How to Cut Sheet Metal: Effective Techniques & Tips

Sheet metal comes in various thicknesses and strengths and is used in a wide range of projects. Choosing the right tools depends on the design and the material you’re working with. When straight cuts, normally, an electric saw is used. For complex designs and curved design geometries, the options are tin snips, dremels, or metal nibblers for accurate and well-controlled cutting. With the right tools, sheet cutting becomes easy and productive. Conventional hacksaws are the least effective, though they may take a considerable time when employed in a large work. Power saws or nibblers make the process easier and more accurate than with a hacksaw and chopsaw respectively. No matter whether you are cutting a specially designed part or fixing some machinery, they provide the precision needed for clean cuts. Let’s identify how to cut sheet metal, the techniques, and the tools required.

Items You Needed When Cutting Sheet Metal

During sheet metal shearing, using the right set of tools is significant to get accurate work in a shorter time lead. Here’s a list of essential materials you’ll need for this task:

• Tin snips – For making straight or curved cuts.
• Tools – Needs the tape and ruler to measure the distance properly.
• Wood clamps – Use for holding the sheet metal whilst cutting it.
• Metal cutting drill bit – Ideal when working on metal to make precise clean holes.
• Sawhorses – The best cutting tables are made from sawhorses which create a firm platform for your cutting activities.
• Pencil – Used in drawing cutting lines on a metal surface.
• Metal file – Filed down edges to make it even for cutting.
• Angle grinder – Increases efficiency while grinding and cutting surfaces.
• Armor – Refers to gloves and glasses that should be worn.

Having these materials around makes your project neat, secure, and easy to handle. All of these goods have their specific duties and purpose in providing a professional level of work.

How To Shear Sheet Metal: Typical Sheet Metal Shearing Techniques

Sheet metal operation can be defined as the various processes of shaping, punching, and profiling of the materials to the desired intricacy of shapes/holes and profiles. These methods are applicable in operations where bending, forging, and cutting of metals into structured depictions are aspired. Each mentioned technique applies specific tools and equipment to arrive at perfect results. 

Below is a detailed overview of the most common sheet metal cutting operations:

Punching:

Punching is accomplished using a press machine fitted with a punch and die where holes or shapes on sheet metal are made. It is widely used to make uniformly and frequently round-shaped holes on metal objects.

Shearing:

Shearing trims sheet metal along straight lines or angles. It divides it into smaller pieces for additional processing and assembly.

Blanking:

Blanking defines small sections to be cut and separated from the main sheet to produce the finished products right from the cutting.

Punching Variations:

• Slotting: Rectangular slots are punched into the sheet metal to fulfill the required design requirements.
• Lancing: A combination of shearing and bending involved in the fabrication of tabs and vents or louvers.
• Nibbling: The shapes are formed by successive layers of punches to create shapes that are difficult to manufacture.
• Perforation: Punched shapes on metals for specialized use always have their holes closely placed.
• Piercing:  Holes or slots are created by cutting and forming operations. They often leave extruded edges.

Notching:

Notching is a process by which material is cut from the edges/corners of a sheet intended for bending or shaping.

Trimming:

Trimming removes material beyond the desired shape and size of manufacturing components from sheet metal.

Deburring

Deburring eliminates most sharp edges and corner angles, providing safety and a uniform finish.

How To Cut Sheet Metal: 7 Effective Ways of Cutting with Power Tools

Conventional tools are efficient in bending sheet metal as desired, but power tools provide faster and more efficient solutions. Below are some highly effective tools for piercing sheet metal using power tools:

Nibbler

A nibbler is a handheld power tool. It looks like a pistol. Through its operation, specifically in thin gage steel cutting, it is quiet, fast, and does not distort the metal gage. Therefore, it can be useful for precision work.

Angle Grinder

The angle grinder employs a round disc. Generally, it rotates at high speed to slice thin and moderately thick metal sheets. Moreover, it’s light in weight. Besides, it’s relatively portable, suits a variety of materials well, and cuts through with simplicity.

Circular Saw

The Circular Saw is equipped with a carbide-tipped blade. The device is capable of cutting through metals at a rather good pace. Moreover, it provides the least drag experience and is typically designed for general metal-cutting applications.

Miter Saw

A miter saw works almost the same way as a circular saw. However, it typically comes with a swing arm for cutting angles. Push cutting is highly efficient for nonferrous metal when used with the right blade attachment.

Oscillating Saw

The Uptown Oscillating Saws with metal cutting blades are ideal where gradual, flush-type cuts are desired. They are mostly used for cutting metal fittings, bolts, and nails, among other materials, with much accuracy.

Reciprocating Saw

Reciprocating saws are comparatively inexpensive. These are optimal for cutting metals during demolition work. However, they can only develop rough surfaces and are not ideal for applications in fine cutting.

Bandsaw

Metal cutting can also be done on bandsaws. Provided that the tool has a bi-metal or carbon steel blade. Even though they are productive and function at a slower pace. These are not preferred for cutting thick metal stock since bladed parts wear out quickly.

How To Shearing Sheet Metal: 5 Easy Steps 

Let’s talk about a simple DIY hacks of sheet metal shearing:

Step 1: Collect Everything You Need for The Process and Organize Your Workspace

First, you gather all the materials that will be required for cutting like cutting tools and safety gear. Stand and erect the workplace with enough strength to bear the weight and sheet metal dimensions. A piece of plywood and sawhorse with a flat and stable surface serves the best purpose here.

Step 2: Take Measurements to Mark Your Cut

Make your cuts carefully. If possible, use a pencil, and sketch out on the sheet metal ahead of time. Employ calibration tools when drawing cutting lines on the material of choice. Then, precisely clamp the metal to mitigate marking issues.

Step 3: Begin Cutting with Tin Snips

Put on safety work corresponding to the project you are handling and place the tin snips right at the beginning of where your line is drawn. Cut this steady along a line and apply pressure on the handles as they move toward each other. 

Step 4: Drill Holes for Interior Cuts

If your sheet metal work involves creating an opening through the sheet, use a pencil to draw the opening shape in the middle of the sheet. This may involve a power drill to make an initial hole that will allow a slot to be made big enough to admit the snips. Use the snips to widen the hole along the shape marked.

Step 5: Trim the Edges To Point Them Well

Finally, after making your cuts, you should use a metal file to deburr the parts and round off their edges. Continue performing work along the edges until their condition changes to clean and safe.

Final Summary

The article provides an overview of various techniques for sheet metal shearing. Whether you prefer using hand tools or power once, it’s best to always assess your requirements. Further, choose the right cutting method that aligns best with your project requirements.