How to make a disc cutting machine for metal with your own hands
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 range, craftsmen created a disc cutting machine. Below we will look at everything related to this equipment.
Using a homemade cutting machine
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.
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.
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.
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
Layout of machine parts
Next, let's look at the device of a disk tool. In the figure we will see the location of the main parts and their arrangement:
Frame
Or a metal structure that plays the role of the base of the unit.
Pendulum unit
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 whole 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.
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
Machine bed
Any invention will require certain parts, whether purchased elements 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:
Motor for a homemade cutting machine
- 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
Metal cutting machine with 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.
s
disc cutting machine:
cutting machine using a grinder instead of a disk:
homemade machine assembly:
cutting machine operation:
Source: https://stanki-info.ru/diskovyj-otreznoj-po-metallu-svoimi-rukami.html
DIY disc cutting machine for metal
Constant work related to cutting metals and wood materials requires the use of a cutting machine. With the help of an electric tool, it is possible to quickly and efficiently cut metal structures. A disc cutting machine is used to form blanks for profile pipes, channels, rods and other rolled metal parts.
The equipment is used in large production enterprises; band and hacksaw machines are used for mass work. The complexity of the metal structure of special machines makes it impossible to use them in limited areas. The cutting machine can be used under any conditions, which makes it popular. A circular saw is responsible for cutting work.
DIY disc cutting machine for metal
Classification of disc cutting machines
Disc metal cutting machines are divided into 4 main categories. A universal tool applicable to all types of metals is a disk machine of the first category. The disc element of cutting equipment allows processing metal products in large quantities. Subsequent classes differ in power and performance; a cutting machine of the fourth category is used for domestic purposes and is not equipped with full functionality like professional equipment.
There are many types of industrial and household machines. The main difference is the number of cutting edges; two main types are offered for use:
- The design with one disk element has low power and efficiency. Single-head machines have limited functionality and low cutting speed. They are used when cutting one element; they allow you to cut frame profiles or pipes and prepare equipment.
- A cutting machine with a design of two cutting elements allows you to process metal in several directions at once. The two-head equipment has a rigidly fixed head, the second rotating cutting element moves. The productivity of the tool doubles, so this tool is suitable for large-scale production and automated process conditions. When working with a frame profile, one pass is enough, which significantly saves time.
Double head cutting machine
Several types of cutting machines are used, and they are also divided according to the method of feeding the tool. It is necessary to select the equipment correctly in accordance with the requirements for it. Only in this case is it possible to recoup the costs of cutting metals during subsequent work.
Classification according to the method of feeding the cutting element
There are a large number of machines on sale; before purchasing, it is important to understand how the cutting element feeding system works. The cutting element can be fed in the following ways:
- front feed of cutting disc;
- a device with the implementation of lower feed of the cutting element;
- a structure whose base works in a pendulum manner.
The metal base of the cutting machine can be floor-standing or table-top when used. In the first case, a larger diameter disk is installed, which allows cutting a larger volume of parts. Desktop equipment is more mobile and has a reduced weight.
Types of disk machines
In addition to tool feeding, various shapes and designs of cutting saws have been developed. The most common are abrasive cut-off saws, usually cutting and cut-off saws. The selection of design depends on the specific type of task and metals.
Metal cutting disc machines are used for cutting various types of profiles and non-ferrous metals. The metal structure does not have the characteristics of increased productivity; it is used in small-scale production and for free tasks.
It is used with square and channel metal; depending on the density of the metal, the optimal number of revolutions is selected.
The machine is economically located in relation to consumables, this is possible due to the processing of the disk metal structure with increased speed and electric drive power.
Abrasive cutting machine
The abrasive cutting machine is capable of processing metals of any profile and thickness. Used for cutting single pieces at different angles, up to 45 degrees. It is used in preparatory shops for cutting long rolled metal products. Models with dust extraction allow comfortable cutting in confined spaces. Also, more expensive modifications provide a liquid supply for cooling the disk element and an automatic chamfering design.
Cutting of metals supplied in coils is usually done using cutting-off machines. Several types of steel are supplied in packaged form or in coils:
- rods of various sections;
- wire;
- pipe strips;
- reinforcing steel.
The device is implemented in such a way that the mechanism captures the beginning of the material and runs it through the rule. The aligned part is automatically cut off and transferred to a tray with finished products. Cutting machines of the correct type, regardless of purpose and dimensions, are equipped with various unwinders:
- driven;
- mechanized;
- stationary
- roller impact.
Rule-cutting machine
Cutting machines are mainly used in mass production, where high cutting accuracy and low cut roughness are required. A variety of modifications allows you to select a disc cutting machine in accordance with the needs and production volumes.
Device of a disk cutting machine
Metal parts are made of hard steel alloys for more uniform and stable operation. The platform consists of a rigid base made of metal. The cutting machine can be stationary or removable; some types are equipped with a vice for securely holding the workpiece during cutting.
The disc is made of carbide steel or high-speed elements. Depending on the type of structure, a wheel with an abrasive surface is used, which allows you to process chamfers and edges from burrs. Stationary metal cutting machines use a gear drive to provide reliable connections and long-lasting performance.
Disc cutting machine diagram
The belt type of mechanical energy transmission is installed on portable devices in which weight is important. Low-power designs of the fourth category are connected directly to the disk mechanism.
Manufacturing of a disc cutting machine, preparation of tools and
materials
If you have some metalworking experience and a place to carry out the work, you can make any circular saw for metal yourself. A disc cutting machine for metal involves dangerous actions with the cutting element at high speeds. It is important to observe all the design features of the disk device and make accurate calculations before assembly.
A homemade cutting machine for working with metal is made in the following order:
- Safety comes first, so protective covers are prepared for the cutting elements.
- To power the cutting blade, an electric motor must be connected. The drive is selected depending on the type of machine; it can be a belt or gear drive.
- The drive pulley is installed on a pre-prepared drive shaft. A purchased or self-made cutting disc is mounted to the pendulum. In this situation, the upper part of the installation acts as a pendulum on which the engine and disk are located.
- On the frame of the future machine, a place is prepared for the spark arrester and workpieces.
- After installing the pendulum to the frame, the electric motor wires are installed.
- At the end of the work, a test run and debugging of the nodes is carried out.
The electric motor is one of the most important components of the metal disk structure. It is necessary to install a circuit diagram for the cutting machine with a start button, as well as an emergency stop. The engine is placed in such a way as to correctly connect the electrical circuit through the machine. The engine is fixed to the frame; the best material for connection is bolts and nuts. The switch box is located in close proximity to the electrical part of the motor.
Work methodology
The principles of making a machine with your own hands consist of several rules that are taken into account before carrying out any actions. A cutting machine is made from available tools and materials, so it is important to follow consistently to obtain a quality tool:
- The pressure of the cutting element on the metal and the engine torque depend on the correct choice of gear. An overtightened chain or belt can break, stopping metal cutting.
- The vice is used to avoid exposure to vibrations, ensure comfortable work, safe working conditions.
- The cutting angle is selected only when necessary; the range is from 45 to 90°. In standard situations, craftsmen prefer cutting metals at right angles.
- The diameter of the cutting machine disc is selected depending on the type of metal that needs to be processed. The increased diameter can easily cope with thick-walled parts. Protection should be considered; working without a casing is unsafe and can cause injury if the disc is deformed.
Homemade metal cutting machine
Using an angle grinder as a cutting tool is possible when working with small workpieces. The design has two variations, when the angle grinder is fixed motionless, and also by fastening the workpiece. In the first case, accuracy is lost, because the part is not attached to the frame; when moving the tool manually, safety rules must be observed.
How to calculate the required pulley diameter
The diameter of the drive pulley is calculated according to the rated motor power and speed. Positioning on one side can lead to the nut unscrewing, so the pulley or tool of the metal cutting machine is located on opposite sides of the structure.
The maximum permissible rotation speed is marked by the disk manufacturer in the operating instructions. For example, it is possible to take an engine with a maximum shaft rotation speed of 1500 rpm, the diameter of the pulley attached to the shaft is 6.5 cm.
The necessary task is to obtain a disk rotation speed at the output of about 3000 rpm, for this we calculate:
- The length of the shaft along the perimeter is calculated from the formula 3.14 × 6.5, the result is 20.41 cm.
- The value is multiplied by the required number of revolutions, resulting in 61230 cm.
- Next, the result is divided by the nominal speed of the electric drive, which is equal to 40.82, indicating the length of the pulley along the perimeter.
- The value is divided by the number π, resulting in a pulley diameter of 13 cm.
Cutting machine drawing
The maximum permissible value on the cutting disc can be taken as the number of revolutions; in this case, it is necessary to select a higher power of the electric drive.
How to calculate the length of the drive belt
Calculation of the belt length of a homemade machine is based on the following parameters:
- radius of the drive pulley mounted on the drive;
- distance from the center points of the two pulleys;
- parameters of the size of the pulley to the axis.
Calculating the length of the belt is not difficult, it is important to consider some factors. The cutting machine operates under significant loads, so the degree of belt tension is important, otherwise the drive will slip. You should select a high-quality product; if the belt breaks, damage to the disc or workpiece is possible.
Desktop
The machine table is a frame made of a metal channel. It is possible to make a frame from a corner, the connections are made by welding.
A channel is installed on the frame from the top; its purpose is to guide the parts during the cutting process. The racks are fastened with a bolted connection; if necessary, the channel can be replaced in accordance with the work on the cutting machine.
Source: https://stankiexpert.ru/ehlektroinstrument/diskovyjj-otreznojj-stanok-po-metallu-svoimi-rukami.html
Do-it-yourself homemade metal cutting machine - Metalworker's Guide
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 range, craftsmen created a disc cutting machine. Below we will look at everything related to this equipment.
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.
reviews
review of the disc cutting machine:
review of a cutting machine using a grinder instead of a disc:
review of the homemade machine assembly:
overview of the cutting machine:
Source: https://ssk2121.com/samodelnyy-otreznoy-stanok-po-metallu-svoimi-rukami/
How to make a cutting disc machine for metal?
Carrying out the process of cutting metal and metal structures using machine tools is much easier, safer and more comfortable than using hand tools and tools. But not every tinkerer can purchase a high-quality machine.
This is the reason that many people prefer to construct 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: replacing a greenhouse post that has worn out over time, making a metal fence for a plot of land, repairing a garden wheelbarrow or cart - cutting metal at right angles or with a bevel is always necessary. Making blanks for any metal products is easier and more efficient using the machine.
Using cutting machines, you can cut any materials: steel, cast iron, copper. Cutting is done at angles of 45º and 90º. You can make products with your own hands from pipes of all diameters. As a rule, cutting mechanisms are used for cutting semi-finished products into measured lengths.
Metal processing equipment can also be used to process other materials, eliminating the work of the cutter. The machine, made with your own hands, is compact; it is possible to install it under a canopy, and in winter, move it to the workroom.
You need a flat and hard surface with lighting. A similar corner can be found on the site of any building. All-welded and dismountable equipment designs are used. In order to reduce manufacturing costs, the device can be periodically given to neighbors for temporary use.
Any work that involves either metal or wood requires a cutting process, for which special cutting equipment is used. The application of this device is incredibly wide: from everyday needs and everyday 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 blanks. Semi-finished products can be cut at right and sharp angles. Using a cutting machine, you can cut pipes of large and medium diameters.
The most important mechanism of the device, its “soul,” is an electric motor and a working element – a cutting wheel, which are connected to each other through gear or belt drives. Each of these types has its own advantages. For example, the inherent easy running of the belt, resistant to various types of loads, less noisy. It can even be mounted on a massive cutting machine.
The gear drive is oversized, and due to this feature it is suitable for a miniature homemade cutting unit. Therefore, in the process of purchasing 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 you come across 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.
homemade cutting machine from a grinder.
Homemade metal cutting machine: manufacturing instructions
A machine made with one’s own hands has an undeniable advantage: it is made to meet the requirements of a specific craftsman and the products planned for future production. To work you will need:
- 24th corner;
- 10th channel;
- shaft;
- pipes;
- welder;
- rolling bearings;
- electric drive;
- container for mounting an electrical circuit;
- start toggle switch;
- starting circuit;
- winding;
- drill.
Assembly progress:
- From corner No. 24 and using an angle grinder, cut the blanks onto the frame with your own hands, its dimensions are 400x600x1200 mm;
- Using a welding machine, the workpieces are welded together;
- Channel No. 10 is welded as a guide, which at the same time will add strength to the entire structure.
- Using screws, two vertical supports are secured to the channel;
- Using pipes, make a frame 400x600 mm for subsequent installation 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 purpose, you can give preference to a motor whose power will be in the range of 1.53 kW and “power it” from a three-phase network. If it is possible to use only a 1-phase network, select a motor with 1/3 power greater than the calculated value, connected using capacitors;
- Using a lathe, make the shaft and flanges, pulley and supports. The flange must protrude by 30.,.32 mm.
- Install the support bearings and pulley;
- The installation of the box with the electrical circuit is carried out directly in the lower area of the frame.
- A 12 mm shaft is attached between the racks, onto which the sleeve is placed. The distance between the shaft and the bushing must be kept to a minimum 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 short section of the rocker arm, and a cutting mechanism is installed on the long section.
- A belt drive is laid from the electric motor to the shaft.
The price of a container for an electrical circuit made by yourself will be slightly lower compared to one purchased at a hardware store. To provide power 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 make.
Based on the above, making a cutting mechanism with your own hands is not only cheaper, but also more practical, since during its manufacture you yourself adjust its parameters and make adjustments for its future operation.
Also, having done this 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.
homemade metal cutting machine with your own hands.
Source: https://metmastanki.ru/otreznoy-diskoviy-stanok-svoimi-rukami
Metal cutting machine
I have long wanted to build a workshop for myself abrasive - metal cutting machine. Cutting metal with a grinder is not always convenient. An angle grinder does an excellent job of cutting sheet steel, but cutting 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 metal cutting machine, when there is no need to bend over, and the workpiece is securely and securely fixed 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 adjustments and make the machine even better from “what is at hand” at your disposal. 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 starting to make 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. Below are some photos 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. It is possible to adjust the tilt of the rocker arm 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 a vice for clamping the workpiece from an old factory-made cutting machine, but I had to redo them a little. In this vice, the clamping screw nut can be divided into two halves, this 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. 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?
In this way you can also calculate the size of the pulleys if:
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 we will take the length between the 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 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. and operation! |
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Source: http://FactoryHand.ru/masterskaya/instrumentyi/otreznoy-stanok-po-metallu
Homemade metal cutting machine with your own hands - Metals, equipment, instructions
A metal cutting machine is useful for any workshop. It is required during construction work and in the metalwork shop. The market offers a wide variety of machines, but not all of them are affordable.
For home workshops, the way out of this situation will be a homemade metal cutting machine. To manufacture it, you will need certain skills in working with a welding machine and plumbing tools.
It will require a metal cutting unit from a master and the skills of an electrician.
In order for the future machine to reliably perform its functions, you will need a simple set of tools:
- drill;
- Bulgarian;
- taps;
- welding apparatus;
- spanners;
- dies.
An additional engine will be required. The optimal 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;
- shaft.
Any homemade mechanism must be customized to suit your needs and drawings. The master pays special attention to safety precautions. When working with cutting units, a particularly vulnerable part of the body is the hands, which can easily be damaged by neglecting simple work safety rules.
Disc cutting machines
In practice, craftsmen make machines of three types: belt, pendulum, disk. The first type is the most difficult to make in a home workshop. The best option is a disk-type metal cutting machine.
Band saw machine
These units include:
- cutting disc;
- pendulum;
- Desktop;
- Electrical engine;
- drive mechanism.
For a standard workshop, the sufficient power of the engine 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 will be sufficient for such an engine. To carry out frequent work cutting pipes from profiles, you will need a 3 kW unit.
An important indicator of the engine is the number of revolutions it makes in the process of cutting a metal part. The recommended speed is at least 3000 per minute. At low motor speeds, the cutting disc is not able to operate optimally.
Particular attention must be paid to the diameter of the circle used. Experts advise choosing circles with a diameter of 300-350 mm with an electric motor power of 2 kW. With the specified parameters, the recommended engine speed is 3000-4400 rpm. As the indicator increases, the circle is destroyed, and at low speeds it quickly overheats and wears out.
What to pay attention to
The choice of drive mechanism matters. A belt drive does this job well. To make it you will need 2 pulleys of the same size. The first pulley is fixed on the drive shaft of the cutting wheel, the second on the electric motor shaft. The shaft is mounted on two bearings.
To prevent the belt from slipping and maintain the necessary tension, it is necessary to secure the electric motor in the rear part of the pendulum. Fastening is done with 4 bolts.
The pendulum has its own separate requirements. It should be:
- balanced;
- well cooked;
- move perpendicular to the desktop.
The pendulum is mounted on two vertical posts. Each post has slots into which a bushing with a diameter of 11 mm is inserted. The stands are made of a metal square measuring 40*40 mm. The optimal height is 90 mm.
Desktop Design Requirements
The cutting unit must have a working table of optimal dimensions. 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 where the circle rotates.
A clamp with a rotary clamp and a rotary stop are fixed at the workplace. Such a homemade 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 rotation angle is required (its location must be perpendicular to the surface of the desktop);
- the master needs to protect his hands from damage by installing covers around the disk and rotating elements;
- it is important to calculate the rotational speed of the circle in advance;
- equip the handle with an emergency stop button, which, when pressed by hand, instantly stops the operation of the entire mechanism;
- Place the wheel feed force in the cutting zone.
Rotation angle adjustment
Procedure for making your own machine
Any machine with which it is possible to cut metal is assembled according to the following scheme:
- preparation of protective covers intended for installation on the drive belt;
- installing a motor using a drive belt as a connecting part between the motor and the shaft;
- manufacturing a shaft for attaching a pulley and a cutting disc to it (the unit is assembled and mounted on a pendulum, which is the upper part of the structure);
- manufacturing a shaft for mounting a pendulum on it;
- manufacturing a machine frame on which the metal for processing and a spark catcher are supposed to be mounted;
- 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 device based on the grinder
In a workshop, it is possible to assemble a homemade metal cutting machine based on a grinder. Tools and materials needed:
- channel;
- start relay;
- several profile pipes with a square or rectangular cross-section;
- shaft;
- control pedal;
- metal sheet for desktop;
- spring;
- metal corner;
- two bearings.
Machine start relay
Unlike a disk-type machine, the operation of such a device has a more accurate result. The assembly process is very similar to the disk assembly, but has a number of features:
- frame parts are manufactured;
- a hinge joint is installed on the pendulum arm;
- 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 grinder is secured to the pendulum;
- welding the clamp, bracket and cutting tool (an alternative would be to use a threaded connection for mounting these elements);
- pressing into bearing supports;
- pressing bearings onto the shaft from both sides;
- welding the pendulum on the edge of the working platform with a mandatory distance of 0.5 cm from the edge;
- installation of an angle grinder and a protective casing;
- installation of the return spring.
After installing all structural elements, the machine is started in trial mode. Additionally, you will need to fit the groove under the tool and install supports with which the metal being processed is secured.
At the final stage of work, the machine is coated with enamel. It will protect the unit from the adverse effects of rust.
When working with an angle grinder, the master must protect his hands and eyes from the effects of sparks. Any work is carried out wearing protective gloves and a mask.
on topic: Cutting machine for metal
Source: https://spb-metalloobrabotka.com/samodelnyy-otreznoy-stanok-po-metallu-svoimi-rukami/
Homemade metal cutting machine with your own hands
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
- Depending on the scale of production, the power of the installed electric motor is selected. Most of the finished equipment has a fairly high power, but for domestic needs there is even an excess.
- You need to choose the right gear and install it yourself. It determines how much torque will be maintained and correctly transmitted from the motor to the cutting disc.
- Installation of vices. Even for the simplest metal cutting machine, it is advisable to include a vice in the kit - this will not only increase the comfort of work, but will also be correct from a safety point of view. Cutting wheels
- Selecting the cutting angle. It can be from 45° to 90°, but more often craftsmen choose a right angle.
- Diameter of cutting disc. This parameter determines how thick a piece of metal a disc cutting machine can cut.
- When designing, you need to take into account the weight and dimensions of the equipment. This parameter depends on the materials used and the layout of the machine. Also, during the design process, pay attention to vibration supports on the legs.
- Select the type of feed - pendulum, front or bottom.
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.
- Shaft.
- 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.
: Homemade cutting machine from an angle grinder
Source: https://steelfactoryrus.com/samodelnyy-otreznoy-stanok-po-metallu-svoimi-rukami/
How to make a disc cutting machine for metal with your own hands - Site about
17.12.2019
| I have long wanted to build a workshop for myself abrasive - metal cutting machine. Cutting metal with a grinder is not always convenient. An angle grinder does an excellent job of cutting sheet steel, but cutting 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 adjustments and make the machine even better from “what is at hand” at your disposal. 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. How to wash cutlery at home: TOP 17 methods and cleaning products Rules and advantages of cleaning coins with citric acid Cleaning coins with citric acid is carried out in Cleaning copper coins. — Numismatics Most novice collectors sooner or later develop Cleaning copper-nickel coins Copper-nickel coins are preserved quite well both in an aggressive environment and How to clean rust from metal: the most effective methods Rust is a red-brown coating on metal, Tempering of steels Tempering is a heat treatment process that involves heating hardened steel to -- Sideb lion (lipk) --> For any suggestions regarding the site: [email protected]
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