Bachelor of Dramatic Art (Properties)

Subject: Properties Foundation Module: Metal Tutor: Marcelo Zavala-Baeza

Cutting metal sheet Hack Saw A hacksaw is a fine-tooth saw with a blade under tension in a frame, used for cutting materials such as metal or bone. Handheld hacksaws consist of a metal arch with a handle, usually a pistol grip, with pins for attaching a narrow disposable blade. A screw or other mechanism is used to put the thin blade under tension. The blade can be mounted with the teeth facing toward or away from the handle, resulting in cutting action on either the push or pull stroke. On the push stroke, the arch will flex slightly, decreasing the tension on the blade. Blade Types Hacksaw blades are available with tooth counts ranging from 14 to 32 teeth per inch. Thin stock calls for finer teeth; thicker metal requires fewer teeth per inch. The way teeth are positioned on a blade is called set. There are three typical tooth sets: Regular: These work well on softer metals that dont contain iron. The teeth are lined up touching each other and alternating to the left and right. Raker: Perfect for cutting into thick metals. The teeth are placed in sets of three. Wavy: The right choice for hard, thin metals. The teeth are set in a wave pattern from left to right for a smooth, fine cut. Frame Types Hacksaw frames can be either fixed or adjustable. A fixed frame accepts one blade length; while the adjustable typically handles 10- and 12-inch blades, some can accept blades ranging from 8 to 16 inches. Theres a slight price difference, but the versatility of an adjustable frame is well worth the additional cost. A hacksaw blade has a hole at each end that fits onto posts on the frame, and these posts can be set in four positions: up, down, left and right. In addition, the blade can be mounted on the posts with the tooth side in either direction, giving you a total of eight blade positions to choose from. Using a Hacksaw Americans are accustomed to saws that cut on the push stroke, but reversing the blade to cut on the pull stroke like a fine Japanese woodworking saw might give you a better result. Whatever the blades orientation, its essential that you cut slowly, no more than one stroke per second; metal on metal produces tremendous heat and can quickly ruin a blade. A drop of oil on the blade is a good idea to reduce friction and to keep the temperature down. Hacksaw Safety Tips Choose the correct blade for the material being cut. Secure the blade with the teeth pointing forward. Keep the blade rigid and the frame properly aligned. Cut using strong, steady strokes directed away from you. Use the entire length of the blade in each cutting stroke. Keep saw blades clean, and use light machine oil on the blade to keep it from overheating and breaking. Cut harder materials more slowly than soft materials. Clamp thin, flat pieces that require edge cutting. If youre cutting pipe, always secure it in a vise before cutting. Types of Hacksaw Blades and their usages

Bachelor of Dramatic Art (Properties)

Subject: Properties Foundation Module: Metal Tutor: Marcelo Zavala-Baeza

By Karl Thelen, Hacksaw blades, designed to cut mainly metal, are categorized by the number of teeth per inch. The standard hacksaw blade has 14 to 32 teeth per inch. The set of the teeth, how they are angled in relation to the sides of the blade, determines how well the blade cuts. Hacksaw blades cut many things from thin copper tubing to unruly rusted bolts. Garden hose, water pipes, plastics and old fencing all succumb to the hacksaw blade. 32 teeth per inch 1. A hacksaw blade with 32 teeth per inch gives a finer cut and is good for cutting thin gauge steel or thin-walled tubing, copper tubing or heating duct. 24 teeth per inch 2. Hacksaw blades with 24 teeth per inch are used for medium steel and regular walled tubing. According to the Aviation; Integrated Publishing web site, 24 teeth per inch are also good for cutting angle iron, heavy pipe, brass and copper. Lug nuts, stubborn bolts and iron re-bar are cut with this blade. 18 teeth per inch 3. Hacksaw blades with 18 teeth per inch are used for hard metal iron pipe and large pieces of steel. If you are cutting an old metal water pipe or a chain link fence frame, use this blade. 14 teeth per inch 4. Hacksaw blades with 14 teeth per inch work well with soft metals like aluminum and tin. This blade cuts electrical wire, aluminum chairs and plastic for windows. 12 teeth per inch, bi-metal 5. Bi-metal hacksaw blades have 12 teeth per inch and are used for pipe, tubing, plastic, wood or high speed steel. This blade is good for cutting garden hose, picture frames and plastic chairs. Set of the teeth 6. There are four different sets, or angles, of the teeth, according to the Aviation; Integrated Publishing website: Alternate set (regular), where one tooth leans to the left and one tooth to the right the length of the blade; double alternate set (regular), with two teeth to the right and two to the left; raker set, where single teeth alternate, but every third tooth is straight; and the wave set, where short sections of teeth bend opposite each other. According to Builder Bill, this wave pattern, with its fine cut, works best on sheet materials.

When starting a cut with a hacksaw, start downward, not against the edge. By starting out correctly the life of the blade will be extended.

Bachelor of Dramatic Art (Properties)

Subject: Properties Foundation Module: Metal Tutor: Marcelo Zavala-Baeza

Nibbler

A nibbler is a tool for cutting sheet metal with minimal distortion. One type operates much like a punch and die, with a blade that moves in a linear fashion against a fixed die, removing small bits of metal and leaving a kerf approximately 6 mm wide. Another type operates similar to tin snips, but shears the sheet along two parallel tracks 36 mm apart, rolling up the waste in a tight spiral as it cuts. Nibblers may be manual (hand operated) or powered. Power nibblers are often powered by compressed air, though electrical types also exist. A common DIY nibbler tool is an electric drill attachment, which converts the rotary motion of the drill into a reciprocating motion of the jaw.

Manual nibbler

Air nibbler

Shear Bench shear, also known as a lever shear, is a bench mounted shear with a compound mechanism to increase the mechanical advantage. It is usually used for cutting rough shapes out of medium sized pieces of sheet metal, but cannot do delicate work. Usually this type of shear can handle steel sheet metal up to 3 mm (0.12 in) thick.

A shearing machine can be used for cutting medium gauge sheet metal and small rods.

Bachelor of Dramatic Art (Properties)

Subject: Properties Foundation Module: Metal Tutor: Marcelo Zavala-Baeza