Choosing the Best Cutting Tool for the Job
This guide breaks down the categories of cutting tools along with their pros and cons BY: TIM LYMAN (tlyman@starrett.com) is welding channel manager, The L. S. Starrett Co., Athol, Mass. Reprinted with permission: The AWS Welding Journal- Cuts all types of metal
- Higher cutting speeds — great for fast, straight cuts of thin metals
- Dross free — No after treatment required
- Thickness limitations on most shop plasma cutting machines
- Broader kerf than laser cutting
- Expensive upfront cost and not cross functional
- Suitable for medium-sized and thick materials
- Bevel cutting with up to three torches on one aggregate
- Cross functional and relatively inexpensive — cut, weld, braze, heat, etc.
- Suitable for cutting mild steel only
- Low-cut speed and reduced dimensional accuracy when making repeat cuts
- Can cause warpage and partial dross formation, requiring after treatment
- Causes heavy scale on workpiece, which can be a challenge to remove before welding operations can be done effectively
- Works well in making cuts on most metals
- Effectively makes quick cuts on bolts, nets, sheet metal, etc.
- Versatile tool that can also be used to sharpen blades and grind metals
- Due to various grain compositions, each abrasive has specific material operating parameters and are not universal to all metals
- Sparks are upwards of 1700°C, which are molten metal, and can easily cover more than 15 ft of distance during the operation
- Suitable for jobs that require precise and delicate cuts on a flat surface
- Often used to make straight or curved cuts in the middle of a workpiece
- High degree of safety due to ease of use
- Great longevity on lightweight, cordless tools
- Cannot be used to make flush cuts
- Requires a somewhat even surface for the base to be stable
- Only has a moderate level of power
- Ability to quickly cut all types of metals
- Suitable for demolition and quick, rough cuts
- Ease-of-use when reaching into tight or hard-to-reach places
- Great mobility due to design for use on cordless tools
- Careful user attention is required for consistent, accurate cutting
- Higher skill level is required to make a puncture/cut into a flat surface
- Strong power can be dangerous when used in low-leverage situations
- Able to cut in several directions and angles on most types of metal
- Long blade life and portable use
- Can be used as a stationary or mobile tool, allowing users to transport the least amount of mass for any given application
- Not able to make consistent curved cuts
- Needs a specific blade made for cutting metal
- Can be dangerous — sparks and metal chips will fly during usage
- Effectively cuts most metals and allows for straight and curved lines
- Powerful and fast cutting. Makes fast cuts with very few sparks
- Versatile and allows for vertical and horizontal cuts
- Portable band saw blades can wear down quickly if proper operating parameters are not followed to
- Not suited for making thick cuts
- Potentially dangerous if operator does not attend to proper safety and personal protection equipment requirements
- Highly accurate in making straight cuts in most materials up to a ½-in. thick
- Convenient when needing to quickly make many similar type cuts
- Cost effective option for cutting many materials
- Stationary. Only able to move up and down
- Typically used for more specialized, consistent cuts
- Often leaves a burr on the cut, which requires secondary cleanup
- Can cut all thicknesses of metal, including bundles
- Most are programmable, facilitating increased productivity and semiautomation
- Affordable option that operates quietly and cleaner when compared to other options
- Stationary. Saw takes up space in shop
- Requires operator to know how to break in the blade and set saw
- Coolant is required for many applications for ideal operating parameters
- Works well on most soft, thin metals
- Ideal for quick, inexpensive straight-line cuts of simply shaped parts
- Produces minimal kerf with virtually no loss of material
- Not ideal for cutting harder metals or thick material
- Can only make straight-line cuts
- Often creates burrs and end deformation on cut
- Better suited for cutting through thinner materials
- Very safe — poses less risk than power tools because user is in full control
- Size and light weight make it easy to reach awkward cutting places
- Blades can easily get damaged when cutting thick or hard metals
- Can be a slow cutting process due to small teeth and gullets on blade
- Can be physically draining on projects with a lot to cut — less ergonomic than other available alternatives
- Designed for cutting thin sheets of soft metal
- Affordable and very easy to use
- Highly durable tool
- Low on versatility
- Can be a slow cutting process depending on material and individuals’ experience
- Takes extra effort to cut tougher material due to spring-loaded handles