Cutting out of a large angle grinder with their own hands
Types of fixtures, their advantages and disadvantages
There are two types of cut-off machine designs, differing in the location of the angle grinder, which can be home-built.
The first unit is a bed with an angle grinder rigidly fixed under it. Only the saw blade is visible on the work surface and slides freely through the slit in the table. Cutting of metal profiles or sheets in this case is completely identical to cutting of wooden billets with a circular saw. Despite a very simple design, such a scheme is not very popular. Those who have made such a device note the inconvenience in use due to the need to move the workpiece. This significantly reduces the accuracy of the work and makes the process unsafe. The only advantage of a bottom-mounted angle grinder is the ability to quickly cut thin metal sheets.
The bottom-mounted angle grinder cutting machine can be used both for cutting metal and as a circular saw
The second layout, where the workpiece remains stationary, but the cutting wheel itself moves, is more convenient. The so-called pendulum saw, placed above the tabletop, allows you to cut the workpiece exactly at the required angle, while it becomes possible to make the required number of similar parts. Cutting workpieces can be effortless because the grinder is mounted on top, which makes the unit easy and safe to operate. The undoubted merits of the design include the ability to quickly dismantle the angle grinder for traditional use. As for the disadvantages of this method, the weak link can be considered a swivel joint, which complicates the construction of the machine.
Machine for cutting metal with the top location of the angle grinder has a more convenient design and makes it possible to cut workpieces at the desired angle
How to make a cutting machine out of an angle grinder with your own hands
Cutting machines. this is universal equipment, which is used in industry in metalworking and ordinary homeowners when working with lumber. To make a cutting machine from the angle grinder with your own hands will not be difficult, which will save on the purchase of expensive equipment. Such work is not especially difficult, so anyone can make a versatile machine for working with wood and metal.
Needed tools and materials
Proceeding to the manufacture of a cutting machine, it should be understood that the accuracy of its work is directly related to the stability of the design. That’s why the choice of material of a certain thickness is dictated not so much by the strength requirements of the hull, as by the necessity of its rigidity.
Before you begin, you need to prepare:
- Square profile pipe (25 x 25 x 2.5 mm);
- Rectangular profile pipe (40x20x2,5 mm);
- Sheet metal thickness of 4-5 mm;
- ball bearings 02, 203 or 204. 2 pcs.;
- A calibrated bar with a thickness equal to the diameter of the hole of the inner ring of the bearing (up to 100 mm);
- rod with a diameter of 8-10 mm;
- busbar metal (20×4 mm);
- bolts and nuts with thread M8 or M.
From the tools we will need:
- angle grinder;
- a drill or a boring machine, a set of drills;
- a set of dies for cutting metric threads;
- open-end wrenches;
- welding machine.
Electric welding is desirable, but not required. all connections can be made on the threaded joints. However, it should be understood that this method reduces the reliability and durability of the construction.
The main node of the cutting machine is an angle grinder. It is not recommended to use a “small” angle grinder, designed for cutting discs up to 125 mm in diameter with power up to 500-600 W. Remember that the larger the diameter of the cutting wheel, the more versatile and reliable the machine will be.
Careful choice of power tools is also due to the great variety of designs of bolt cutters present in the market. Since such equipment is not unified, then the cutting machine is built for a particular model and size angle grinder. If the equipment will be unreliable, then if it fails, it will be difficult to install another angle grinder in its place without the need to redo the fixtures and pendulum. That is why it is better to choose products from proven manufacturers. Makita, Bosch and so on.
Cutting machine from an angle grinder
Simple and practical homemade metal cutting machine from the angle grinder: detailed photo report on making a device for the angle grinder.
The process of cutting metal with an angle grinder, you can make easier with a simple device, and cut off metal parts will be perfectly flat, which is not always possible when working with an angle grinder.
That’s actually the process of making a homemade device for the angle grinder is shown in the photo.
First of all, we need a 45 angle with a length of 20 cm.
You will also need a plate with a length of 20 cm, the width of the plate should be at least 45 mm.
Then we make a guide for our device and a movable carriage. Take an angle piece at 100, about two meters long, that will be the guide.
Let’s make a carriage, take our blanks: angle 45 and a plate with length 20 cm, they need to be welded together with a gap under the rib of the guide angle at 100.
Between the wall of the angle and the welded plate we get such a gap, which is enough to freely insert a rib of a large angle.
Try on a small angle on one side of a large angle and try to move it along the edge of the angle back and forth, the angle should move freely, without wedging anywhere.
Next, let’s make fasteners for the angle grinder, we need two such plates.
Drill holes in the plates for bolts to secure the angle grinder.
After that, we weld the plates crosswise to the ends of the plates welded vertically.
Excessive protrusions at the cross plates can be cut off.
Now you need to fix the angle grinder in our machine, insert the bolts into the holes in the plates, tighten the nuts on them. Tighten the bolts and nuts.
The cut-off machine works in the following way: we put a metal plate under the big guide bar from which we have to cut an even strip.
Fix the angle and sheet metal with a clamp.
We put the device with the angle grinder on the guide angle, and move it evenly along the guide, so that the disk had time to cut through the plate.
As you can see, we have a very handy cutting machine from the angle grinder made with their own hands, great do-it-yourself for the home workshop!
What are we actually talking about??
There are dozens of traditional machine designs for precisely cutting sheet, coil and long materials, not counting laser and other cutting machines, which are usually called pendulum cutters. from the high-tech age. We will further consider machines with oscillating working module and circular rotating cutting organ. abrasive or circular saw blade. Such cutting machines are called pendulum cutting machines. They are the most versatile (i.e., they are the best in the world) and the most flexible.ч. are suitable for broaching. making longitudinal cuts of limited length) and can be done independently in a shed-garage workshop. When they say “cutting machine”, in the vast majority of cases they mean a pendulum cut grinder (pendulum cut grinder in English).).
Note: the pendulum cutting machine is suitable for work on metal, wood, fiberboard, sheet plastic and any other material that can be cut. All the readjustment is a change of the working body (abrasive or abrasive or abrasive) and the grinding tool (angle grinder). saw blade assignment).
Motor or angle grinder?
It refers to the drive of the machine. separate or combined in a monoblock with the working (cutting) tool and the power transmission to it. A separate motor has the advantage that the oscillating part of the machine. rocker (pendulum, rocker arm) can be made properly balanced, which greatly simplifies the work on the machine and increases its productivity; the latter depends comparatively little on the resistance of the material to cutting. Besides, the whole machine can be made suitable for hard round-the-clock work, which can be important for those who earn their living by having the right hands and the right head. angle grinder (angle grinder), as you know, can work continuously for 20-60 min. (depending on the model), and then. forced technical downtime for cooling the tool. But for occasional use, the angle grinder has a number of advantages:
- A sufficiently rugged and accurate cut-off machine from an angle grinder can be made with no turned parts and with little or no welding work, see “The Angle Grinder“. further.
- The basic tool remains suitable for off-machine manual work.
- The power supply is single-phase 220 V from a household socket.
- No need for starters and protective grounding, t.к. Only double-insulated angle grinders are commercially available.
- The external characteristic of a collector motor angle grinder is softer than a squirrel-cage induction motor, which saves motor power and electricity consumption. In most cases (except for cutting thick tough and/or ductile materials) it can be considered that an 800 W electric angle grinder is equivalent to an asynchronous motor with 1.2 kW per shaft (cf. further), and the angle grinder at 1300 watts. a separate motor at 2.2 kW.
- Angle grinders are lighter, more compact and more transportable than those with separate drives.
- Inexpensive angle grinders are not equipped with speed regulators, but they fit the usual speed regulator for a drill (no more than 20; usually 5. 6). “Frequency control” for asynchronous motor up to 2,5 kW costs from 50.
About RPM Control
Why do you need to adjust the speed of the blade?? In order not to exceed the maximum linear speed of the edge and/or rotational speed indicated on it. Otherwise, the disk may not tear, but its performance will drop dramatically, wear will increase, and cutting quality will deteriorate. Rated rotational speeds of asynchronous motors 2800-2850 min-1 allow the use of conventional discs with a diameter of 350-400 mm or more, which gives a cutting depth of at least 150 mm. The spindle of angle grinder rotates much faster (from 6000 min-1) and it is dangerous to put a usual disk with diameter more than 160 mm on it. cutting depths up to 50-60mm, but the speed blade is expensive and wears out quickly. Installing a speed controller solves the problem. Productivity and cutting quality are unaffected, i.e.к. are defined by the linear velocity of the cutting edge.
About the name
angle grinder sounds “technically” but is inherently inaccurate, t.к. an angle grinder is much more for cutting than grinding. “Angle drill” is even more unfortunate, t.к. to drill, to bore, for which the angle grinder is not suitable at all. Angle grinder is the acronym for “angle grinder”. “angle grinder machine”. But the English to grind is much broader in meaning than all types of grinding. e.g., A meat grinder is a meat grinder. to grind” has no exact Russian analogue; the meaning is something like “to grind by the scraps of cloth”. In general, the colloquial “angle grinder” is terminologically incorrect, but it is brief enough, and it is clear what it is.
A note, by the way. During the Korean War, the US troops had to face up to the IL-2 attack aircraft. Why the English “Meat grinder from Hell” was added to honorary nicknames of this legendary machine. indirectly testifies to fortitude of American soldiers in comparison with Germans; they were more likely to use “Betonflugzeug” (concrete plane). It was very difficult to shoot down the “humpback” (this is our style. infantrymen).
Disc cut-off machines are tools based on a special platform or frame made of metal. The machine itself is equipped with details that ensure a secure fixation of the material in a certain position at the required angle during the cutting process.
The cutting element in such constructions is a disk made of high-speed steel. This is also called a carbide blade. Can also be used to cut metal with a wheel coated in the form of abrasive material. The cutting element is driven by an electric motor with belt or gear transmission.
Device diagram of a pendulum type metal cutting machine
Please note! In low-power versions of the tool is allowed to use a cutting element mounted directly on the shaft of the electric motor. In other cases it can be dangerous to use a disc in this way.
Three different cutting component feeds are found in disc machines:
According to the number of cutting elements, the machines can be as follows
- Single-headed. only one cutting element is included in the unit, so when the operation needs to be changed, the cutting edge is readjusted according to the new task;
- double-headed. the design makes it possible to work with two tools at the same time, thus increasing efficiency. In such machines, one head is in a fixed position and remains stable, the second head can move. Double-headed designs can perform the work automatically.
Example of self-made metal cutting machine
Making a disk metal cutting machine with their own hands: the procedure
When making a machine designed to work with metal, the actions are performed in the following order:
- The guards to be installed on the drive belt as well as the cutting disk are prepared.
- A motor is installed. The drive belt serves as the connecting piece between the cutting element shaft and the motor.
- The shaft, on which the drive pulley will be attached, and the cutting disk will be installed, is made. The assembly is to be assembled and then mounted on the pendulum. In this case the pendulum is the movable upper part of the construction, where the cutting element and the motor are located.
- The shaft for fixing the pendulum is made.
- The frame for the installation of the machine is made. The spark arrester and the workpiece will be attached to it.
- The pendulum is mounted on the frame.
- Electrical wiring is performed.
- Test run of the tool and fine tuning of the equipment.
Self-made metal cutting machines use a disk made of high-speed steel or a disc with a coating of abrasive material as a cutting element
Calculation of the pulley for your home-made metal cutting machine
Calculation of the diameter of the pulleys is carried out taking into account the rotational speed of the disc and other parameters. If we assume that the motor power will be at least 300 W, the rotational speed of the disc will be at least 3000 rpm./min., and its size in diameter. 40 cm.
Useful tip! While cutting metal, the nut in the blade clamping area can be unscrewed. To avoid this, it is recommended to locate the drive pulleys on the left side, and the disk itself on the shaft. on the right.
Discs are usually marked by the manufacturer, who puts the maximum allowable rotational speed on the product. In this case the value is 4400 rpm./min. Therefore it is possible to choose any speed within the range 3000-4400 rpm./min.
- motor rotational speed. 1500 rpm./min.;
- the diameter of the pulley designed for installation on the shaft is 6.5 cm;
- disc rotational speed. 3000 rpm./min.
Make your own large angle grinder stand and metal chop saw
Drawing of a frame-type cutting machine (the dimensions of the frame depend on the dimensions of the tool used)
The calculation is carried out in the following sequence:
- Set shaft length on perimeter. To do this, we multiply the number π, which is equal to 3.14 by the size of the diameter: 3.14 x 6.5 = 20.41 cm (shaft perimeter length).
- This is multiplied by the required number of revolutions: 20.41 x 3000 rpm./min. = 61230 cpm.
- The result should be divided by the number of engine rpm: 61230 cpm/1500 rpm./min. = 40.82 cm (perimeter pulley length for the motor).
- Divide the result by π: 40.82 cm/3.14 = 13 cm (required pulley size).
Calculating the length of the belt for homemade metal cutting machine with their own hands
To perform these calculations, the following data will be required:
If you have two pulleys with dimensions of 13 cm and 6.5 cm, you can make the necessary calculations. Since the distance between the centers of these elements can be changed (since the belt must be tensioned), we will use a distance of 50 cm as an example.
The larger the diameter of the cutting element, the easier it will be to cut thicker metal
Now count 1/2 of the circumference of each pulley. Since the drive belt runs between them twice, you must add twice the distance between the center points to this value.
Useful tip! To get a more accurate result, the maximum and minimum distances between the central points of the pulleys should be calculated and the average value selected.
To build your own metal cutting machine design, you need to prepare the necessary tools.
Drawing of the cutting machine of pendulum type: on the left. base dimensions, on the right. features of the design of the pendulum
Mandatory set of tools and materials includes:
- welding machine;
- metal angle (steel);
- channel and chain;
- an on/off button;
- shaft and electric motor;
- electric drill;
- Sheet steel to create a working surface;
- A box for placing the electrical components of the machine.
Principles of making a machine for cutting metal
The scheme of making a homemade machine is subject to certain principles, they must be taken into account before you get down to business:
- It is very important to choose the right gear and make its installation. This component is responsible for the torque retention and its correct transmission from the motor to the cutting element (disc);
- A vise should always be provided. This tool contributes to more comfortable work, as well as increases its safety;
The presence of a vice increases the level of comfort and safety when working with a homemade machine
- choosing the optimum cutting angle. Permissible range is between 45°-90°. In most cases, specialists give preference to cutting at a right angle;
- the diameter of the cutting disc is chosen taking into account the kind of materials with which the master will work in the future on this machine. The larger the diameter of the cutting element, the easier it will be to cope with the cutting of thick metal;
- When designing and drawing, such indicators as dimensions of the future machine and its weight must be taken into account. These values are directly influenced by the materials from which the equipment will be made. Component layout also matters.
Please note! When making drawings, special attention should be paid to the vibratory supports, which are installed on the legs.
Assembling the metal frame for the cut-off machine
Once all the tools are prepared and the drawings selected, you can proceed directly to the process of creating the machine. Using steel angle, you need to make the frame part of the structure. According to the drawings, which can be made on your own or found on the Internet, cut out the elements of the frame. All of them are connected to each other by welding. Beforehand it is necessary to check the size.
The process of creating a frame for a metal cutting machine
To the upper part of the frame a channel is welded, it will become a guide element and serve as a base for further installation of the cutting component on the machine. This channel is the link between the electric motor and the cutting element. After that, the vertically positioned uprights are bolted to it.
Another frame structure needs to be welded. The dimensional parameters are chosen individually, taking into account the dimensions of the electric motor and its features. When choosing an electric motor for the machine it is better to pay attention to modifications of asynchronous type. This type of equipment is characterized by high reliability and durability.
There is one subtlety when choosing a motor. The more powerful the motor, the smoother the travel of the disc.
Assembling the electrical component for the machine
Installation of equipment supposes installation and connection of the working shaft to the machine’s electric motor. The way in which this can be done is not crucial. If there is an instruction for this procedure on the drawings, it is better to follow it, because the quality of installation depends on the correct operation and reliability of the tool.
It is better to use asynchronous type electric motors for homemade cutting machines
Useful tip! Some parts, which you can not make yourself, you can order from the turner. These include the flanges for fixation, as well as the pulley.
To fix the motor to the metal frame it is better to use a bolted connection with nuts. It is advisable to place a box near the motor, where you can find a switch and an electric circuit, as well as a remote control for controlling the tool.
The channel designed for clamping the cutting wheel is better placed on a spring. You need to make it so that when it is released it returns to its original place. To fix the spring, you can use bolts and a clamp.
The electrical component is the most important part of the tool. Always include a circuit for starting the machine and a button for switching it off in an emergency. Place the machine in such a way that the electric motor is electrically connected to the mains through a machine and a box, not directly to it. A three-way automatic starter is sufficient to switch the motor on and get it running at full speed. It will also power the off button.
Finally, it is worth taking care of the availability of protective devices, which will protect a person in the process of work. To do this, you need to make a protective cover. It will prevent sparks and small metal particles in the eyes.
A protective cover is a prerequisite for working with a self-made metal-cutting machine, protecting your eyes from sparks and small metal particles
Homemade machine from an angle grinder for metal cutting
Machine for cutting metal, made from an angle grinder: detailed description of manufacturing with photos.
An excellent machine for a home workshop, you can make from an angle grinder. Such a device allows you to quickly and accurately cut sheet metal of large size.
Self-made machine, is a mobile carriage with a fixed angle grinder, which moves along the guide.
- Profile pipe 20×20 and 25×25 mm;
- door hinge;
- Angle 50×50 mm;
- diamond-shaped jack;
- band 20 mm;
- furniture board or 20 mm plywood;
- saw blade;
- nuts, bolts.
From a profile tube is welded 2 U-shaped blanks of the table of the machine with convenient size legs.
They are welded to each other by two crosspieces.
To make the mechanism for adjusting the blade protrusion a T-shaped piece is welded from a tube of a larger diameter. According to its length, it must be 1 cm shorter than the distance between the tubes of the table top base.
The resulting part through the hinge is welded to the table frame.
Then, from thin sections of angle is made 2 nozzles, which are screwed to the angle grinder through its regular holes for the removable handle.
The eyelets are welded to the rod of the adjustment mechanism on the hinge. It is necessary to watch that the gearbox of the angle grinder does not protrude over the frame. If so, the lugs should be welded displaced downwards.
At the bottom of the table, between the legs, crosspieces are welded. Then they are connected by a tube running down the center directly under the adjustment bar on the hinge.
Next you need to finalize the diamond-shaped jack. A wheel with a handle is welded to its adjustment screw. A sleeve is welded into its bearing area, whose length corresponds to the width of the profile tube of the frame. To the hub screwed 2 eyelets from a strip.
It is necessary to drill the edge of the rod with an angle grinder, and screw the jack to it by means of eyelets. It is then welded to the lintel at the bottom.
A saw blade is installed on the angle grinder.
Tabletop made of board or plywood is fastened to the table. Then the angle grinder is started, and the jack is lifted. The disc makes the cut for itself.
On the edges of the table top a groove is milled transverse to the direction of the saw blade.
They are used to bolt the pipe to the machine with wing bolts, which will serve as a parallel stop when sawing.