The Best Hand Tools for Cutting Metal: A Comprehensive Guide

From making fine jewelry to efficiently handling DIY home repairs, being able to cut metal accurately and effectively is an essential skill. Although power tools provide speed and efficiency for bigger operations, hand tools, on the other hand, remain vital for precise work, smaller projects, and conditions where accessibility and control is necessary. This guide will introduce you to the exciting world of cutting metal with hand tools. 

AN OVERVIEW OF METAL CUTTING

To achieve the required shape and size, metal cutting involves eliminating material from a workpiece. Both hand tools and power tools can be used for this, each of which provides various levels of accuracy, speed, and force. selecting the tool is totally based on the type and thickness of the metal, the required cut and the experience of a user.

BEST HAND TOOLS TO CUT METAL

Hand tools are very useful for delicate cuts, smaller jobs, and situations where power tools are not possible. The following are a few of the top hand tools for metal cutting:

1. HACKSAW

A multipurpose, reasonably priced tool with a finely toothed blade that is stretched across a frame. The hacksaw is perfectly suitable for cutting pipes, bolts, rods, and thin to medium-thickness metal sheets. They are available in different teeth-per-inch counts i.e., higher TPI for tougher, thinner metals and Lower TPI for softer and thicker metals. Additionally, their blades are replaceable.

2. TIN SNIPS (METAL SHEARS)

Tin snips are hand tools which are sometimes called metal shears. These tools are designed to cut metal roofs, gutters, sheet metal, and other thin materials. and look like heavy-duty scissors that use two sharp blades to cut the metal by closely passing one another. there are different types of tin snips, including:

• Straight snips: these blades work really well for cutting long, straight cuts in sheet metal due to their straight blades. They are not suitable for tight radii yet they are capable of mild bends. 

• Curved snips (Left cutting or Right cutting): The curved blades of these snips are usually designed to cut in a circular or curved manner. The curved snips are usually available in two different variations i.e., Right cutting snips, usually have green handles, are perfect for cutting curves that deviate to the right. It diverts the waste material from the right-hand cut.

Left-cutting snips, usually have red handles, are perfectly suitable for cutting curves that go to the left. The waste product is shifted from the left side cut.

• Compound snips: these are the most commonly used or, we can say, popular type of tin snips because of their greater leverage. They can cut thicker gauges of metal with less effort because of their compound hinge system, which amplifies the user's force. Additionally, they are available in straight-cutting, left-cutting, and right-cutting versions (often denoted by handles that are yellow, red, and green, respectively).

3. BOLT CUTTERS

Bolt cutters are robust hand tools specifically made to cut through thick, unhardened metal parts, including bolts, rods, chains, and padlocks. They work by using a substantial compound leverage mechanism that multiplies the force applied by the users. bolt cutters feature short and robust jaws made of hardened steel and long, strong handles that offer the required leverage. These cutters operate by applying tremendous pressure on the material being cut.

Though they are often not appropriate for particularly hardened steel or operations needing a clean, accurate cut, their strong shearing action makes them invaluable in construction, demolition, security, maintenance, and even do-it-yourself projects where thicker metal has to be separated.

4. FILES

files are commonly known for their ability to shape, smooth edges, and eliminate burrs from metal surfaces and also act as fundamental cutting tools specifically for thinner pieces of softer metals. These hand tools feature a hardened steel bar with rows of teeth carved onto its surface. As the file is pushed over the workpiece, the teeth's abrasive action scrapes the material. files can be suitable for slow, controlled material removal and also used for cutting through thin, malleable metals by continuously scoring and wearing away the material along a particular line. although, files are not as efficient or accurate as compared to saws or snips.

5. HAND NIBBLERS

Hand nibblers are popular hand tools that are particularly made for cutting sheet metal by continuously punching out small and overlapping pieces of material. Unlike some other cutting techniques, this motion produces both straight and finely curved slices in sheet metal without significantly altering the surrounding material. 

Mostly the tool consists of a punch and die mechanism that is activated by applying or squeezing pressure to the handles. Each squeeze eliminates a small chip of metal. This process of nibbling offers a more controlled approach to shaping metal which makes them significantly useful for developing unique shapes, notches, and working in places where bigger power tools would not be able to reach.

They are a useful tool for intricate sheet metal work because they can handle intricate curves and create rather clean edges, even if they are slower than shears for long, straight cuts.

6. SCRIBER

A scriber is a thin, compact tool with a sharp raised tip, majorly used not only for cutting but for accurately drawing lines on metal surfaces. This marking is a vital first step in any metal-cutting process since it offers a clear and precise guide for future tool operation. This scriber creates a tiny, permanent scratch or groove on the metal by pressing gently while dragging the sharp point over it.

Compared to a pencil or marker line on metal, this line is far more precise and less likely to smudge, guaranteeing that cuts done with saws, snips, or other instruments adhere to the desired measurements and shape. Therefore, even though the scriber is not a cutting tool itself, it still is an essential supplement to metal cutting hand tools, ensuring precision and accuracy in all metalworking operations.

TIPS FOR USING HAND TOOLS

Following are some useful tips for using hand tools during operation:

• Secure the workpiece: ensure to clamp the workpiece securely to the vise to prevent movement and vibrations while cutting the metal. This will result in providing clean and accurate cuts. 

• Use the correct tool/blade for the material: ensure to use the appropriate tools or blades for the material being worked. Metal thickness requires certain blades or tools to cut efficiently and effectively. This also helps in avoiding any damage to the workpiece as well as the tool.

• Apply Gentle pressure: ensure to apply gentle pressure and let the tool do their work. Applying excessive pressure can cause damage to the workpiece or the tool itself and generate rough cuts in the case of a saw, exert pressure during the cutting stroke, and relax during the return stroke.

• Observe the indicated line: Pay close attention to your marked cutting line to ensure precision.

• Wear Safety gear: ensure to wear proper safety gear to prevent accidents and to protect you from getting injured.

This article offers an introduction to metal cutting and the best hand tools on the market. Always put safety first and select the appropriate tool for your requirements.