Guide to Metal Cutting Tools | Best Power Tools to Cut Metal

Summary:

Choosing the right metal-cutting tool depends on your material, type of cut, and expertise. Here is a list of the best power tools for cutting metal.

• Angle Grinder - Versatile, great for fast and rough cuts.
• Reciprocating Saw - Powerful, cuts almost anything but lacks precision.
• Circular Saw - Provides clean, straight cuts but can't cut curves.
• Hole Saw - Ideal for cutting perfect circular holes in metal.
• Cut-Off Tool - Compact and precise for small cuts but not for thicker materials.
• Plasma Cutter - Fast and accurate for conductive metals but requires ventilation.
• Laser Cutter - Extremely accurate but expensive and power-consuming.
• Band Saw - Great for precise cuts, but expensive and requires maintenance.

Each tool has its own advantages and disadvantages, so choose based on your project's needs.

Learn about the best metal cutting tools, as well as the most suitable methods for cutting common materials like metal sheets, studs, and metal pipes.

The selection of ideal metal cutting tools mainly depends on your workpiece quality, quantity, and your experience. A different metal cutting tool is required for different types of cut, for example, hole saw for a circular cut, chop saw for a straight cut, and rotary tools for precision and a small cut.

Today, we will cover all metal cutting tools and their works so you can choose the best one according to your needs and applications.

Read More: 7 Best Ways to Cut Metal Fast

Best Power Tools to Cut Metal

Power tools are used for almost all metal fabrication and industrial workings. These cutting tools are required to perform numerous tasks such as grinding, polishing, drilling, cutting, sharpening, and sanding of metals.

Following are the most typical metal cutting power tools.

1. Angle Grinder

An angle grinder is a standard metal cutting tool for using cut-off wheels.

An angle grinder or hand grinder is one of the most important metal cutting tools. The standard 4-1/2" cut-off wheel is a widely used disc for angle grinders. You can also customize wheel sizes according to needs.

Angle grinder cuts metal fast and efficiently. Removing rough cuts, weld spatter, and rust is common applications of an angle grinder.

Pros

• Highly versatile tool
• Capable to work on small areas
• Compatible with different cutting wheels and material surfaces

Cons

• Not good to obtain fine and finished cuts
• High pressure can break wheels
• Irritating noise and kickback

2. Reciprocating Saw

Reciprocating Saw for metal cutting

A reciprocating saw also known as an oscillating saw is the most common and useful metal cutting tool. It is capable of cutting metal fast and efficiently. Reciprocating saws are among the most powerful and aggressive saws. Reciprocating saw tool works with standard metal reciprocating saw blades. You can use it to cut through metal sheets, wood, PVC, and pipes.

Pros

• Cuts through almost anything
• Powerful and fast cutting
• Perform a number of functions

Cons

• Quite rough and inaccurate
• Its large blade can cut wires
• No smooth cuts

3. Circular Saw

Circular Saw for metal cutting

Circular saws are one of the most commonly used power tools nowadays. Circular saws are capable of cutting metal, wood, hard steel, stone, and ceramic tile with a TCT saw blade.

Pros

• Provides clean cut-through metals
• Easily available and accessible tool

Cons

• Can't cut curves
• Saw blades are expensive & break easily
• Noisy tool

4. Hole Saw

Hole saw connected to drill

Hole saw cutters or hole cutting tools are made to be extremely tough to cut metals. They are capable to resist high temperatures produced by cutting through a number of popular metals including stainless steel. Bi-metal 5 inch hole saw is ideal for creating holes in timber and wood sheets. Apart from the metal hole saw can easily cut through wood, tile, concrete, and glass.

Pros

• Multipurpose cutting tool
• Cuts a perfect circle
• Less expensive

Cons

• Not a versatile tool

5. Cut-Off Tool

This metal cutting tool is similar to an angle grinder and works with cut-off wheels. Cut-off tools are ideal to cut stainless steel, carbon steel, aluminum, and other metals for general purposes. They are designed to provide a quick and accurate cut, also last longer and perform better than any traditional tool.

A cut-off tool is useful to work in small areas where other large tools can not work. But, this tool can not cut through thicker materials.

Pros

• Compact and easy to handle
• Can work in narrow space
• Ideal for removing weld splatter

Cons

• Too small for more extensive applications
• Can’t cut through thick material

6. Plasma Cutter

Plasma cutting is a widely used technique for cutting metal. It uses the heat from an electric arc to cut through the material with minimal effort, producing precise, clean cuts.  Plasma cutting might be a great choice for people searching for a quick and affordable solution to cutting materials.

A plasma cutting machine, sometimes referred to as a plasma cutter, uses a plasma stream to deliver energy to a conductive work material. An external power source generates an electric current that gives the gas flow enough energy to ionize it and transform it into a plasma arc. For this reason, the procedure is frequently referred to as plasma arc cutting. Once the metal has been melted by the plasma arc, it is first expelled from the workpiece.

PROS:

• This method is perfect for complicated and detailed work because it can help produce clean cuts with no thermal distortion.
• Plasma is used to cut a variety of conductive metals, regardless of their thickness.
• The approach is significantly faster compared to the numerous old ways. Each could efficiently finish the cutting and save time.
• Compared to other conventional methods, this contemporary methodology is relatively inexpensive and requires minimal operating expenditures.
• Compared to oxygen-based cutting, which has an explosive risk, the devices use inert gases, which are far safer. Depending on the strategy, the availability of parts like the CNC plasma table can also be quite beneficial.

 CONS:

• It is limited to conductive materials.
• Using metals thicker than 150mm, or about 6 inches, is not recommended.
• Bright flashes from cutting could damage the eyes.
• Due to the potentially noisy nature of the operation, hearing protection is required.
• It usually emits fumes; thus, it should only be used in a place with adequate ventilation.
• Using low-life consumables like electrodes and nozzles could be expensive.

7. Laser Cutter

The most common use of laser cutters is cutting two-dimensional objects. They melt or burn metal using a narrow laser beam, providing precise and clean cuts. The manufacturing industry extensively uses laser cutters, and they can also be applied to creative tasks. This widely used method is effective in producing precise two-dimensional components in large quantities.

 PROS:

• The accuracy and precision of laser cutters are extraordinarily great.
• The procedure may be completed at high speeds, albeit the rates vary based on the material's thickness and nature.
• With minimal operator interaction, the process is highly automated and may incorporate material handling devices. 
• Laser cutting is often a clean procedure, even if it requires cutting fluids or other chemicals.
• No extra work holders or tooling are needed. 
• After being cut, they typically don't need much additional effort.
• Capable of cutting a variety of materials.
• Able to cut and engrave materials.

 CONS:

• Lasers can only cut things up to a certain thickness. Usually, the maximum is 25 mm. 
• Ventilation is necessary because some compounds release harmful fumes. 
• It requires a lot of electricity.
• The initial outlay for laser cutting equipment is more than that of other technologies, such as flame or plasma cutters.
• Some laser systems, including CO2, require more expensive replacement parts on a regular basis. 
• The procedure needs to be enhanced to prevent discoloration or burning.
• The laser could cause severe burns.
• Rates vary according to the material's thickness.

8. Band Saw

Band saws are tools used for cutting materials. You can get the precise cut you need with its broad, toothed blade. They are motor-powered and come in a variety of sizes and combinations. Depending on the project, they can be placed on a stand or carried about.

In order to make exact cuts that meet the user's demands, band saws work by sinking their teeth into metal, wood, or other materials. The kind of blade you use will determine the type of cut you get. But if the blade is smaller, the curves will be tighter. Blades for woodworking that have fewer teeth work better.

 PROS:

• One of a band saw's greatest advantages is its ability to make accurate cuts. With the correct blade, you can produce precise angles, sharp edges, and complex curves.
• Another benefit of a band saw is its versatility. This tool can cut other materials like wood, plastic, etc., in addition to metal. It is mainly used in the metalworking and furniture manufacturing sectors.
• Many modern band saws have safety features that reduce the likelihood of accidents. These features include automated shutdown, safety switches, and blade guards. These features can provide an extra layer of protection, but they shouldn't be used in place of safe work standards. 
• A band saw can help you operate more efficiently by making timely, accurate cuts. This is particularly valid while working on a project that calls for a lot of precise cutting. You can achieve better results and save time by using a band saw.

CONS:

• One of the primary drawbacks of a band saw is its cost. These gadgets could be pricey, particularly if you're looking for a high-end model. If you plan to use the equipment frequently, the initial investment may be worth the comparatively high cost.
• Due to their frequently considerable size, these tools require a distinct workspace.
• Like any other cutting tool, a band saw requires regular maintenance to remain in good working order. This could mean changing the blade, lubricating the mechanism, and modifying the tension.
• The fact that band saws are quite noisy is another crucial factor to take into account. If you have your workspace, a band saw might be OK, but if you work in a shared office or are sensitive to noise, it might not be the best option.

That was all about metal cutting tools and power tools for metal cutting.