Self-construction of a metal-cutting machine. Convenient and practical - we make a cutting machine from a grinder with our own hands Making a pendulum saw for metal with our own hands

It’s not worth even remembering that every owner should have a cutting machine in their arsenal. There is no need to describe how necessary and useful such equipment is. This is quite obvious. Using a cutting machine, you can quickly and accurately cut any material into the necessary workpieces - aluminum, plastic and rolled steel. Today we will be making a cutting machine with our own hands.

Cutting machine design

Any work related to metal requires its processing and cutting, for which specialized cutting machines are used. The application of this device is extremely wide: from home needs to large enterprises and factories.

It should be noted that machines of this type are devices that allow transverse cutting of metal - blanks of angles, channels, rods, I-beams and other products.

The cutting machine is capable of sawing parts from any type of metal - from aluminum and PVC profile to thick steel workpieces. The profile can be cut at two angles: straight and sharp at 45 degrees. Using a cutting machine, you can saw and cut pipes of large and small diameters.

The most important element of the device, its “heart” is Electrical engine and a cutting disc, which are connected to each other using a gear or belt drive. Each gear has its own advantages over the other. For example, a belt drive is characterized by a quieter running, is more resistant to overload and produces less noise. It can be installed even on powerful cutting equipment.

And the gear drive can take up little space and, thanks to this characteristic, is suitable for a small homemade cutting machine. Therefore, when choosing a cutting machine, you need to pay attention to the type of transmission.

Almost all machine models are equipped abrasive wheels, but sometimes there are aggregates with carbide wheels. Besides this, everything cutting saws for metal are equipped with a vice that can securely hold workpieces.

Choosing a cutting machine

If you need to choose a cutting machine, it is recommended to pay attention to certain characteristics and capabilities of the device, which depend on the conditions of its use. One of them has already been mentioned above - the presence of a gear or belt drive. And now other features should be cited.

Motor power is a parameter on which the performance of the equipment will directly depend. Cutting machines typically have high power, approximately 2000 watts.

Next you should move on to the characteristics of the disk speed. The more often the cutting disc rotates, the higher the overall speed of the device. In addition, the number of revolutions also affects the quality of the resulting products.

Look in the documentation to see what diameter a particular manual cutting machine disc has. From maximum size The maximum height of the part that you can process on such a device will depend. The dependence in this case is directly proportional: the larger the diameter, the greater the height, the smaller the diameter, the smaller the height. Typically, cutting machines are equipped with discs whose diameter is within the limit of 400 millimeters.

Another important characteristic is the cutting angle, which can determine the position of the part during the sawing process relative to the cutting disc. This indicator can be adjusted, as a rule, from a right angle to an acute angle of 45 degrees.

The last thing you should look at is the weight of the cutter. The assortment of modern retail chains includes mobile models, and some are quite bulky, weighing more than a hundred kilograms.

Classification of cutting machines by the number of cutting heads

Various cutting machines differ in their own parameters: the number of cutting heads, cutting capabilities at an adjustable angle, and the method of feeding the saw blade. Depending on the number of cutting heads that are present in the design of the cutting machine, single- and double-head machines are distinguished.

From the name, you can tell that this cutting machine is equipped with a single cutting tool - a saw blade. It follows from this that such a homemade metal cutting machine has lower productivity compared to others. To cut a blank for a part for a frame profile, you need to perform not one operation, but two.

Roller tables are installed on such machines - a device with which the length of the processed profile is measured. There are inlet and outlet roller tables. The output is equipped with a thrust-measuring device, presented in the form of a simple metric ruler.

However, there is also a manual optical unit or a special automatic one, which are used in more high-precision models. The equipment of the first option almost completely eliminates errors during operation and defects in manufacturing.

Double-head cutting machines, unlike single-head cutting machines, have two cutting tools in their design. This allows the frame profile to be cut in one operation, in other words, in one pass. In this equipment, one cutting head is stationary, and the other can move to the desired distance.

To measure the distance at which the heads are located, the equipment uses a = metric ruler, supplemented by a special digital display or optical visor. Also, instead of a ruler, it is customary to use the built-in ability to automatically move the working head to a certain distance.

Classification of machines by cutting tool feed

According to the type of feed of the tool that carries out cutting, drawings of cutting machines come with pendulum, frontal and bottom feed. On cutting machines with pendulum feed, the saw blade is fed from above. Moreover, if the cutting machine has one such tool, then saw blade supplied manually or automatically. If the machine is equipped with two-head equipment, then the saw feed occurs exclusively in automatic mode.

To make cuts at an angle, the discs in vertical plane can turn. Some models provide the ability to tilt the saw horizontally. In cutting equipment with pendulum feed, the tilting and rotation of saw blades does not have an automated mode. Everything must be done manually.

On cutting machines that are equipped with a front feed of the cutting tool, the tilt of the disk changes automatically. There are special models on sale, equipped with special electronic control units that allow you to enter up to 99 different types of profiles into the machine’s memory, which can be cut.

It is possible to calculate all cutting parameters, and this happens automatically. Cutting machines with front-feed cutting tools memorize up to 100 different types of window and door designs. In many machines, by writing certain commands on a floppy disk, cut maps can be loaded into the machine’s memory, unlike homemade cutting machines from an angle grinder.

Cutting machines that have a bottom disk feed have a more universal purpose. The working tool for cutting is fed in such machines completely automatically. Its tilt can occur in any direction. Thanks to this characteristic, bending machines of this type, regardless of whether they are single-head or double-head, are capable of performing complex spatial cuts, which are used in the manufacture of translucent structures.

Making a cutting machine

In the trade sector there are many machines available different price, but you can assemble a cutting machine correctly with your own hands from scrap materials with the characteristics that you need.

In the process of work, you will need the following tools and materials: channel, angle, welding machine, drill, coil, shaft, bearing pair, electric motor, automatic machine, starting circuit, button and electrical box for the layout of the electrical circuit.

Manufacturing should begin from a frame-frame, the dimensions of which should be 40 by 60 by 120 centimeters. The material for the frame is corner No. 25, cut the blanks with a grinder and weld. After welding the frame, you need to weld the legs from a corner or the same profile to it. Weld channel No. 10 to the table on top, which serves as a guide and strengthens the frame and, of course, the entire structure. Two vertical posts are bolted to it.

Then you need from profile pipe Weld a second frame measuring 60 by 45, which is intended for mounting an electric motor and a shaft for cutting stone on it. Install a rotating plate at the rear of the frame, on which an electric motor should be mounted, which has a power of 1.5 kW.

It is recommended to give preference to asynchronous motors, which are considered more reliable and durable. Practice shows that in order for a homemade cutting machine to function correctly, a “three-thousander”, which has a power of 2.2 kW and is powered by a three-phase network, is ideal.

A “one and a half thousand kilometer” will also do, but it is recommended to select the gear ratio of the belt drive in such a way that the shaft is close to 6000 revolutions per minute. In a situation where power is supplied from a single-phase network, it is necessary to increase the motor power by 30% and use starting and running capacitors.

The design of the shaft and the principle of its fastening can be arbitrary; the main thing to remember is that the transmission of rotation from the electric motor to the shaft must be transmitted using a V-belt. It is better to order a working shaft with supports, a pulley for a belt and flanges for a disk from a turner, and it is worth ensuring that the flange protrusion is Ø32 millimeters.

A pulley and support bearings must be installed on the shaft. They should be strengthened in the nests of the plates that are on the upper frame. To locate the electrical circuit, it is advisable to buy a box and attach it to the bottom of the cutting machine frame. The shaft and motor are secured with nuts and bolts.

The uprights are connected by a Ø12 mm shaft with a fitted bushing. To avoid axial movements of the disk, the shaft and bushing are connected with a minimum clearance with a sliding fit. It is necessary to weld a rocker arm from channel No. 10, which has a size of 800 millimeters, to this bushing, so that the arms are in a ratio of 1 to 3.

The stroke of the rocker arm is limited by the chain, and on the motor side, to facilitate return, springs are installed, for example, from a sports expander. Springs and chains are fastened using bolts. The electric motor is mounted on the smaller part of the rocker arm, the working shaft is mounted on the larger part. The movement is transmitted using a belt drive.

To assemble the electrical circuit, you need a ready-made box, the cost of which is much cheaper than making it yourself. To connect the machine, you need a three-pole starting circuit breaker, it should be connected to the engine, a starting circuit and an emergency stop button. The motor is connected through a three-pole circuit breaker and a box, the emergency stop button is connected directly.

And finally, remember that the table is usually made of planed boards, and in order to even out small irregularities, it is covered with plywood. After you have made the cutting machine, you can connect it to the mains and conduct trial run. Make sure the cutting machine is operating correctly, attach the cutting disc to the shaft and get to work.

From this article you can learn how to make a metal cutting machine with your own hands at home using the most simple materials. All stages of creating structures based on a cutting disc or grinder are described here in detail: preparation of materials and tools, calculation formulas, detailed step-by-step instructions, as well as related information with useful tips.

Disc cutting machines are tools whose design is based on a special platform or frame made of metal. The machine itself is equipped with parts that ensure reliable fixation of the material in a certain position at the required angle during the cutting process. A disk made of high-speed steel is used as a cutting element in such structures. It is also called carbide. A wheel coated with an abrasive material can also be used for cutting metal. The cutting element is driven by an electric motor with a belt or gear drive.

Note! In low-power versions of the tool, it is possible to use a cutting element mounted directly on the shaft of an electric motor. In other cases, using the disc in this way can be dangerous.

In disk machines, there are three different feeds of the cutting component:

lower;
pendulum;
frontal.

Depending on the number of cutting elements, machines are:

Making a disc cutting machine for metal with your own hands: procedure

When manufacturing a machine designed to work with metal, the actions are performed in the following order:

Calculation of a pulley for a homemade metal cutting machine

The calculation of the diameter of the pulleys is carried out taking into account the rotational speed of the disk and other parameters. Assuming that the motor power is at least 300 W, the rotational speed of the disk will be at least 3000 rpm, and its diameter will be 40 cm.

Helpful advice! During the process of cutting metal, the nut in the disk fixation area may come loose. To avoid this, it is recommended to place the drive pulleys on the left side, and the disk itself on the shaft on the right.

Typically, discs are marked by the manufacturer, who marks the product with the maximum permissible rotational speed value. In this case, the indicator is 4400 rpm. Therefore, you can select any speed within the range of 3000-4400 rpm. Data for calculations:

rotational speed of the motor – 1500 rpm;
the diameter of the pulley intended for installation on the shaft is 6.5 cm;
rotational speed of the disk – 3000 rpm.

The calculation is performed in the following sequence:

Set the length of the shaft around the perimeter. To do this, multiply the number π, which is equal to 3.14, by the diameter size: 3.14 x 6.5 = 20.41 cm (shaft length around the perimeter).
The resulting value is multiplied by required amount revolutions: 20.41 x 3000 rpm. = 61230 cm/min.
The result must be divided by the number of engine revolutions: 61230 cm/min/1500 rpm. = 40.82 cm (perimeter motor pulley length).
The resulting value is divided by the number π: 40.82 cm/3.14 = 13 cm (required pulley size).

Calculating the length of the belt for a homemade metal cutting machine with your own hands

To perform these calculations you will need the following data:

drive pulley parameters (radius);
the distance separating the center points of the pulleys;
parameters of the driven pulley (radius).

Having 2 pulleys with dimensional parameters of 13 cm and 6.5 cm, you can make the necessary calculations. Since the distance between the centers of these elements can be changed (since it is necessary to bring the belt into a state of tension), a segment 50 cm long will be taken as an example.

Now you need to calculate 1/2 the circumference of each pulley. Since the drive belt runs between them twice, double the distance between the center points must be added to this value. First pulley (circumference):

3.14 (number π) x 3.25 cm = 10.20 cm

Second pulley (circumference):

3.14 (π number) x 6.5 cm = 20.41 cm

Drive belt (required length):

20.41 cm + 10.20 cm + 50cm x 2 = 13.06 cm

Helpful advice! To get a more accurate result, you should make calculations with the maximum and minimum distance between the central points of the pulleys and select the average meaning.

Drawing of a pendulum-type cutting machine: on the left - dimensions of the base, on the right - design features of the pendulum

To make your own machine design for working with metal, you should prepare the necessary tools.

The required set of tools and materials includes:

welding machine;
metal corner(steel);
channel and chain;
button to turn on/off;
bearings;
shaft and electric motor;
electric drill;
sheet steel to create a working surface;
box for placing the electrical components of the machine.

Principles of creating a machine for cutting metal

Manufacturing scheme homemade machine obeys certain principles, they must be taken into account before getting down to business:

choice optimal angle cutting The acceptable range is 45-90°. In most cases, experts prefer cutting at right angles;
The diameter of the cutting disc is selected taking into account what materials the master will work with on this machine in the future. The larger the diameter of the cutting element, the easier it will be to cut thick metal;
When designing and drawing up drawings, indicators such as the dimensions of the future machine and its weight must be taken into account. These values are directly influenced by the materials from which the equipment will be made. The layout of the parts also matters.

When drawing up drawings Special attention attention should be paid to vibration supports that are installed on the legs.

Assembling a metal frame for a cutting machine

After all the tools have been prepared and the drawings have been selected, you can proceed directly to the process of creating the machine. Using a steel angle, it is necessary to make the frame part of the structure. In accordance with the drawings, which you can draw up yourself or find on the Internet, frame elements are cut out. All of them are connected to each other by welding. First you need to check the size suitability.

A channel is welded to the top of the frame - it will become a guide element and will serve as the basis for further installation of the cutting component on the machine. This channel will become a kind of connecting link between the electric motor and the cutting element. After this, vertically located racks are secured to it using bolts. It will be necessary to weld the structure of another frame. Dimensional parameters are selected individually, taking into account the dimensions of the electric motor and its features. When choosing an electric motor for a machine, it is better to pay attention to asynchronous type modifications. This type equipment is characterized by increased reliability and durability. There is one subtlety when choosing a motor. The more powerful the engine, the smoother the drive will move.

Assembling the electrical components for the machine

Installation of equipment involves mounting and connecting the working shaft to the electric motor of the machine. The way in which this can be done is not fundamental. If the drawings contain instructions for performing this procedure, it is better to follow them, since the correct operation and reliability of the tool depends on the quality of installation.

Helpful advice! Some parts that you cannot make yourself can be ordered from a turner. These include flanges for fixation, as well as a pulley.

To fix the motor on a metal frame, it is better to use bolted connection with nuts. It is recommended to place a box near the engine where the switch and electrical circuit are located, as well as the remote control for controlling the tool. It is better to place the channel, intended for fixing the cutting disc, on a spring. You need to make sure that when you release it, it returns to its original place. To secure the spring, you can take bolts and a clamp. The electrical component is the most important part of the tool. Be sure to include in the design a starting circuit, as well as a button for emergency shutdown of the machine. It is necessary to achieve such an arrangement of parts in which the electric motor will be connected to electricity through an automatic machine and gearbox, and not directly. A three-way starter will be enough to turn on and fully start the engine. It will also power the shutdown button. Finally, it is worth taking care of the presence of protective devices that will protect a person during the work process. To do this, you need to make a protective casing. It will prevent sparks and small metal particles from getting into your eyes.

Making a cutting machine from a grinder with your own hands: drawings, technology

The designs of cutting machines made on the basis of an angle grinder are of two types (depending on the placement of the angle grinder). In the first case, you get a frame on which the angle grinder is very rigidly fixed. Only the disk rises above the working surface, for which there is a special slot in the table. This machine operates on the principle circular saw.

Note! When working with such a machine, you have to move the workpiece yourself, which is why the accuracy of the work is lost. In addition, this process can be unsafe, so drawings with a hidden type of placement of an angle grinder are not in high demand.

The second option assumes that the workpiece remains stationary and cutting element moves. Due to the fact that the grinding machine is located on top of the tabletop, cutting parts does not require much effort.

List of tools and materials for a do-it-yourself grinder cutting machine

When making a tool yourself, it should be taken into account that the accuracy with which it will work largely depends on the stability of the structure. For this reason, the thickness of materials for manufacturing is associated not so much with the requirements for the strength of the machine body, but with the need to ensure the proper level of rigidity. List of materials:

profiled pipe with square section(2.5x2.5x0.25 cm);
sheet steel (sheet thickness 0.4-0.5 cm);
profiled pipe with rectangular cross-section(4x2x0.25 cm);
ball bearings – 2 pcs. (No. 203, 204 or 202);
calibrated rod no more than 10 cm (thickness is selected taking into account the hole on the inner race of the bearing);
metal rod (diameter 0.8-1 cm);
fasteners (bolts with nuts, M or M8 thread);
metal tire (2x0.4 cm).

List of tools:

angle grinder;
electric drill (can be replaced with a drilling machine);
set of drills;
a set of dies designed for forming metal threads;
welding machine;
open-end wrenches.

Choosing a suitable cutting tool for a homemade cutting machine from an angle grinder

An angle grinder is the main component of a machine for working with metal. Experts do not recommend using a small tool for these purposes, which has a power of no more than 500-600 W. In such grinders, the cutting discs have a diameter of no more than 12.5 cm. These restrictions are due to the fact that a cutting element with a large diameter is considered universal and very reliable - it is able to cope with cutting thick workpieces.

Helpful advice! Instead of welding, threaded connections can be used to secure parts, but they are less reliable and will not provide the required level of strength.

You also need to be careful when choosing an angle grinder because there is a wide variety of designs on the market. Since this power tool is not completely unified, the construction of the machine will be carried out according to a certain modification and size of the angle grinder. If the machine breaks down, installing another angle grinder may be not only problematic, but also impossible. We'll have to redo the pendulum and all the fastenings. Therefore, it is worth choosing a tool from the range of large and already proven companies, for example, Bosch or Makita.

Cutting machine drawings: how to make a cutting tool from a grinder

On preparatory stage design and drawing are carried out. There are no uniform sizes for the reason that the design of each machine is subject to a specific model of cutting tool. Ready-made drawings, of which there are many online, can be adjusted to fit the grinder. They allow you to navigate what the structure of the structure and its dimensions will be.

It is better to start drawing up a drawing with the body part. In some cases, it may be necessary to build a separate platform instead of a frame. Such a platform will be fixed on a metalworking bench. Next, the dimensions and nature of the location of the key elements on the machine are determined. It is necessary to measure the center distances between the mounting holes located on the gearbox, and also measure the grinder itself. All this data is used to create drawings. After the mounts for the pendulum and grinder are designed, the rotary assembly is designed.

Helpful advice! The accuracy and rigidity of the machine depends on the distance between the cutting element and the hinge joint. The smaller this gap, the better. It is recommended to install a pendulum with a minimum length.

After drawing up the drawings, all that remains is to select the materials, calculate their quantities and begin constructing the structure.

Technology for creating a cutting machine from an angle grinder

The manufacturing technology of a machine for cutting metal based on a grinder is almost the same as in the case of a cutting disc:

Preparation and production of parts for the frame.
Arrangement of a hinge joint on a pendulum arm.
Manufacturing a U-shaped bracket with holes for mounting a grinding machine gearbox.
Making a U-shaped clamp and strip that will fix the angle grinder body to the pendulum.
Installation of the U-shaped clamp and U-shaped bracket to the cutting tool: by welding or threaded connection, all these parts are attached to the console part.
Pressing bearings into supports.
Double-sided pressing of bearing units onto the shaft. To increase the strength of the connection, you can tin the axle with a thin layer of tin using a soldering iron.
Fixing the pendulum with supporting node parts on the edge of the platform (distance from the edge 0.5-0.6 cm) using welding machine.
Installation of the grinder and protective casing.
Installation of the return spring.

After the structure is assembled, it is necessary to perform a test run and check the correct operation of the equipment, as well as the placement of all parts on it. On final stage The groove is adjusted to fit the cutting element, and supports are installed to secure the workpieces. When finishing is completed, the body of the machine must be covered with a thin layer of enamel. Painting will protect the instrument from damage that rust can cause.

You can’t do without an angle grinder - an angle grinder - either in a garage or in a private yard. The unit allows you to cut a metal profile, clean a weld or remove rust from the surface of workpieces and parts; it has a low price and incredible ease of use. The grinder also has disadvantages, one of which is the unstable quality of the cut and the danger of skewing the cutting disc during use. You can eliminate annoying shortcomings by making a special frame with your own hands, which will turn hand tool into a real cutting machine. This will increase the speed of work and achieve accuracy that can only be obtained with industrially manufactured equipment.

Scope of application of cutting machines

Cutting disc machines are widely used in metalworking, mechanical engineering, woodworking and furniture industries. The units have found their application in household: They are used as a handy tool to perform various jobs in the workshop and garage. The cutting machine is convenient to use to solve a number of problems:

The advantages of disc cutting machines include convenience and ease of use, high speed and cutting accuracy, the ability to replace the cutting disc in a matter of minutes.

Due to their relatively low cost, universal units have a quick payback period, so they are profitable to use in small industries and small workshops.

In the household, a cutting machine is used irregularly, so buying a factory-made tool is irrational. It is better to make a special stand for an angle grinder. This will increase the versatility of the grinder, turning it into a small-sized cutting machine.

Types of devices, their advantages and disadvantages

There are two types of designs of cutting machines, differing in the location of the grinder, which can be made at home.

The first installation is a frame with a corner rigidly fixed underneath it. grinder. Only the cutting disc is visible on the working surface, which fits freely into the table slot. Uncover metal profile or sheet in this case is completely identical to cutting wooden blanks using a circular saw. Despite the very simple design, such a scheme is not particularly popular. Those who have made such a device note that it is inconvenient to use due to the need to move the workpiece. This significantly reduces the accuracy of the work and makes the process unsafe. The only advantage of a machine with a bottom angle grinder is the ability to quickly cut thin metal sheets.

A cutting machine with a lower angle grinder can be used both for cutting metal and as a circular saw

The second scheme, in which the part remains stationary and the cutting wheel itself moves, is more convenient. The so-called pendulum saw, placed above the tabletop, allows you to cut the workpiece exactly at the required angle, and it becomes possible to make the required number of parts of the same type. Due to the location of the grinder on top, cutting workpieces does not require effort, and operation of the unit becomes simple and safe. The undoubted advantages of the design include the possibility quick dismantling grinders for traditional use. As for the disadvantages of this method, the weak link can be considered the hinge joint, which complicates the design of the machine.

A machine for cutting metal with an upper angle grinder has a more convenient design and makes it possible to cut workpieces at the desired angle

The device of a pendulum saw from a grinder

A pendulum saw made from an angle grinder is available for assembly at home and does not require expensive materials or special qualifications. The cutting machine has a simple design and consists of several components:

bed;
pendulum;
mount for angle grinder.

The bed is a steel frame welded from profile pipes, with a platform made of sheet metal thickness of at least 3 mm. A bracket is attached to this plate, on which the pendulum saw hinge is mounted, as well as a stop for holding the workpiece. By the way, there can be several such stops: it is convenient when one element allows you to make a perpendicular cut, and the other makes it possible to cut the material at the required angle. The most perfect stop is a rotary device with a protractor, with the help of which any angle between the part and the cutting disc is set. Important detail: where the saw touches the platform in the tabletop, a cut is made, its width should be equal to twice the thickness of the cutting wheel, and its length should correspond to the diameter.

The standard design consists of a frame, a pendulum and a mount for an angle grinder

The pendulum of the cutting machine is a T-shaped part made of a rectangular metal profile. On one side, this unit is attached with a movable connection to the frame bracket, and on the other, a mount for an angle grinder is attached to it. The mobility of the pendulum saw hinge is provided by rolling bearings or bushings, and the return of the tool to its original position is provided by a flexible element (rubber band or spring).

The angle grinder mount is a console with one or two brackets connected to the pendulum. The angle grinder is attached to one of them with bolts. For this purpose, threaded holes are provided in the gearbox housing for attaching the handle. The second bracket is a regular clamp (stepladder) that holds the cutting tool by the body.

The ease of operation of the equipment can be significantly increased by connecting the angle grinder to a foot switch/pedal. Of course, in this case, the starting lever of the angle grinder is brought into the working position and fixed with a special button.

Required tools and materials

When starting to manufacture a cutting machine, you should understand that the accuracy of its operation is directly related to the stability of the structure. Therefore, the choice of a material of a certain thickness is dictated not so much by the requirements for the strength of the body, but by the need for its rigidity.

Before you start working, you need to prepare:

square profile pipe (25x25x2.5 mm);
profile pipe “rectangle” (40x20x2.5 mm);
metal sheet 4–5 mm thick;
ball bearings No. 202, 203 or 204 – 2 pcs.;
calibrated rod with a thickness equal to the diameter of the hole in the inner race of the bearing (up to 100 mm);
rod with a diameter of 8–10 mm;
metal tire (20x4 mm);
bolts and nuts with M8 or M thread.

Tools you will need:

Angle Grinder;
drill or drilling machine, set of drills;
a set of dies for cutting metric threads;
open-end wrenches;
welding machine.

The presence of electric welding is desirable, but not necessary - all connections can be made on threaded connections. However, it should be understood that this method reduces the reliability and strength of the structure.

To make a machine, it is better to choose an angle grinder from a well-known manufacturer.

The main component of the cutting machine is the angle grinder. It is not recommended to use a “small” grinder designed for cutting discs with a diameter of up to 125 mm and a power of up to 500–600 W. Remember that the larger the diameter of the cutting wheel, the more versatile and reliable the machine will be.

The careful selection of power tools is also due to the wide variety of angle grinder designs available on the market. Since such equipment is not unified, the cutting machine is built for a specific model and size of angle grinder. If the equipment is unreliable, then if it fails, it will be difficult to install another angle grinder in its place without the need to rework the mounts and pendulum. That is why it is better to choose products from trusted manufacturers - Makita, Bosch and so on.

Making a cutting machine with your own hands

Preparatory stage

Work on a cutting machine begins with design. It is impossible to give the exact dimensions of the device, since the design depends on the model and size of the specific angle grinder. Nevertheless, from the presented drawings you can get an idea of the dimensions and structure of the equipment.

The design sketch begins with a drawing of the body. You may not need a frame, but a separate platform that can be attached to a bench. In any case, determine the dimensions of the device and the location of the main components on the body. Next, the angle grinder and the center distances of the mounting holes on the gearbox housing are measured. Based on these indicators, a drawing is drawn up for attaching the angle grinder to the pendulum. After this, the rotary unit itself is designed. The shorter the distance from the hinge joint to the cutting wheel, the stiffer and more accurate the machine will be. In other words, the length of the pendulum should be as short as possible.

On last stage Designers calculate how much and what kind of material will be needed.

Photo gallery: Drawings for making a homemade cutting machine

Drawing of a frame-type cutting machine. Frame dimensions are selected based on the size of the tool used

Drawing of a pendulum type cutting machine. The dimensions of the base are indicated on the left. On the right are the design features of the pendulum.

Step-by-step instruction

In accordance with the drawing, blanks of the future machine are cut. For the frame and pendulum, profile pipes are used, and for cantilever mounting, a metal profile, a metal tire and a steel rod are used. If the design provides for a load-bearing platform, then sheet steel 4–5 mm thick is cut to size.
A transverse axis (shaft) is welded to the pendulum arm, which is a section of a profile pipe, for an articulated connection. In this case, it is important to ensure that the shaft is attached to the pendulum perpendicularly.
After cutting the material, a shaft is welded to the pendulum arm
A U-shaped bracket is bent from a steel tire, holes are drilled in its sides for bolts, with which the gearbox housing of the angle grinder is secured.
To attach to the threaded holes on the angle grinder gearbox housing you will need a U-shaped bracket
A U-shaped clamp (ladder) that goes around the angle grinder is made from a steel bar and clamping bar for fixing the tool body to the pendulum. The latter is a metal plate 15–20 mm longer than the width of the clamp. The threaded ends of the stepladder fit freely into the holes at the edges of the pressure plate, and fixation is carried out with nuts with suitable threads.
Trying on the U-shaped bracket and clamp to the angle grinder, mount these parts onto the console using a welding or threaded connection.
This is what the console for attaching the angle grinder to the pendulum arm looks like, complete with a U-shaped bracket and clamp
The bearings that will ensure the rotation of the pendulum are pressed into the supports. As the latter, you can use both ready-made factory bearing units and sections steel pipe(15–20 mm) with a diameter equal to the outer race of the bearing.
Bearing units are pressed onto the shaft from both sides. It is important that the connection is tight - this will eliminate unwanted longitudinal and transverse displacements. If the resulting connection is weakened for some reason, you can use a proven method - tin the axle with a soldering iron, applying thin layer tin (you will need soldering acid as a flux).
At a distance of 50–60 mm from the edge of the platform, the pendulum assembly with support units is welded. At the same time, it is important not to overheat the bearings, so these parts are wrapped in a wet rag or constantly watered with water to cool.
The pendulum arm assembly with bearing units is welded to the platform at a distance of 50–60 mm from the edge
A console with an installed clamp and a U-shaped angle grinder mount is welded onto the pendulum arm. The position of the grinder is chosen based on personal preferences. There are different opinions on how to attach the angle grinder (“from yourself” or “towards you”). Professional mechanics work with the tool, orienting the sheaf of sparks towards themselves, arguing that if the grinder falls out of their hands for any reason, the tool will fly off in the opposite direction. Hobbyists most often work with medium or small sanders, so they prefer to have the disk rotate “pull”, as this allows for control of the cut and prevents damage to clothing. When securing the tool, do not forget to place the protective casing correctly - it should protect the worker in the event of a disk rupture.
An angle grinder is attached to the assembled machine. Based on the weight of the tool, select and install the return spring. To do this, hinges are welded to the frame and pendulum or holes with a diameter of up to 5 mm are drilled.
In order not to damage the plastic body of the angle grinder, strips of rubber are laid between it and the brackets
Perform a test run of the grinder. First, check the operation of the machine in idle mode. At the same time, pay attention to vibrations and play in the working parts of the equipment, which are eliminated if necessary.
Using a cutting wheel of maximum thickness, a groove is cut in the machine platform for the cutting disc. If necessary, the grinder is removed and the slot is expanded to the desired size.
This is what an improved stop with a clamping device looks like

At the last stage, workpiece stops are attached to the platform. Most often, two strips are provided (for cutting at an angle of 45 and 90 degrees), fixing them with a welded or threaded connection.

Often, devices for holding the workpiece are equipped measuring instrument. By attaching a metal ruler to the stop bar with a reference point from the grinder disk, you can quickly and accurately cut the part to the required length. Also, if desired, you can install protractors, vices and clamps various designs. Such additional details allow you to make, for example, a full cut or groove in a workpiece at any angle, free your hands, and so on.

Don’t forget to paint the fixture after all finishing work has been completed. Even a thin layer of enamel will protect the equipment from rust and make it appearance more aesthetic.

Video: How to make a cutting machine from a grinder with your own hands

Safety precautions

While working on the cutting machine (as well as during its operation in the future), safety precautions should be strictly observed. Be sure to use a protective mask or goggles, and position the angle grinder in such a way that the sheaf of sparks is directed “away from you.” The high fire hazard of the equipment requires work to be carried out in a ventilated area and away from fuels and lubricants. During welding activities, you should also use a protective mask, thick leather gloves, closed shoes and protective overalls.

When working with a cutting machine, do not try to speed up the process by applying excessive pressure on the tool. IN best case scenario such a rush can result in a torn disk and a jammed clamping nut.

When using a welding machine, ensure good grounding and avoid operating equipment with exposed cable sections. Remember that welding open area prohibited in rainy weather. As for the operation of the cutting machine, when arranging a button to turn it on, protect yourself by installing a simple decoupling with a 12-volt power relay. To do this, you can make a pedal with any non-latching switch (for example, a doorbell button) and use any solid-state relay designed for switching currents of at least 10A. A battery or accumulator with a voltage of 5 to 24 V is used as a power source.

The cutting machine from the grinder is handy tool, which can be easily made if you have skills in working with electric welding and plumbing tools. Pendulum made in just one day Circular Saw will save time in the future and allow you to perform metalworking and welding work accurately and accurately.

An indispensable tool in the home workshop, metalwork shop, construction site. Many industrial models of these tools are produced, but their price is sometimes unaffordable not only for a private craftsman, but also for a small enterprise. There is a solution - it’s not at all difficult to make a metal cutting machine with your own hands. This requires only certain skills in working with a welding machine, plumbing tools, and some qualifications as an electrician. You also don’t need anything scarce or unavailable for free sale from materials.

To work you will need:

Bulgarian;
welding machine;
drill;
set of dies, taps, wrenches.

You will have to buy an electric motor with a power of 1.5-2 kW, single-phase or three-phase. In addition, you will need two pulleys, a shaft, bearings 204 or 205, a metal corner, and sheet steel 2-4 millimeters thick. When all this is assembled, the actual production of the machine begins.

You can make the drawings yourself using material from the Internet, or use ready-made ones, such as these. But experience shows that it is best to adapt the drawings to the materials that you have available. As a rule, DIY designs work best when you “customize” them to suit you. Naturally, in this case, certain rules and requirements must be observed that apply to a high-risk tool, such as a cutting tool. disc machine or pendulum saw, both homemade and industrial.

Most do-it-yourself metal cutting machines are of the pendulum type. more complex to manufacture, but they can be made in a small workshop or metalworking shop. For now, let's focus on the most convenient type of cutting machine - a disk one. General design can be seen in the video.

It consists of several main components:

electric motor;
pendulum;
drive mechanism;
cutting disc;
desktop.

Let's look at them separately.

Engine

Depending on the required power of the metal-cutting machine and the scope of its use, we select the engine power. It should be in the range of 1.5-3 kW. If you plan to use a cutting machine in a home workshop, a small metalworking shop, where cutting profile pipes, fittings, angles or other rolled products is done relatively rarely, and thin-walled metal is used as workpieces, a power of one and a half kilowatts will be enough. For small-scale production, work on a construction site, or the manufacture of frames for any purpose, a more powerful engine will be required.

If you have a three-phase motor with a power of about 3 kilowatts, it can be connected to 220 volts using a star circuit instead of a delta circuit. But it must be taken into account that its power will decrease by 25-30%. The main thing is that the speed indicated on the nameplate will be maintained.

To install on a metal cutting machine, the engine must have a speed of 2500-3000 per minute. This is due to the fact that it is at these speeds that the cutting disc operates optimally.

For a homemade metal cutting machine, circles with a diameter of 300-400 millimeters are used. Here, too, you need to proceed from the needs of production. You shouldn’t chase too large a disk diameter - the farther the working edge is from the center, the less cutting force, and a more powerful engine will be required. The optimal ratio of engine power and disc diameter is 2 kilowatts at three thousand revolutions and 300 millimeters in diameter.

A self-made metal cutting machine must first of all be safe. The cutting discs indicate the maximum number of revolutions at which they can be operated. As a rule, it should not exceed 4400 rpm. If it turns out more, the disk may collapse, which is unsafe. If the number of revolutions is less than 3000, then the cutting speed will be insufficient, and the disk will overheat and wear out. It is these figures that should be taken as the starting point for calculating the power transmission.

Drive unit

It is most convenient to use a belt drive as a drive mechanism. To do this you will have to find two pulleys of the same diameter. One of them is mounted on the motor shaft, the second - on the drive shaft of the cutting disc. The disk shaft is mounted on two bearings. It is best to use the scheme when the drive mechanism is located on the left of the disk mounting cloud. It’s more convenient to work this way, and safety rules are followed. The disc fastening nut will not be at risk of loosening.

To tension the drive belt, the engine is mounted at the rear of the pendulum with 4 bolts located in longitudinal slots. It can shift in the direction of the central axis of the machine (perpendicular to the axis of rotation of the motor shaft) by 5-7 centimeters. This will maintain the required belt tension and prevent it from slipping. It will also be easier to replace the belt if the previous one becomes unusable.

Console (pendulum)

The cantilever part of a metal cutting machine is one of the most important. In addition to the fact that it must be carefully balanced, reliably welded in compliance with all required sizes, it must still move strictly perpendicular to the desktop. The basis for mounting the pendulum are two vertical posts with slots for the pendulum bushing (diameter 10-12 mm). It is best to make them from a steel square of 40x40 millimeters. The height is approximately 80-100 millimeters, but you can calculate your own version.

A bushing shaft is installed horizontally in the holes of the racks, to which a rocker arm is welded, consisting of two levers, the ratio of which is one to three. A platform for installing the electric motor is welded on the short arm. On the long arm there is a cutting wheel drive shaft. The ratio of the lengths of the levers is approximate; it must be calculated so that in the non-working position the weight of the engine outweighs the weight of the assembled saw part (with protective covers). To bring the disk of the switched-on machine into contact with the metal, it is necessary to apply a small but noticeable force.

For ease of operation, a return spring is attached to the bottom of the engine platform, and the upward deflection angle of the pendulum is adjusted by a cable or chain, fixed at one end to the table and the other to the bottom of the long lever.

Desktop

The optimal dimensions are 700x1000x900 mm. It is welded from a 25x25 mm corner and covered steel sheet 3-4 mm thick, in which slots are made in the disk rotation zone. A rotary stop and a clamp with a rotary clamp are fixed on the table. This allows you to cut both perpendicularly and at the required angle. A very interesting version of a homemade machine is shown in the video. Here it is not the workpiece that turns, but the console with the disk and the motor.

Installing a disc-type cutting machine is not particularly difficult for a qualified mechanic. It is important to adhere to some fundamental requirements:

correctly calculate the disk rotation speed;
adjust the angle of rotation, it must be strictly perpendicular to the plane of the desktop;
set the force for feeding the disk into the cutting zone;
install an emergency stop button on the handle;
equip the cutting machine with protective covers for the disk and rotating parts.

Carrying out the process of cutting metal and metal structures using machine tools is much easier, safer and more comfortable than using hand tools and tools. But not every tinkerer can purchase a high-quality machine.

This is the reason that many people prefer to construct such mechanisms with their own hands, using what is in everyday life, for example, saws or grinders.

Why are cutting machines needed?

Summer cottages always require minor repairs: replace a greenhouse pole that has decayed over time, make a fence for land plot made of metal, repair a garden wheelbarrow or cart - cutting metal at a right angle or with a bevel is always necessary. Complete preparations for any metal products easier and more quickly due to the machine.

Using cutting machines, you can cut any materials: steel, cast iron, copper. Cutting is done at angles of 45º and 90º. You can make products with your own hands from pipes of all diameters. As a rule, cutting mechanisms are used for cutting semi-finished products into measured lengths.

Metal processing equipment can also be used to process other materials, eliminating the work of the cutter. The machine, made with your own hands, is compact; it is possible to install it under a canopy, and in winter, move it to the workroom.

You need a flat and hard surface with lighting. A similar corner can be found on the site of any building. All-welded and dismountable equipment designs are used. In order to reduce manufacturing costs, the device can be periodically given to neighbors for temporary use.

Cutting machine device

Any work that involves either metal or wood requires a cutting process, for which special cutting equipment is used. The application of this device is incredibly wide: from everyday needs and everyday life, to large plants and factories.

It should be noted that machines of this type are mechanisms that will allow you to perform transverse cutting of metal.

Cutting machines can cut parts from any type of metal: from copper and PVC profiles to large steel blanks. Semi-finished products can be cut at right and sharp angles. Using a cutting machine, you can cut pipes of large and medium diameters.

The most important mechanism of the device, its “soul,” is an electric motor and a working element – a cutting wheel, which are connected to each other through gear or belt drives. Each of these types has its own advantages. For example, the inherent easy running of the belt, resistant to various types loads, less noisy. It can even be mounted on a massive cutting machine.

The gear train is oversized, and due to this feature it is suitable for a miniature homemade cutting unit. Therefore, in the process of purchasing a cutting mechanism, you need to look at the type of gear used.

Almost any type of machine is equipped with abrasive wheels, but sometimes you come across mechanisms on which a carbide disc is installed. Moreover, all such metal saws are equipped with a vice that securely fixes the product or semi-finished product.

Video: homemade cutting machine from an angle grinder.

Homemade metal cutting machine: manufacturing instructions

A machine made with one’s own hands has an undeniable advantage: it is made to meet the requirements of a specific craftsman and the products planned for future production. To work you will need:

24th corner;
10th channel;
pipes;
welder;
rolling bearings;
electric drive;
container for mounting an electrical circuit;
start toggle switch;
starting circuit;
winding;
drill.

Assembly progress:

From corner No. 24 and using an angle grinder, cut the blanks onto the frame with your own hands, its dimensions are 400x600x1200 mm;
Using a welding machine, the workpieces are welded together;
Channel No. 10 is welded as a guide, which at the same time will add strength to the entire structure.
Using screws, two vertical supports are secured to the channel;
Using pipes, make a frame 400x600 mm for subsequent installation of the electric drive and shaft at the required angle;
On the “tail” part of the frame there is a plate with a fixed electric motor. It is advisable to apply asynchronous motor, since he is unpretentious. Depending on the future purpose, you can give preference to a motor whose power will be in the range of 1.5...3 kW and “power it” from a three-phase network. If it is possible to use only a 1-phase network, select a motor with 1/3 power greater than the calculated value, connected using capacitors;
With help lathe, make the shaft and flanges, pulley and supports. The flange must protrude by 30.32 mm.
Install the support bearings and pulley;
The installation of the box with the electrical circuit is carried out directly in the lower area of the frame.
A 12 mm shaft is attached between the racks, onto which the sleeve is placed. The distance between the shaft and the bushing must be kept to a minimum and a sliding fit must be ensured.
A rocker arm from the 10th channel (L=800 mm) is welded onto the bushing using a welding machine; the ratio of the arms of the rocker arm is 1 to 3. Its stroke is limited by a chain.
An electric motor is installed on the short section of the rocker, and a cutting mechanism is installed on the long section.
A belt drive is laid from the electric motor to the shaft.

The price of a container for an electrical circuit made by yourself will be slightly lower compared to one purchased at a hardware store. To extend the power supply to the equipment, you need a three-pole circuit breaker, from which power is supplied to the electric motor, an emergency shutdown button and a starting circuit.

The emergency button is connected directly, the electric motor is connected using a box and an automatic machine. This will ensure complete safety and electrical protection of the equipment you make.

Based on the above, making a cutting mechanism with your own hands is not only cheaper, but also more practical, since during its manufacture you yourself adjust its parameters and make adjustments for its future operation.

Also, having done this procedure once, you can repair such equipment without any problems. Moreover, if necessary, you can earn money by making cutting equipment with your own hands.

Video: homemade metal cutting machine with your own hands.