Contents
How To Cut Stainless Steel?
- John
Cutting stainless steel can be tough due to its strength and resistance. Unlike other metals, it requires specific tools and methods for a clean cut.
This article will discuss the techniques for cutting various types of stainless steel, including sheets, pipes, and bars.
Prepare a Workplace To Cut Stainless Steel
- Ensure that the area is properly ventilated, especially when cutting methods produce fumes or dust.
- Bright, focused light allows for precision in cutting and helps maintain safety during the process.
- Inspect the workspace to ensure there are no flammable materials. Keep a fire extinguisher nearby to prevent potential fires.
- The workbench should be stable, large enough to hold the material securely, and free of clutter.
- Personal protective equipment is essential. Wear heat-resistant gloves, safety goggles, and protective clothing to protect yourself from sharp edges, sparks, and flying debris.
How to Cut Stainless Steel Sheets And Plates
- Choose The Right Tool
This table lists cutting tools for different stainless steel sheets and plates.
| Metal Type | Thickness Range | Cutting Tools |
| Thin | less than 3 mm (0.12 in) | Laser cutters, snips, jigsaws, angle grinders, hand tools |
| Medium | 3 mm to 6 mm (0.12 to 0.24 in) | Plasma cutters, circular saws with carbide-tipped blades, band saws |
| Thick | 6 mm to 25 mm (0.24 to 1 in) | Plasma cutters, waterjet cutters, band saws |
| Very Thick | Above 25 mm (1 in) | Waterjet cutters, industrial band saws, plasma cutters |
- Mark the Cutting Line
Make a clear-cutting line with a marker, chalk, or metal scribe. Use a ruler or template to help with straight or curved cuts.
Ensure the line is easy to see and follows the exact shape you want to cut.
- Secure the Plate or Sheet
Use C-clamps, G-clamps, or a vice to firmly hold the material in place. Ensure the clamps are tight. But notice that too tight may damage the material.
Place clamps at both ends and, if needed, in the middle, ensuring they do not obstruct the cutting line.
- Position the Blade and Tool
Place the blade slightly above and align it with the marked line. Position the blade perpendicular to the material to achieve a straight and uniform cut.
- For tools like a circular saw or angle grinder, position the blade just in front of the starting point to allow the tool to reach full speed before making contact with the metal.
- For a jigsaw, position the blade directly on the cutting line.
- Firmly Grip the Tool
Hold the tool securely with both hands.
- For a circular saw or angle grinder, one hand should grip the rear handle for power control, while the other should guide the tool from the front.
- For a jigsaw, one hand holds the tool while the other helps guide it along the material.
To keep the cut perfectly straight, you can use a straight edge or guide.
- Start Slowly
Turn on the tool. The blade should reach full speed and then contact with the stainless steel.
Gently lower the blade onto the cutting line, avoiding any sudden force that might cause the tool to jump or deviate from the line. The blade should go just beyond the thickness of the steel.
- Steady Movement
Move the tool slowly and consistently along the marked line. Do not rush—allow the blade to cut through the metal naturally. Forcing the tool can lead to uneven cuts or damage to the blade.
- Finish the Cut Properly
- Slow down as you finish the cut to avoid tearing or leaving a rough edge.
- Continue using the tool until the stainless steel is completely cut.
- Finishing the Edges
Use a grinding wheel or a file for deburring and smoothing the edges.
After the edges are smoothed, check the cut for straightness and precision. If any additional adjustments are needed, use a file or sanding disc.
How To Cut Stainless Steel Pipes and tubings
- Choose The Right Tool
This table lists cutting tools for different stainless steel pipes.
| Metal Type | Wall Thickness Range | Cutting Tools |
| Thin-Walled | Less than 2 mm (0.08 in) | Hacksaws, tube cutters, handheld tools like angle grinders |
| Medium-Walled | 2 mm to 4 mm (0.08 to 0.16 in) | Reciprocating saws, band saws, plasma cutters |
| Thick-Walled | Above 4 mm (0.16 in) | Plasma cutters, band saws, waterjet cutters |
- The process of cutting pipes and tubing is very similar to cutting sheets and plates. You can refer to the How to Cut Stainless Steel Sheets and Plates guide for general instructions.
- Tubing cutters are designed exclusively to cut pipes. This section will specifically explain how to use it.
- Mark and Secure
- For pipes, you need to mark a continuous line around the pipe’s circumference.
- A pipe vice or pipe clamp is used to hold the pipe in place without causing it to roll or shift during cutting.
- Open the Tubing Cutter
loosen the tubing cutter’s knob or lever to open the cutting wheel. Position the pipe between the cutting wheel and the guide rollers.
- Position the tubing cutter.
Position the cutting wheel along the marked line. Tighten the knob until the cutting wheel lightly touches the surface of the pipe.
- Begin Rotating the Cutter
Hold the handle of the tubing cutter and begin rotating it around the pipe. Ensure that the cutter rotates smoothly around the pipe, maintaining steady pressure.
- Tighten Gradually
After completing a full rotation, slightly tighten the tubing cutter’s knob to increase pressure on the pipe. Continue rotating the cutter around the pipe. After each full rotation, tighten the knob a little more until the cutter slices through the pipe entirely.
- Don’t rush the process or over-tighten the cutter too quickly, as this could cause the pipe to deform or result in an uneven cut.
- Finish the Cut
Continue rotating and tightening the cutter until the cutting wheel slices cleanly through the pipe. Once the cut is complete, remove the pipe from the tubing cutter.
Tubing cutters typically produce a smooth, straight cut. But if you notice any rough edges or burrs, proceed to Finish the Edges.
- Dealing with a Stuck Cutter
If the tubing cutter gets stuck or does not rotate smoothly:
- Maybe because the cutting wheel is too tight. Loosen the knob slightly and try rotating the cutter again.
- Use a small amount of lubricant on the cutting wheel and pipe surface.
How To Cut Stainless Steel Bar and Rod
- Choose The Right Tool
This table lists cutting tools for different stainless steel tubings.
| Metal Type | Diameter Range | Cutting Tools |
| Thin | Less than 10 mm (0.4 in) | Hacksaws, tube cutters, angle grinders |
| Medium | 10 mm to 30 mm (0.4 to 1.2 in) | Reciprocating saws, band saws, power tools with carbide-tipped blades |
| Thick | Above 30 mm (1.2 in) | Plasma cutters, industrial band saws, waterjet cutters |
- Mark and Secure
- Use a strip of paper or masking tape to wrap around the bar. Trace the edge of that with a scribe or marker.
- Place the rod or bar in a bench vise with V-shaped jaws. For larger or longer rods, use a pipe clamp or a heavy-duty rod clamp.
- Make sure the rod is tightly secured but not overtightened, which could deform the material.
- Start Slowly
Begin cutting by applying light pressure, especially if using a hacksaw or angle grinder. Let the blade make the initial cut before applying more pressure.
- Positioning the Blade
Make sure the cutting blade (whether a hacksaw, grinder, saw, or band saw) is directly aligned with the marked line to ensure an accurate cut.
- Cutting the Rod or Bar
- Hhacksaw or angle grinder:
Move the tool, not the rod. Keep the rod stationary in the vise, applying steady pressure with the saw or grinder as you follow the cutting line.
- Band saw
Move the rod into the blade. Feed the rod slowly and consistently into the saw, maintaining alignment with the cutting line.
- Cut-Off Saw
Lower the blade down onto the rod with a steady, controlled motion. The rod stays fixed while the saw blade moves to cut through it.
- Finishing the Cut
Near the cut’s end, slightly reduce pressure to prevent the tool from binding or creating rough edges. Follow through with the tool until the blade has passed completely through the rod.
If burrs need to be removed, please refer to the Finishing the Cut of sheets and plates.
How to Drill Holes in Stainless Steel
- Mark the Drilling Spot
Stabilize the material. Use a center punch to create a slight indentation. This will keep the drill bit steady and prevent it slip on the smooth surface of the stainless steel.
For larger holes, use a pilot hole strategy. Begin by drilling a small hole (1/8 inch) at the center punch mark, then gradually increase the size with larger bits.
- Prepare the Drill and Bit
Use a cobalt drill bit since it is designed to cut through tough materials like stainless steel. Ensure the bit is sharp for clean, smooth holes.
Set the drill’s speed to a low setting, roughly 300 RPM. Drilling stainless steel at slow speeds reduces heat buildup, prolonging the bit’s life and ensuring a cleaner cut.
- Lubricate the Drill Bit and Material
Before drilling, apply cutting fluid or oil to both the drill bit and the surface of the stainless steel.
Continue to add cutting fluid throughout the drilling process, especially for thicker materials, to keep the bit cool and reduce wear.
- Drill the Hole
- For Thin Stainless Steel
Drill with light, consistent pressure. Don’t force the bit into the material. Keep the backing support underneath the material to ensure it stays flat and does not bend during drilling.
- For Thick Stainless Steel
Gradually increase the drill bit size if you’re making a larger hole. Apply moderate pressure but don’t push too hard. Take breaks to cool the bit if necessary.
- Finishing the Hole
After drilling, the edges of the hole may have burrs. Use a deburring tool or file to smooth out these edges.
Critical Considerations To Cut Stainless Steel
When cutting stainless steel, proper handling, and attention to detail are essential for achieving clean, precise results and ensuring safety.
Below are the key internal factors to consider during the cutting process:
Avoid Overheating
Stainless steel tends to retain heat, and excessive heat during cutting can cause problems such as:
- Work Hardening: Overheating can harden the material, making it more difficult to cut and potentially leading to premature wear on tools.
- Discoloration: High temperatures may lead to unwanted color changes on the steel surface.
- Tool Damage: Excess heat can dull blades and shorten tool life.
To reduce heat buildup, use lubricants or coolants during cutting. Slow down the cutting speed.
Control Cutting Speed and Feed Rate
The cutting speed can directly impact the quality of the cut. Cutting too fast can lead to overheating, while cutting too slowly may result in jagged edges or blade wear. Control the speed and feed rate based on the thickness of the material. This helps a lot.
Choose Suitable Blade to Cut Stainless Steel
When cutting stainless steel, the type of blade you use is just as important as the tool itself. When choosing a blade for cutting stainless steel, consider the following factors:
- Material of the Blade
- Carbide-Tipped Blades
These blades are highly durable and maintain sharpness longer. They’re ideal for cutting tough materials like stainless steel, as they resist heat and wear.
- Bi-Metal Blades
Made from two metals (high-speed steel and spring steel), these blades are flexible and tough, making them suitable for cutting thin to medium-thickness stainless steel.
- Diamond Blades
These are extremely hard and perfect for cutting very thick or high-strength stainless steel, especially in industrial settings.
- Heat Resistance
Cutting stainless steel generates a lot of heat, so choosing blades that can withstand high temperatures without warping or dulling is critical.
Carbide-tipped and diamond blades excel in heat resistance. Bi-metal blades are flexible and tough, but they tend to wear out faster when exposed to high heat.
- Tooth Configuration
- Fine-Tooth Blades
Blades with fine teeth are preferable for cutting thin stainless steel sheets, as they provide smoother cuts with fewer burrs.
- Coarse-Tooth Blades
Coarse teeth work better for cutting thicker sections, such as rods or plates, as they allow for quicker cutting and less clogging.
Different Tools to Cut Stainless Steel
Hacksaw
A manual tool with a fine-tooth blade used for cutting stainless steel sheets, rods, and pipes by hand.
Angle Grinder
Uses a rotating cutting disc or blade to grind through stainless steel, commonly used for medium to thick sheets and rods.
Circular Saw
Equipped with a carbide-tipped blade, it cuts through thicker stainless steel sheets and plates.
Reciprocating Saw
Features a bi-metal or carbide-tipped blade that moves back and forth to cut through stainless steel pipes, rods, and sheets.
Tube Cutter
Uses a rotating cutting wheel to slice through stainless steel tubing with precision.
Jigsaw
A handheld saw with a bi-metal blade, ideal for cutting curves or intricate shapes in stainless steel sheets.
Band Saw
A continuous blade moves in a loop to cut through stainless steel bars, rods, or thick plates.
Plasma Cutter
Uses ionized gas (plasma) to melt through stainless steel, providing fast, precise cuts for thicker materials.
Laser Cutter
Uses a precision laser beam to either melt or vaporize stainless steel during the cutting process. It is suitable for intricate designs and high-precision work.
Waterjet Cutter
Uses abrasive-infused high-pressure water to cut stainless steel. It can avoid heat buildup, perfect for thicker sections.
Oxy-Fuel Torch
Though less common for stainless steel, it uses a gas flame to melt the material. It requires careful adjustment to prevent oxidation.
Different Techniques to Cut Stainless Steel
Shearing
- A mechanical cutting process. Straight cut to separated large sheets or plates.
- Common Tools: Guillotine shears, mechanical or hydraulic shearing machines.
- Applications: Used in mass-production environments for simple, clean straight cuts in sheet metal.
Contour Cutting
- Cutting along curved or non-linear paths to produce specific shapes or patterns.
- Common Tools: Bandsaws, CNC-controlled machines, and waterjet cutters.
- Applications: Custom-shaped components, decorative elements, and industrial parts.
Beveling
- Creating angled edges, typically in preparation for welding or for specific angled parts.
- Common Tools: Beveling machines, angle grinders with beveling attachments.
- Applications: Welding preparation, creating chamfered edges for metal joints.
Pipe and Tube Cutting
- Making accurate cuts on cylindrical materials, including pipes and tubes.
- Common Tools: Tube saws, pipe cutters, CNC tube cutting machines.
- Applications: Construction, automotive, plumbing, and structural frameworks.
Punching or Piercing
- A metal fabrication process where holes are punched out of the material.
- Common Tools: Punch presses, drilling machines.
- Applications: Creating holes for fasteners, passageways, or ventilation.
Profiling
- Cutting intricate patterns or shapes from stainless steel, often used for decorative or functional components.
- Common Tools: CNC laser cutters, waterjet cutters, plasma cutters.
- Applications: Architectural designs, automotive parts, complex industrial components.
Precision Cutting
- High-precision cutting for components that require tight tolerances.
- Common Tools: CNC laser cutters, CNC waterjet, CNC plasma machines.
- Applications: Aerospace, medical devices, electronics, and high-end manufacturing.
Why Is Stainless Steel So Hard To Cut?
Here are the key reasons why cutting stainless steel is challenging:
Toughness and Ductility
Stainless steel resists cracking or breaking under pressure. This toughness can cause resistance during cutting, requiring more force and precision than softer or more brittle metals.
High Hardness
Stainless steel is harder than many metals, such as aluminum or mild steel. Its high hardness requires stronger, more durable cutting tools like carbide or diamond blades, as regular tools may wear out quickly.
Work Hardening
When stainless steel is subjected to the heat and stress of cutting, its surface can become harder. Further cutting is even more difficult and requires specialized techniques to avoid tool damage.
Heat Generation
Stainless steel doesn’t dissipate heat efficiently. When cutting, heat builds up at the cutting edge, which can lead to tool overheating, distortion of the material, and quicker tool wear. Proper cooling methods are essential to manage this.
Questions about How to Cut Stainless Steel
What Is the Best Bit to Cut through Stainless Steel?
Cobalt drill bits are widely recognized as the best option for cutting through stainless steel due to their hardness and heat resistance.
What Is the Best Tool Steel for Cutting Stainless Steel?
One of the best tool steel for cutting stainless steel is M42 high-speed steel (HSS). However, the optimal choice depends on the task, material thickness, and cutting conditions.
Summary
Cutting stainless steel requires the right tools, techniques, and considerations based on the material’s thickness and the complexity of the cut. This article covered a variety of cutting methods, tools, and processes, helping you understand how to make clean and precise cuts on stainless steel.
If you’re looking for stainless steel products for your project, SteelPRO Group offers high-quality options. You can visit our website or contact us for a quote for more details.
