How to cut steel

Thin-gauge steel, like sheet metal, can be cut with a large variety of tools. Thicker steel – like pipes, tubes and plates – may require the use of power saws and torches. Saws and torches can also be used on thin steel, but are impractical choices unless you’re cutting high volume or need to cut steel often.

An angle grinder fitted with an abrasive metal-cutting disc works well to cut all kinds of metal, including bolts, angle iron, rebar and even sheet metal. But the discs wear down quickly, cut slowly and shrink in diameter as you use them. Instead, we recommend using a diamond blade that’s rated to cut ferrous metal.

Ferrous blades are ideal for cutting metals that contain iron, such as stainless steel or cast iron. Choose a non-ferrous blade when cutting softer metals, like aluminum or copper. For the best results, use a diamond blade that’s rated to cut the type of metal you are working with.

Most home and commercial workshops contain an angle grinder as they are one of the most versatile tools; by simply changing the disc you can quickly and easily perform a range of tasks such as cutting metal, stripping rust and paint, deburring, preparing metal for welding tasks, scoring and cutting stone, tiles, and …

If a clean cut is desired when cutting through hardened steel, or if the steel’s hardness must be retained, a fine toothed hacksaw will work wonderfully, though the process is long and will require a great deal of intense effort. … Use a bench vise to firmly hold the hardened steel as it is cut.

While a metal-cutting saw has a collection bin to prevent metal chips from getting into the machine, a woodcutting saw isn’t designed this way. If you do decide to use a wood saw on metal, only use a 7 1/4-inch blade and preferably a worm drive blade, which provides extra torque.