How to Cut Metal Easily Using Different Tools

If you are a professional tradesman or just a keen DIY’er the chances are at some point you are going to need to cut some metal of some kind.

Whether that’s a copper pipe or a sheet of steel it’s important to know about the different methods of cutting metal and what method should be used in what situation.

Different Methods for Cutting Metal

The metals you are most likely to find yourself using on a domestic level and needing to cut are steel, iron, aluminium, brass and copper.

When cutting metal you will have several choices on how to carry out this process and also a range of tools to use, some being cheaper and more accessible than others.

Here follows the most common methods:

Using a Disc Cutter

There are a few different types of disc cutter that are used by builders and metal workers alike for cutting and shaping metal; the angle grinder and the petrol cut off saw

The angle grinder is powered by electricity and features an electric motor that is used to turn various types of cutting disc (discs are available to cut stone and metal). The motor turns the disc at high speed and when it comes into contact with the metal object you’re working on it easily cuts it.

There are 2 different sizes of angle grinder, 6 inch and 9 inch, with 6 inch being geared more towards smaller jobs and the larger version for bigger heavier jobs and deeper cuts.

The angle grinder offers a cheap and cost effective way for anyone to cut most metal objects of a reasonable size. To learn how to use an angle grinder see our project here.

The other main type of disc cutter available is the petrol cut off saw. This is essentially a much larger and more powerful version of an angle grinder with a petrol engine instead of an electric motor.

As the size of the saw is much bigger it can take larger discs which in turn can cut larger and heavier materials. To find out how to use a petrol cut off saw see our project here.

All of these types of saw are capable of cutting pretty much any metal object using the correct disc, the only limitation is how deep you can go which depends on the size of the disc.

One further point to make is that it is technically possible to use circular saws and mitre saws to cut metal if the blade in the tool is a TCT blade (tungsten carbide tipped). If you have such a blade it can be used to cut thin sheet metal and aluminium when needed, however it will blunt the blade a little quicker.

One point to be aware of with any of these tools is that they are dangerous! Always ensure you know exactly how to use them safely and correctly, always wear eye (preferably face) protection as they throw shards of metal and debris everywhere and always wear old clothes and gloves.

Using a Blade (Hand Tools & Power Tools)

The more old school and traditional approach to cutting metal is to use a blade and the most common tool featuring a metal cutting blade is the hacksaw.

Available in a range of different sizes, the hacksaw is essentially a frame with a handle at one end with a blade fixed between the two ends of the frame at the base.

The blade is positioned at the cutting point and then it’s up to pure elbow grease to push and pull the saw backwards and forwards and cut through the object you’re working on.

One point to be aware of when inserting hacksaw blades is to make sure you insert the blade the correct way around. For pretty much all jobs this will be so it cuts on the forward stroke.

As with the disc cutters above, you can cut most things with a hacksaw, your only real limitation is how much energy you’ve got.

Despite the handheld traditional method of using a blade to cut metal above, it is possible to automate this a little more today.

Tools such as jigsaws and reciprocating saws can all take metal cutting blades and these are certainly quicker and easier than using the handheld alternative.

Finally, different blades will be needed to cut different metals as some metals are harder than others e.g. cutting aluminum and say stainless steel. The softer the metal, the smaller and finer the teeth will need to be to cut a controlled straight line, especially in sheet metal.

Using a Drill

If you are without the go-to solutions for cutting metal such as an angle grinder or hacksaw it is possible to cut metal using a power drill.

To do so simply insert a medium sized drill bit into the drill, around 6mm or so and then drill along or around your cutting line ensuring that every hole butts up to the next. Once complete you should then be able to repeatedly bend the item up and down until it breaks off.

The downside to this method is that you have a lot of tidying up to do in that all of the half semicircle drill holes need to be filed down flat and smooth, not an easy job.

This method of cutting metal should really only be used when there is no other choice and due to this it’s really limited to cutting sheet metal, probably no more than 6mm thick.

Turning (Lathe, Milling Machine etc.)

Lathes and milling machines are normally reserved for industrial engineering however both can be used on a domestic level for engineering jobs if you have the space and money to afford them.

A lathe is effectively a machining tool that features a long bed at the base and what you would describe as a drill chuck at one end and a moveable clamp that slides along the bed.

Lathes can be used for many jobs including cutting, shaping, drilling, turning and more. The item that you are working on is generally clamped into the machine chuck and a cutting tool is fixed in the sliding clamp. Using a series of wheels the clamp can be moved forwards and backwards, in and out to position the cutting tool exactly where needed.

Lathes are extremely accurate machines and can shape and cut items to within microns.

Milling machines are very similar tools to a lathe but they differ in that most operate vertically instead of horizontally as a lathe does, but this isn’t always the case.

A milling machine is in essence a large drill and although it can drill holes it operate a little more like a router does in that it can cut complicated shapes and objects, shape gears, cut slots and also bore items out.

Although both of these machines can be used for cutting metal, it’s not really their primary job and neither of these machines are really domestically accessible, however they certainly need to be mentioned.

Oxy-Acetylene Cutting Torch

The oxy-acetylene cutting torch looks more like a traditional welding torch for those of you familiar with these items and using the correct torch the gas can certainly be used for welding and joining metal together.

The difference comes in the way that the gas is used. When welding the oxygen and acetylene are combined and mixed using the torch to produce a flame hot enough to weld metal (effectively melting it together).

The difference with the oxy-acetylene cutting torch is that, firstly is does exactly the same as a welding torch as can heat metal to melting point but it also features a handle, that when squeezed, shoots a jet or pure oxygen onto the cutting area super heating it and blowing the melted metal away at the same time.

The oxy-acetylene torch can be used to cut any metal object of pretty much any size but as you are dealing with extreme heat, the dangers of using this tool are great so the correct PPE must be worn at all times. This also includes a special helmet to protect your eyes from the extreme brightness of the flame.

Laser

Cutting metal with a laser may sound like something out of a James Bond film and indeed it certainly is as years ago laser technology would only have been accessible to a super villain with limitless finances but over the years laser technology has been fine tuned and refined to the point it is now affordable (well on an industrial level anyway).

Today, many CNC machines (large computer controlled cutting machines) use high powered focused-beam lasers to heat metal to melting point and cut it.

Due to the accuracy of both the laser and the computer controlling it, it’s possible to cut extremely complicated and detailed shapes that are unbelievably accurate.

However even though the cost of laser technology has come down it’s still out of reach to pretty much all, but it is possible to certainly commission a company that has a CNC laser cutting machine to do some wok for you, but again, this isn’t cheap!

Plasma Cutting

Plasma cutters are a fairly new technology that’s emerged recently even to the point you can buy domestic plasma cutters.

These handy tools work on a similar principle as an arc welder in that electricity is used to create an arc that heats the metal to the point of melting where it then joins.

With a plasma cutter at this point oxygen is introduced that both heats and blows the melted metal away allowing you to cut with it.

Using a plasma cutter you can cut quite complicated shapes accurately in a range of different metals and objects.

High Pressure Water Jet

High pressure water jet cutting machines are also a fairly new innovation. As you may have guessed from the name they use a high pressure water jet to cut and as unbelievable as it may sound, many materials including metal!

To increase the cutting power of the water jet a metal abrasive is also introduced in with the water.

Water jet cutters are fast becoming the industrial cutting tool of choice in place of laser as they’re much cheaper to buy and run, work fast and can also be used to clean surfaces and smooth cut edges.

Again as with laser cutting machines, water jet cutters can also be controlled by computer again producing extremely accurate detailed and intricate shapes.

Although the technology is reasonably cheap compared to the likes of laser cutters, it’s still hugely expensive and out of the reach of most.

Cutting Different Types of Metal

After looking at the different methods available for cutting metal above, it’s now time to take a look and see how the more domestically accessible solutions can be used for cutting metal objects you may encounter regularly during building and DIY projects.

Cutting Pipe

If you are needing to cut a pipe of some kind chances are that it’s going o be a copper plumbing pipe and in this case, the best tool to use is going to be a pipe cutter (find out more about pipe cutters in our project here).

When cutting a metal pipe it is always advised to clamp it so the cut is stable and controlled regardless of what tool you are using.

In the absence of a specific pipe cutter, this procedure is normally carried out with the use of a hacksaw or junior hacksaw depending on the size of pipe.

To cut metal pipe with a hacksaw, firstly clamp your pipe, then measure and mark the required length with a scribe as pencil may smudge or rub off. Check that your blade is new or of a good working order and fixed securely in the cutting tool.

Always start your cutting movements slowly to create a cutting groove which your blade will remain in for the duration of the cut. Once you have finished your cut you will find that the edges of each piece of pipe will have rough edges (burrs) which are sharp jagged fine pieces of metal created during the cutting process. Remove these with a file or emery paper. (metalwork’s version of sand paper).

If the pipe you are wanting to cut isn’t copper then the best tool to use will be a hacksaw.

Due to the shape of a pipe they’re very hard to cut accurately using a power tool such as a jigsaw or reciprocating saw so it’s best to stay away form these, unless accuracy is not a concern in which case go for it!

Cutting Sheet Metal

As sheet metal and large flat metal objects are by they’re nature flat they’re much easier to cut using a power tool, however if you don’t have access to such items then the go-to tool is the pair of tin snips.

Tin snips are essentially scissors for cutting sheet metal with. Also known as aviation tin snips you use them in the same way as a pair of scissors by positioning them on your cutting line and simply opening and closing the jaws to cut. As you cut keep the metal at the very back of the jaws and this will give you the longest cut.

Before any cutting starts, position the sheet of metal to be cut onto a stable work bench with the section to be cut over-hanging the end of the bench. This way any cutting tool will not get snagged on the work bench below your cutting line.

If possible, always clamp your sheet metal to the work bench. This is another safety procedure but also enables you to produce a clean and straight cut without everything moving about.

If you opt for using an electrical device such as a jigsaw and metal cutting blade always commence your cutting action slowly and gently. Forcing a cutting action will always lead to a mistake or damaged tool.

If the section of metal being cut off is too big for one person to handle then it is advisable to have another person on hand to help you out. You do not want an accident to happen!

Cutting Metal Bar, Rebar and A142 Reinforcing Mesh

If you have a metal bar, piece of rebar or some A142 reinforcing mesh to cut for helping to reinforce concrete or another project then this can be done several ways.

The quickest and easiest method is to use a disc cutter, either an angle grinder or petrol cut off saw but if you don’t have either of these to hand you can also use a jigsaw or reciprocating saw with a metal cutting blade.

Last but not least is if you don’t have any power tools to do the job at all then it’s down to the good old hacksaw, however depending on how tough the metal is, it may be a bit of a job.

Cutting EML – Expanded Metal Lathe

Expanded metal lath can come in several forms, either as a large sheet or roll or small strip around 100mm wide for reinforcing layers of brickwork and the similar.

Visually it looks like a webbed mesh so with no straight sections to follow, to cut it accurately you will need to mark your cuts with a marker pen.

When it comes to cutting this can be done using numerous different tools, the quickest and easiest being a disc cutter of some kind, jigsaw, reciprocating saw etc. however if you don’t have one then the next best option is to use tin snips.

Dangers of Cut Metal

Metal in any form can be fairly dangerous. It can be heavy, bulk, awkward to move and in respect to the information above sharp.

Newly cut edges of metal will always be rough and sharp and after making any cuts and before actually using the object make sure you remove these burrs with a file so that you or the next person who picks up the sheet metal does not injure themselves.

As always with machinery that create dust, debris and has sharp components DIY Doctor recommends the use of gloves, dust masks and eye protection and this is certainly the case when cutting any type of metal.

If you do DIY regularly or are a trade professional it is inevitable that at some point you are going to need to cut metal of some kind and this can certainly be done easily even with basic tools.