move independently in the first. This equipment is considered a high performance tool.
By saw blade feed type
Front feed of the saw blade
The center of the disk moves in a horizontal plane.
bottom feed
The center of the disk moves from bottom to top in a vertical plane.
pendulum feed
Center cutting disc performs a movement similar to an arc, from top to bottom.
Vertical feed
The center of the disk moves in a horizontal plane from top to bottom.
By main view
Cut-off saws
With the help of this tool, a cut of dimensional parts of rolled metal is made. Good for small batch production.
Abrasive - cutting
When working with such equipment, abrasive wheels are used. High-quality cutting of the remains (burrs) of rolled metal is carried out. Cutting the material into blanks, cutting profile metal at the required angle from 0 to 45 degrees.
Correct-cutting
Such equipment carries out the processing of metal produced and supplied on coils (reinforcing steel, metal strip, wire, bars with a profile section). This equipment is equipped with a correct mechanism and automatic unwinding of metal from a reel. The twisted wire enters this mechanism, straightens out over the entire plane and is fed into a special receiver for further processing.
Tip: Depending on the material to be cut, it is necessary to select suitable cutting discs. Discs must match specifications.
Disc machine device
Frame
Or a metal structure that plays the role of the base of the unit.
pendulum knot
This is a kind of metal part from 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 (strong tourniquet, or a small spring).
Pipe clamp
The so-called vice, fixed on the bed. They allow you to press the workpiece to give it a stationary position.
Pendulum axis
This axis is used to move the disk.
Electrical engine
The heart of the unit. It is he who drives the whole mechanism. For this equipment, an asynchronous motor is used.
Actuator
A box with electronics that is connected to the electrical network. This box has buttons to turn it on and off.
Wheel guard
Steel protection, which prevents splinters from the disk from falling directly into the person working on the unit.
Belt guard
It is located where the belt makes its movement. This casing is designed to protect against getting into a working person belt, when it breaks.
pendulum handle
The part with which the cutting disc is pressed against the workpiece.
Ground bolt
As in all machines, there is a bolt on the body of the unit, with the help of which grounding is carried out.
abrasive wheel
Directly cutting disc, consisting of various materials.
Sling shackles
(4 units)
bed
This is the area where the main unit of the unit is located.
Adjustable stop
Due to it, it is fixed right size future product.
Tip: If your budget is rather modest, then you can use improvised materials to create parts of the unit. If the budget allows, then it is advisable to purchase all the components in the store. This will improve performance and service life.
Production of a disc cutting machine
Any invention will require certain parts, whether they are purchased items 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 the manufacture of the handle.
- Welding machine.
- Bearings for the pendulum mechanism.
- The drive is electric.
- Box for the location of electronics.
- Toggle switch on and off.
- Starting circuit.
- Winding.
- Electric drill.
- Fasteners (bolts, screws).
Let's analyze the assembly process of all equipment:
- First of all, the grinder cuts blanks into a frame with dimensions of 400x600x1200 mm.
- By 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 will serve as a guide.
- Several vertical supports are screwed onto the channel.
- Next, the next frame is mounted, on which the engine and shaft will be located. The dimensions of the frame should be 400x600 mm.
- A plate designed 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.
- Shaft, flanges, bearings with a pulley are made on a lathe.
- Next, the bearings and pulley are installed.
- The installation of the box in which the circuit is located is carried out at the bottom of the frame.
- A shaft with a bushing is inserted between the vertical supports. Shaft diameter 12 mm. The clearance between the bushing and the shaft must be kept to a minimum.
- On both sides of the sleeve, limiters from pieces of the channel are welded.
- An electric motor and a cutting mechanism are installed on a long support beam and on pieces of a channel.
- The final step is to install the belt that ties the shaft to 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 regulate the entire mechanism, as they say for yourself.
Connecting a button that is designed for emergencies, carried out directly, and the engine 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 whole mechanism of such a machine by heart.
Making 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 fixed using metal fasteners.
In order for the angle grinder to be able to return to its original position, it is necessary to fix the frame and the angle grinder with a tight elastic band or spring. The frame itself is fixed on a prepared frame or on a large and heavy table. The weight of the table will ensure a minimum of vibration. If the frame is being prepared, then it must be fixed on a foundation prepared in advance. Such an invention could serve good tool in a home workshop or an excellent tool for cutting metal.
General feedback 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 it, you do not need to suffer with a grinder in your hands, in a bent state. If you choose a cutting tool for certain jobs, then only a disk cutting machine.
Video reviews
Video review of the disc cutting machine:
Video review of a cutting machine using a grinder instead of a disk:
Assembly video review homemade machine:
Video review of the cutting machine:
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 of a cutting machine for metal, even the most primitive used one, there is a desire to make something like this device on your own. There are several ways to make a cutting machine with your own hands, for example, based on a grinder or a disk. All designs have their drawbacks or obvious advantages.
The use of cutting machines in everyday life
In metal work, it is impossible to do without welding, cutting, grinding and other types of processing. The ability to have the simplest machines in your household, for woodworking and metalworking, is a huge help. home master. In places where it is difficult to get to work, for example, to cut off metal ladder or change something in the design of the attic, there you will need a grinder or a circular saw. And cutting equal pieces of reinforcement, rods, small pipes and all kinds of metal blanks is much easier to do on the working surface of the machine.
The same cut-off tank can also be used for other applications such as cutting aluminium, plastic and other synthetic materials. However, it is not recommended to use metal machines for woodworking purposes. Given the small size of a household metal-cutting machine and the general simplicity of such a design, it will not be difficult to place it on your estate.
To work on the machine, you will need a well-lit area in the yard or in the garage, an outlet and Smooth surface gender. And if not needed, it can always be taken out to the workshop, pantry or utility room until the next use in the economy. Some designs of homemade machines can be assembled and dismantled, the frame or base of the structure will remain intact.
A home-made cutting machine can also not only be used in the house, but also rented out to recoup the cost of its manufacture - in a word, this is a very profitable device.
Machine classification
Structurally, all metal-cutting machines combine an engine with a transmission, a cutting disc and the working surface of the machine. On the cutting machine, there are drawings on most sites dedicated to various homemade products. Knowing the basics of the principle of operation of this device, it is easy to make your own adjustments in order to use those materials and mechanisms that are already on the farm.
1. The power of the motor used depends on the intended performance, and it is important to decide on this before making a cutting machine. Most ready-made cutting machines have a fairly high power - up to 2000 watts. Although a machine for domestic use may have smaller parameters, you should not forget that the metal is the same everywhere.
2. In order to maintain the power of the engine on which the machine will operate, it is important to select a suitable kinematic transmission method. The most common are belt and friction friction transmission, each method has its own advantages. Gear transmission - gear, worm, chain, but the latter option is the most popular. The belt drive produces the least noise and is used most often on homemade machines, and it is not suitable for more accurate machines due to the likelihood of the belt slipping. However, with any design of the machine, it is important to remember that safety precautions are observed.
3. It is advisable to equip even a home-made machine with a vise - for guaranteed retention of the material being processed. Carbide disc or abrasive wheel- the choice is up to the master, depending on what is at hand, as well as on the most frequently performed work.
4. Metal cutting angle parameters can vary from 45° to 90°, but usually cutting is done at a right angle. Not every homemade machine has a similar advantage.
5. The diameter of the disk determines the height of the cut piece of metal, but these parameters can be changed. For example, a wide, thin-walled pipe can be turned while cutting, but is difficult to secure with a vise. Mark up 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 performance largely depends on the speed of the disk manual machine for precision metal cutting. High speed the operation of the machine directly affects the quality of the cut.
7. The mass and dimensions of a home-made machine are formed depending on the material of the overall design, which is desirable to be equipped with vibration mounts on the legs.
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 with a pendulum feed.
9. A home-made machine can have 2 cutting heads or one, respectively, there are single-head and two-head options.
The abrasive cutting machine is designed for cutting metal fittings, rods, profiles, I-beams, pipes of different diameters, solid parts and profiles at different angles. Works with an abrasive wheel.
A band saw or band saw works on the basis of the principle of a closed metal strip moving along pulleys.
At home, the easiest way 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 process of manufacturing a machine tool based on a cutting disc
For work you will need:
- steel corner,
- channel,
- drill,
- welding machine,
- electric motor,
- bearing pair,
- starting chain,
- switch,
- coil,
- wooden shield or steel sheet for work surface,
- box to ensure the operation of the electrical circuit.
1. After preparing all the tools, a frame or a common frame of suitable sizes is made, for example, from corner No. 25. Parts of the structure on a cutting machine according to the drawing are measured and cut with a grinder, then proceed to welding. The finished frame can be planted on the vibration supports of the legs, which will facilitate the operation of the machine. Legs are easier to make from the same profile or tubes of small diameter.
2. A channel No. 10 is welded to the resulting table, which acts as a guide axis, it will become the basis for the structure for attaching the cutting part of the machine and connecting it to the motor. Further, the main parts are attached to the channel, including two vertical racks bolted.
3. Next, another frame must be welded from the profiles - this is the base for mounting the electric motor and the main cutting disc. On the other side of the frame, an electric motor with a power of about 1.5-2 kW is fixed. The most durable and reliable are considered asynchronous motors. The motor will need to be powered from a 3-phase network. We remind you that a more powerful engine will provide a more even cut and a good speed for cutting metal.
4. Way of fastening the shaft and general principle its connection to the structure is not critical. A cutting machine, with proper provision of revolutions from an electric motor to a rotating shaft, must work reliably. This will help him provide a V-belt. Some work can be ordered by a turner (shaft with supports, a pulley for a belt and disk flanges). It is advisable to make a ledge of the flange with a diameter of 32 mm.
5. Next, the support bearings are mounted in the nests of the plates of the upper frame on the channel. Bolts with a nut 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 done using a dressed sleeve. To prevent it from slipping, the sleeve and shaft are attached with the smallest clearance in a sliding fit. A rocker from the channel is welded onto the sleeve so that its shoulder is in a ratio of 1: 3.
7. You will need to install a rigid spring near the engine - to ensure return, it will work even from an expander. The springs and chains must be securely fastened with bolts.
8. The electric motor is installed from the side of the smaller section of the rocker arm, and the shaft - from the larger side. The belt drive will ensure the movement of the shaft.
9. An emergency stop button and a starting circuit are required, while the motor must be connected through a box and a three-pole circuit breaker, and the stop button leads to a direct connection to the network. The connection of the machine will provide a three-pole starting machine that starts the electric motor.
10. Be aware of the spark that will fly from the disc - provide it with a casing. The work is first checked for Idling, and only after making sure of the reliability of the design, you can try cutting soft metal, for example, aluminum, in order to correct all inaccuracies. work surface structures can be made of metal or wood and covered with dense plywood, if necessary for work - fix the vise.
The process of manufacturing a machine based on a grinder
There are several ways to make a do-it-yourself metal cutting machine - there are several good videos on this topic.
First way. The simplest device is a frame made of a pipe, which at the same time will serve as a convenient handle. On the one hand, a transverse bar is fastened by welding, on which there should be holes for fastening the grinder. A movable shaft will be attached to this base on a piece of corner, the same part can be attached to the garage floor or to a desktop. And on the other hand, they are fixed to the spring, with the help of which the machine tool structure can return to its original position. With proper fastening of the grinder, the device will help to produce more accurate cutting of metal, while freeing one hand.
Do not forget about the reverse impact of the angle grinder, when the tool is thrown back if the abrasive disc is jammed. And fragments of abrasive on the destruction of the disc can seriously injure. An angle grinder fixed to the machine with a closed casing minimizes such consequences. However, the simple design does not allow high-precision cutting, for example, when it is necessary to cut small pieces of a steel bar that require further adjustment.
The second way to transform the grinder into a cutting machine for metal work. This machine can be made collapsible.
For work you will need:
- welding machine,
- drill,
- steel corner,
- profiled pipe,
- channel,
- spring,
- relay,
- the same bearings
- pedal,
- bolts,
- wooden shield or steel sheet for the work surface.
1. A preliminary drawing or sketch is required, where all dimensions and necessary details. There are ready-made drawings for a cutting machine for metal on the Internet, but you still have to make your own adjustments using what is already on the farm. A light sketch does not require precise measurements, it is enough to observe proportions and have an accurate idea of each element of the structure. And remember that you will have to change the frame under different sizes grinder 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 pressure bracket. The part on which the grinder will be fixed must be made moving vertically relative to the bottom, like a pendulum. You can't do without a spring, it is needed to return to its original position. Additionally, fix the ruler with a limiter by welding - for accurate measurements.
3. Starting the operation of such a machine will provide a starting pedal (button), connected through a low-voltage relay, supplying voltage to the angle grinder. A design check after switching on must be done at idle. If the circle does not touch the casing, rotating freely, then you can put the design into practice - a home-made metal cutting machine 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 the safety precautions and precautions when performing metal work.
An indispensable tool in the home workshop, locksmith shop, on the construction site. Many industrial models of these tools are produced, but their price is sometimes not available not only to a private master, but also to a small enterprise. There is a way out - a cutting machine for metal with your own hands is not difficult to do. This requires only certain skills in working with a welding machine, bench tools, and some qualifications of an electrician. Of the materials, too, you will not need anything scarce, or not available for free sale.
For work you will need:
- Bulgarian;
- welding machine;
- drill;
- a 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, sheet steel 2-4 mm thick. When all this is assembled, the actual manufacture of the machine begins.
You can make drawings yourself using material from the Internet, or use ready-made ones, for example, 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 for yourself. Naturally, in this case, certain rules and requirements should be observed that are put forward for a tool of increased danger, such as a cutting disc machine or pendulum saw, both homemade and industrial.
Most do-it-yourself cutting machines for metal belong to the pendulum type. more difficult 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. General design can be seen on the video.
It consists of several main nodes:
- electric motor;
- pendulum;
- drive mechanism;
- cutting disc;
- desktop.
Let's consider 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 1.5-3kW. If you plan to use the cutting machine in a home workshop, a small metalworking workshop where cutting profile pipe, fittings, angle or other rolled products are produced relatively rarely, and thin-walled metal is used as blanks, in terms of power of one and a half kilowatts, it will be enough. For small-scale production, work on a construction site, or the manufacture of frames for any purpose, more than powerful engine.
If there is a three-phase motor with a power of about 3 kilowatts, it can be connected to 220 volts using the place of the "star" circuit, the "triangle" circuit. But at the same time, it must be borne in mind that its power will decrease by 25-30%. The main thing is that the number of revolutions indicated on the nameplate will remain.
For installation on a cutting machine for metal, the engine must have a number of revolutions equal to 2500-3000 per minute. This is due to the fact that it is at such speeds that the cutting disc works optimally.
For a home-made cutting machine for metal, circles with a diameter of 300-400 millimeters are used. Here, too, it is necessary to proceed from the needs of production. Over too large diameter you should not chase the disc - the further 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 disk diameter is 2 kilowatts at three thousand revolutions and 300 millimeters in diameter.
A self-made cutting machine for metal must first of all be safe. Cutting discs are marked maximum amount rpm at which they can be operated. As a rule, it should not exceed 4400 rpm. If you get more - the disk may be destroyed, which is unsafe. If the number of revolutions is less than 3000, then the cutting speed will be insufficient, and the disc will overheat and wear out. It is these figures that should be taken as the starting points for calculating the power transmission.
Drive unit
As a drive mechanism, it is most convenient to use a belt drive. 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 disc 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. So it is more convenient to work, and safety rules are observed. The clamping nut of the disc will not be at risk of loosening.
To tension the drive belt, the engine is fixed at the back of the pendulum with 4 bolts located in the longitudinal slots. It can be displaced 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 proper belt tension and prevent belt slippage. It will also be easier to replace the belt if the previous one becomes unusable.
Console (pendulum)
The console part of the cutting machine for metal is one of the most important. In addition to the fact that it must be carefully balanced, securely welded in compliance with all the necessary dimensions, it must also move strictly perpendicular to the desktop. The pendulum mount is based on 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 also calculate your own version.
A shaft-sleeve is horizontally installed in the holes of the racks, to which a rocker is welded, consisting of two levers, the ratio of which is one to three. A platform for the installation of an electric motor is welded on a short arm. On the long arm is the cutting wheel drive shaft. The ratio of the length 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 turned on machine into contact with the metal, it is necessary to apply a small but tangible force.
For ease of operation, a return spring is attached to the bottom of the engine platform, and the angle of deviation of the pendulum upwards is regulated by a cable or chain, fixed at one end to the table, and at the other - to the bottom of the long lever.
Desktop
The optimal dimensions are 700x1000x900 mm. It is welded from a corner of 25x25 mm and covered with a steel sheet 3-4 mm thick, in which slots are made in the disk rotation zone. A swivel stop and a clamp with a swivel clamp are fixed on the table. This allows you to cut both perpendicularly and at the required angle. Very interesting option homemade machine is shown in the video. Here it is not the workpiece that turns, but the console with the disk and the engine.
Mounting a disc-type cutting machine for a qualified locksmith is not particularly difficult. It is important to adhere to some fundamental requirements:
- correctly calculate the speed of rotation of the disk;
- adjust the angle of rotation, it must be strictly perpendicular to the plane of the desktop;
- set the force of feeding the disk into the cutting zone;
- install an emergency stop button on the handle;
- equip the cutting machine with protective covers for the disc and rotating parts.
