Cutting machine for metal with their hands: manufacturing technology

can be learned from this article how to make a cutting machine for metal with their hands in the home with the most simple materials. Here are detailed steps of creating structures, which is based on the cutting blade or Bulgarian: preparation materials and tools, calculation formulas, detailed step by step instructions, as well as related information with useful tips.

Cutting machine for metal with their hands: Getting Started Building

Circular cutting tools are tools based structure which has a special platform or frame made of metal. Machine itself is equipped with components that give it a secure fit of the material in a defined position at the required angle in the process of cutting.

As the cutting member in such constructions use a disk made of high speed steel. It is also called carbide. It can also be used for cutting a circle with a metal coating in the form of abrasive material. The cutting member is driven through an electric motor with a belt or a gear.

Note! In embodiments, low power tool allowed cutting element mounted directly on the shaft of the electric motor. In other cases, such use of the disk can be dangerous.

Disc machines found three different feed cutting components:

• lower;
• pendulum;
• front.

By the number of cutting elements of machines are:

• single head - in the packaging device included only one cutting blade, so when the changing operation is performed changeover of the cutting edge in accordance with a new task;
• double-head - design gives the opportunity to work directly with the two instruments, thereby increasing efficiency. In such machines, one head is in a fixed position and is stable, the second head can move. Dual-head design can carry out automatically.

Making disk cutting machine for metal with their hands: Procedure

In the manufacture of machine, designed to work with metal, operations are performed in the following order:

1. Prepared housings which are mounted on the drive belt and the cutting disc.
2. Mounted motor. As the connecting piece protrudes the drive belt between the shaft of the cutting element and the motor.
3. Made shaft on which is secured a drive pulley and mounted the cutting disc. Node subject to assembly and subsequent mounting on the pendulum. In this case, the pendulum acts as a movable upper part of the structure, wherein the cutting element and the motor is located.
4. Made shaft for mounting the pendulum.
5. It is performed to set the machine frame. It will be fixed and the workpiece spark arrester.
6. The pendulum is mounted on the frame.
7. Performed installation of electrical wiring.
8. It carried out a test run the tool and adjusting.

pulley calculation for improvised cutting machine for metal

Calculation of the diameter of the pulleys is performed taking into account the rotational drive speed and other parameters. Assuming that the engine power will not be less than 300 watts, the rotational velocity of the disk will be a minimum of 3000 rev / min, and its size in diameter -.. 40 cm.

Useful advice!In the process of cutting metal nut in the disc holding zone can turn away. To avoid this, we recommend positioning the drive pulley on the left side, and that the drive shaft - right.

Usually discs marked with the manufacturer, which is applied to the product the maximum value of the rotational speed. In this case, the figure is about 4,400. / Min. Therefore the choice of any speed allowed within the limits of 3000-4400. / Min.

Data for the calculations:

• engine rotational speed - 1500 rev / min .;.
• pulley diameter, intended to be mounted on the shaft, - 6.5 cm;
• the rotational velocity of the disk - 3000 rev / min..

The calculation is performed in the following sequence:

1. Set the length of the shaft perimeter. For this, the number π, which equals 3.14 multiplied by the diameter size: 3.14 x 6.5 = 20.41 cm (shaft length of the perimeter).
2. The resulting value is multiplied by the desired number of revolutions: 20.41 x 3000 rev / min.. = 61230 cm / min.
3. The result must be divided by the number of engine revolutions:. 61230 cm / min / 1500ob / min. = 40.82 cm (the length of the pulley for the engine on the perimeter).
4. The resulting value is divided by the number π: 40,82 cm / 3.14 cm = 13 (pulley desired size).

Calculation of the belt length for the self-made cutting machine for metal with their hands

The following data will be required to perform these calculations:

• parameters of the drive pulley (radius);
• the distance separating the central point of the pulleys;
• parameters of the driven pulley (radius).

Having pulley 2 with dimensional parameters 13 cm and 6.5 cm, it is possible to make the necessary calculations. Since the distance between the centers of these elements may be variable (as the required belt tension in the state), a segment length of 50 cm is taken as an example.

Now you need to find half the circumference of each of the pulleys. Since the drive belt passes between them twice this value is necessary to add twice the distance between the center points.

The first pulley (circumference):

3.14 (number of π) x 3.25 cm = 10.20 cm

A second pulley (circumference):

3.14 (number of π) x 6.5 cm = 20.41 cm

Drive belt (the necessary length):

20.41 cm + 10.20 cm + 50 cm x 2 = 13.06 cm

Useful advice! To get a more accurate result, it is necessary to make calculations with the maximum and minimum distance between the centers of pulleys and select average.

To make the machine structure independently for the metal, should prepare the necessary tools.

Mandatory set of tools and materials include:

• welding apparatus;
• Area metal (steel);
• and a channel circuit;
• button to turn on / off;
• bearings;
• and an electric motor shaft;
• electric drill;
• steel plate to create the working surface;
• box for the electrical components of the machine.

Principles for creating machine for cutting metal

Driving the manufacture of homemade machine is subject to certain principles, they need to consider before you get down to business:

• it is very important to choose the right gear and carry out its installation. Of this component depends on the preservation of the torque and its proper transmission from the motor to the cutting element (ROM);
• be sure to provide the presence of the vice. This tool contributes to a more comfortable work and also increases the degree of safety;

• selection of the optimum cutting angle. The allowable range is 45-90 °. Most experts prefer the cut at right angles;
• the diameter of the cutting disc is selected in view of, what in the future will work material master on this machine. The larger the diameter of the cutting element, the easier it will be to cope with the cutting of thick metal;
• the design and preparation of the Drawings necessarily take into account such factors as the size of the machine and its future weight. These values ​​have a direct impact of the materials from which the equipment will be manufactured. Importance is the arrangement of parts.

Note!In drawing up the drawings, particular attention should be paid to vibration dampers that are installed on legs.

Assembling the metal frame to the cutting machine

Once all the tools are prepared and selected in the drawings, you can move directly to the process of creating machine. using steel corner, It is necessary to manufacture a carcass part design. In accordance with the drawings, which can make yourself or find on the net, cut the frame elements. All are interconnected by welding. Pre-need to check the appropriate size.

To the top of the frame is welded steel channel - it will be the guiding element and will serve as a basis for further installation of the cutting component on the machine. This channel will be a connecting link between the electric motor and the cutting element. Thereafter thereon by means of bolts fastened vertically disposed racks.

You need to cook the construction of one more frame. The dimensions are selected on an individual basis taking into account the size of the electric motor and its features. When choosing an electric motor for the machine better pay attention to the modification of the asynchronous type. This type of equipment is characterized by high reliability and durability.

There is a subtlety when choosing a motor. The more powerful the motor, the smoother will move from disk.

Assembling of the electric component for machine

Installation of the equipment requires the installation and connection of the output shaft to the electric motor of the machine. The way in which this can be done, is not critical. If the drawing contains instructions for completing this procedure, it is better to follow it, since the quality of the installation depends on proper operation and reliability of the instrument.

Useful advice! Some of the details that make their own can not afford, can be ordered from Turner. These include flanges for fixation, as well as a pulley.

For fixing the motor to the metal frame is better to use a bolt connection with bolts. Surrounding the engine it is recommended to arrange the box, where the switch and circuitry, as well as remote management tool.

Channel for fixing the cutting disc is better to plant the spring. You need to make sure that when you release it back to its original location. To fix the spring can take the bolts and the clamp.

Electrical component - the most important part of the tool. It is mandatory to include in the design of the circuit for starting and emergency stop button for the machine. It is necessary to achieve the placement of parts, in which the electric motor is connected to electricity by means of the machine and the box, but not directly. Three-way actuators will be enough to turn on and fully start the engine. He will nourish and off button.

Finally it is worth to take care of the presence of guards that will safeguard a person in the process. To do this, you need to make a protective cover. He will prevent sparks and small metal particles in the eye.

Production of the cutting machine of the Bulgarians with their hands: drawings, technology

Design cutting machines made by Bulgarians, there are two types (depending on the grinder placement).

In the first case, a frame in which very rigidly fixed angle grinder. It rises above the work surface only the drive for which there is a special table in the slot. Such a machine operates on the principle of the circular saw.

Note! In the process of working with such a machine has to move on their own preparation, which is why accuracy is lost. Moreover, this process can be dangerous, however drawings concealed type grinder placement is not in high demand.

The second embodiment assumes that the billet remains stationary and the cutting member moves. Due to the fact that the grinder is located on top countertops, it does not need to make serious efforts to cut parts.

List of tools and materials for the cutting machine of the Bulgarians with their hands

With self-manufacturing tools should be borne in mind that the accuracy with which it will work, depends largely on the stability of the structure. For this reason, the thickness of materials for manufacturing is not so much with the requirements with regard to the strength of the housing part of the machine, but with the need to ensure an adequate level of rigidity.

List of materials:

• profiled tube with a square cross section (see 2,5h2,5h0,25);
• steel sheet (sheet thickness of 0.4-0.5 cm);
• profiled tube with rectangular cross section (see 4h2h0,25);
• ball bearings - 2 pieces. (№203, 204 or 202);
• calibrated rod not exceeding 10 cm (thickness is selected considering holes in the inner cage of the bearing);
• a metal rod (diameter 0.8-1 cm);
• fasteners (bolts and nuts, threaded M or M8);
• Metal bus (2h0,4 cm).

List of tools:

• angle grinder;
• electric drill (drilling machine can be replaced);
• set drill;
• a set of dies for forming the metal threads;
• apparatus for welding;
• open-end wrench.

Selection of a suitable cutting tool for the cutting machine of homemade grinders

Angle grinder is the main hub part of the machine to work with metal. Experts do not recommend for this purpose use a small tool, which has a capacity of no more than 500-600 watts. In such grinder cutting discs have a diameter of not more than 12.5 cm. These restrictions are due to the fact that the cutting element with a larger diameter is considered to be a versatile and very reliable - it is able to cope with the cutting of thick workpieces.

Useful advice! Instead of welding for fixing parts may be used screw connections, but they are less reliable and can not provide the required level of strength.

Careful approach to the selection of grinders is necessary also because a large variety of designs on the market. Since this power tool is not completely standardized, machine construction will be carried out under the specific modification and size of the angle grinder.

If the machine breaks down, install the other grinders may not only be difficult, but not impossible. Necessary to alter the pendulum and all fasteners. Therefore it is necessary to choose the tool from the range of large and already proven companies, for example, the Bosch and Makita.

Drawings cutting machine: how to make a tool of grinders for cutting

In the preparatory stage, the design and preparation of the Drawings. Uniform size does not exist for the simple reason that each design of the machine is subject to certain models of the cutting tool. Finished drawings, which are many in the network, you can fit under the grinder. They allow you to navigate in relation to what will be the structure of the design, its dimensions.

Drafting drawing is better to start with the body portion. In some cases, you may need to build a separate platform instead of the frame. Such a platform will be attached to the plumbing work bench. Next, determine the amount and nature of the location of the key elements of the machine. It is necessary to measure the center distance between mounting holes located on the gearbox, as well as to measure very grinders.

All these data are used to compile the drawings. Once designed for mounting of the pendulum and grinding machines, developed swivel.

Useful advice!The accuracy and stiffness of the machine depends on the distance between the cutting member and the swivel. The smaller the gap, the better. It is recommended to install a pendulum with a minimum length.

After compiling drawings will only pick up materials, calculate their number and begin the construction.

Technology for creating cutting machine from Bulgarian

The technology of manufacture of the machine for cutting metal-based grinder is almost the same as in the case of cutting disc:

1. Preparation and production of parts for the frame.
2. Construction of articulation on the idler arm.
3. Making a U-shaped bracket with holes for mounting the gear grinding machine.
4. Making a U-shaped clip and strap, which will fix the housing grinders on the pendulum.
5. Installation of the U-shaped clamp and the U-shaped bracket to the cutting tool: by welding or threaded connections, all these parts are mounted on the arm portion.
6. Pressing bearing support.
7. Bilateral press-fitting the shaft bearing assemblies. To increase the bonding strength can zaludit axis thin tin layer by means of soldering.
8. Fastening pendulum support assemblies with parts on the platform edge (offset from the edge 0.5-0.6 cm) using a welding machine.
9. Installing grinders and guard.
10. Mounting the return spring.

Once the structure is assembled, it is necessary to perform a test run and check the correct operation of the equipment, as well as placing all the details on it. At the final stage is adjusted by the groove cutting element mounted bearings, designed to secure the workpiece.

When lapping is completed, the machine body must be covered with a thin enamel layer. Staining will protect the instrument from damage that can cause rust.