Choosing the Best Cutting Tool for the Job
This guide breaks down the categories of cutting tools along with their pros and cons BY: TIM LYMAN (tlyman@starrett.com) is welding channel manager, The L. S. Starrett Co., Athol, Mass. Reprinted with permission: The AWS Welding Journal
Before metal pieces can be joined, they often need to be cut down to specific measurements or angles. Sometimes they are cut just to create a clean surface to guarantee a strong weld. There are multiple ways that welding professionals complete this cutting task, including the use of gas and plasma cutting machines, power tools, and cutting hand tools. This article provides details on many of the specific tools that fall within these categories and the pros and cons that come with each.
While many of these tools are able to achieve the desired cut, they present potential hazards when used improperly with the hope of saving time or money. These cutting tools are powerful and can be dangerous when used incorrectly or by inexperienced professionals. Be sure to consistently use safety equipment, including goggles and gloves, and to always stand to the side of a power saw to prevent injury due to kickback.
Plasma and Gas Cutting
Two of the most commonly used tools by professional welders are the plasma cutting machine and the oxyacetylene cutting torch. Both are effective options that cut most types and thicknesses of metals. However, they come with some large costs both upfront and in maintaining the necessary parts.
Plasma Cutting Machine Pros
- Cuts all types of metal
- Higher cutting speeds — great for fast, straight cuts of thin metals
- Dross free — No after treatment required
- Thickness limitations on most shop plasma cutting machines
- Broader kerf than laser cutting
- Expensive upfront cost and not cross functional
- Suitable for medium-sized and thick materials
- Bevel cutting with up to three torches on one aggregate
- Cross functional and relatively inexpensive — cut, weld, braze, heat, etc.
- Suitable for cutting mild steel only
- Low-cut speed and reduced dimensional accuracy when making repeat cuts
- Can cause warpage and partial dross formation, requiring after treatment
- Causes heavy scale on workpiece, which can be a challenge to remove before welding operations can be done effectively
- Works well in making cuts on most metals
- Effectively makes quick cuts on bolts, nets, sheet metal, etc.
- Versatile tool that can also be used to sharpen blades and grind metals
- Due to various grain compositions, each abrasive has specific material operating parameters and are not universal to all metals
- Sparks are upwards of 1700°C, which are molten metal, and can easily cover more than 15 ft of distance during the operation
- Suitable for jobs that require precise and delicate cuts on a flat surface
- Often used to make straight or curved cuts in the middle of a workpiece
- High degree of safety due to ease of use
- Great longevity on lightweight, cordless tools
- Cannot be used to make flush cuts
- Requires a somewhat even surface for the base to be stable
- Only has a moderate level of power
- Ability to quickly cut all types of metals
- Suitable for demolition and quick, rough cuts
- Ease-of-use when reaching into tight or hard-to-reach places
- Great mobility due to design for use on cordless tools
- Careful user attention is required for consistent, accurate cutting
- Higher skill level is required to make a puncture/cut into a flat surface
- Strong power can be dangerous when used in low-leverage situations
- Able to cut in several directions and angles on most types of metal
- Long blade life and portable use
- Can be used as a stationary or mobile tool, allowing users to transport the least amount of mass for any given application
- Not able to make consistent curved cuts
- Needs a specific blade made for cutting metal
- Can be dangerous — sparks and metal chips will fly during usage
- Effectively cuts most metals and allows for straight and curved lines
- Powerful and fast cutting. Makes fast cuts with very few sparks
- Versatile and allows for vertical and horizontal cuts
- Portable band saw blades can wear down quickly if proper operating parameters are not followed to
- Not suited for making thick cuts
- Potentially dangerous if operator does not attend to proper safety and personal protection equipment requirements
- Highly accurate in making straight cuts in most materials up to a ½-in. thick
- Convenient when needing to quickly make many similar type cuts
- Cost effective option for cutting many materials
- Stationary. Only able to move up and down
- Typically used for more specialized, consistent cuts
- Often leaves a burr on the cut, which requires secondary cleanup
- Can cut all thicknesses of metal, including bundles
- Most are programmable, facilitating increased productivity and semiautomation
- Affordable option that operates quietly and cleaner when compared to other options
- Stationary. Saw takes up space in shop
- Requires operator to know how to break in the blade and set saw
- Coolant is required for many applications for ideal operating parameters
- Works well on most soft, thin metals
- Ideal for quick, inexpensive straight-line cuts of simply shaped parts
- Produces minimal kerf with virtually no loss of material
- Not ideal for cutting harder metals or thick material
- Can only make straight-line cuts
- Often creates burrs and end deformation on cut
- Better suited for cutting through thinner materials
- Very safe — poses less risk than power tools because user is in full control
- Size and light weight make it easy to reach awkward cutting places
- Blades can easily get damaged when cutting thick or hard metals
- Can be a slow cutting process due to small teeth and gullets on blade
- Can be physically draining on projects with a lot to cut — less ergonomic than other available alternatives
- Designed for cutting thin sheets of soft metal
- Affordable and very easy to use
- Highly durable tool
- Low on versatility
- Can be a slow cutting process depending on material and individuals’ experience
- Takes extra effort to cut tougher material due to spring-loaded handles
