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DIY roller cutter for metal drawings. How to make roller shears for cutting sheet metal with your own hands

Cutting sheet material into pieces is carried out using various instruments. Roller shears for cutting sheet metal are popular, a trend due to their simplicity of design and high performance. The device is used in industrial and small workshop environments.

Characteristics of scissors

The intended purpose of roller knives is to cut steel sheets up to 1 mm thick. They are necessary at the site for the production of ventilation ducts, when working with roofing metal, during the construction of a fence and arrangement of the roof.

The mechanism is used to produce semi-finished products for subsequent bending of profiles for various purposes. The equipment is installed in car body repair shops. In auxiliary production, blanks are prepared for the assembly of racks and cabinets.

Scissors with rollers will successfully replace manual option or guillotine due to a number of advantages:

Compact dimensions and light weight.
Simple device.
Convenient to use.
Just getting set up.
Suitable for working with sheets of different materials: aluminum, tin, steel, roofing iron.

The processed product is obtained with a clean cut and no burrs or bends. It is easy to cut sheet metal with such a device.

Scissors can be purchased at a specialized store or made independently. It all depends on the volumes performed and the economic component. With a daily cutting rate of 30–50 meters or more, an industrial design will be required.

Description of scissors

The task of dividing a sheet of metal into parts is solved by destroying the strength bonds on a local segment.

The power part consists of two cutting roller discs with multidirectional rotation. Their cutting edges lie in the same plane. When rotating, the rollers are pressed into the surface and cutting occurs due to shear deformation. The sheet metal is fed to the tool by friction of the knives against the metal.

The design of the cutting mechanism includes two rotating rollers located one above the other. Depending on the design of the cutting part, roller knives are distinguished:

With one inclined edge for straight longitudinal cutting and cutting out round and ring workpieces.
With parallel position of knives, cutting material in strips with high quality. They occur most often.
With several inclined edges for convenient cutting of curved, round and ring-shaped workpieces with a small radius.

All types of scissors provide cutting of sheet material with high quality, without the need for subsequent cleaning of the cut edge.

To improve productivity and get smooth cut the housing with roller knives is installed on a stationary machine.

The cutting equipment includes a bed with supporting surfaces, equipment for fixing the material and a roller knife. The latter contains a body of steel gauge, overhead handle, cutting rollers, mechanism for adjusting gaps in several planes.

The material for cutting discs is tool steel.

The manufacturer sets an average service life of 25 km to cut sheet metal with a thickness of 0.5 mm. With increasing thickness, the service life decreases proportionally. The cutting element is subject to regrinding, which significantly increases the active service life.

How to make a roller knife

A purchased model of roller shears, even of the simplest design, is unprofitable for purchase in a small workshop or private household. It is not necessary to use it often, and the device is expensive. The optimal solution is making scissors with your own hands.

The design of the mechanism may be different, but the basis will always be cutting knife in the form of a roller. The selected material for making knives determines the performance of the device and the quality of the cut. Knives must be strong and reliable, with a surface hardness significantly greater than the hardness of the material being cut. Otherwise, you won’t get a high-quality cut; the edges will have to be processed additionally.

Homemade roller knives are made from bearings. To do this, the ends are sharpened to create a cutting edge. The drive roller is mounted on the handle. When working with it, the knife is pressed into the workpiece. The lower roller is installed permanently. During the cutting process, you need to press the handle with the roller with one hand and pull the sheet of metal with the other.

Selecting a larger bearing diameter will increase cutting speed.

For convenience and precise cutting, additional guides are installed.

Adjustment is carried out using oval holes, a set of spacers and special bolts.

If you are proficient in metalworking techniques, manufacturing a cutting device takes 7–10 days, including setup.

To each industrial enterprise or an individual who is engaged in metalworking requires a metal cutting machine that meets specified requirements for cost, productivity and safety. Today they highlight a large number of different methods metal processing - metal processing with plasma, laser and pressure, as well as manual cutting metal with scissors. If you haven't decided yet optimal method and suitable equipment for cutting metal, our article will help you do this.

Types of metal cutting

The process of cutting metal is the separation of workpieces from cast, long or sheet metal. The most common and economically effective methods today are plasma, laser and gas cutting. Very often, metal is cut with press shears, which are capable of punching grooves and holes different forms in steel of various strengths.

When choosing one metal processing method from those listed above, it is recommended to focus on the quality of the work process itself, the amount of final waste and the accuracy of execution. An important point There is also the possibility of creating a small batch of parts in the shortest possible lines at an optimal cutting price in specialized production.

Moreover, the choice of one of them is justified taking into account certain criteria, such as work efficiency, final result, and cost of the product. At the same time, there is a certain list of metals and alloys with which it is advisable to work with one or another equipment.

Gas metal cutting

Gas cutting is a process of cutting metal products, which is based on the property of metals that are heated to a certain temperature (1200-1300 degrees) to burn in pure oxygen. Thanks to gas cutting of sheet metal, nowadays it is possible to carry out a wide variety of types of processing - preparation of edges for the welding process, straight cutting of metal, bevel cutting procedure.

The essence of technology

It is customary to start cutting from the edge of the sheet. The surface intended for cutting must be cleaned of rust, scale and dirt. Oxygen and gas are supplied to the burners from cylinders, where they are kept in a compressed state. The mass of one cylinder is 70 kg. The working pressure of oxygen per square meter is 300 kN, and that of gas reaches 50 kN.

In this case, the pressure can be adjusted in the device’s reducer, which is screwed onto the fitting of the oxygen cylinder. The reducer is equipped with a high pressure gauge, which shows the oxygen pressure in the cylinder, and is also equipped with a pressure gauge low pressure, which provides information about the operating pressure.

The metal sheet is burned and cut by a stream of oxygen, which is supplied under high pressure. The resulting iron oxides flow out in a molten state and are blown out of the cut cavity. The technology of gas cutting of metal involves the use of a cutter, which is a kind of welding torch with a special device for oxygen supply.

Types of gas cutting

This type of welding traditionally uses hydrogen (coke, petroleum and natural) and acetylene, kerosene and gasoline vapors, which can reach temperatures of 3200 degrees during the combustion process. Depending on the combustible gas used, hydrogen-oxygen, acetylene-oxygen and gasoline-oxygen cutting are distinguished, as well as machine and manual cutting.

A separate type of gas cutting is flux-oxygen cutting, which makes it possible to separate difficult-to-cut metals - chromium-nickel and high-chromium steels, aluminum alloys and cast irons. In this case, the procedure is facilitated by powdered fluxes, which are injected together with oxygen.

In addition to separation oxygen cutting, when the cutting jet is almost perpendicular to the metal surface, oxygen processing is used, during which the cutting jet is directed to the metal surface at an acute angle.

This method is used to cut sheets of carbon medium- and low-alloy steels, which have a thickness of 1 to 200-300 millimeters. In the video about gas cutting of metal, you will see that gas cutting of steel thicker than 2 meters is considered possible. Oxygen cutting is widely used in non-ferrous and ferrous metallurgy, as well as in private construction.

Requirements

To complete this process, a number of requirements must be met. Remember that the metal must have a higher melting point than the combustion temperature in oxygen. On the contrary, metal oxides must have a melting point lower than the melting point of the selected metal.

Ensure that the thermal exposure level is sufficient to ensure continuity of the cutting process. The metal being processed should not have too high thermal conductivity, otherwise thermal energy will be quickly withdrawn. According to these criteria for gas cutting, low-carbon and low-alloy steels and iron are ideal for this procedure.

Advantages of gas cutting

The main advantage of gas metal cutting is the ability to cut metal sheets that are thick - up to 200 millimeters. In this case, the cutting width is 2-2.5 millimeters. Using equipment for gas cutting of metal, you can make a vertical cut edge, which will not be hardened during the process.

One cannot help but remember economic efficiency this technology - gas cutting does not require large investments financial resources. Minimum requirements related to process maintenance. An undoubted advantage of gas welding of metal is the fact that it does not require any mechanical processing.

Plasma cutting of metal

Cutting metals using a plasma jet instead of a cutter is called plasma cutting. The plasma flow is formed as a result of blowing compressed electric arc a gas that is heated and ionized in the process - breaks up into positively and negatively charged particles. The plasma flow usually has a temperature of close to 15 thousand degrees Celsius.

Plasma cutting methods

There are surface and separation plasma cutting. However, in practice, it is the separation technology of metal cutting that has become widely used. The cutting process itself is carried out using two methods - plasma arc and jet.

When cutting metal with a plasma arc, it is included in the electrical circuit. The above-mentioned arc occurs between the workpiece and the tungsten electrode of the cutter. If you chose the second method, then remember that in the cutter an arc is formed between two electrodes. The sheet being cut is not included in the electrical circuit.

In terms of productivity, plasma cutting is superior to oxygen cutting. But if you need to cut titanium or thick metal, it is recommended to give preference to oxygen cutting. When cutting non-ferrous metals, plasma cutting is considered indispensable. This is especially true for aluminum.

Plasma cutting machines

To form plasma, it is customary to use active and inactive gases. The first group includes air and oxygen, which are used when cutting ferrous metals (copper, steel and aluminum), and inactive ones - hydrogen, argon and nitrogen for cutting alloys and non-ferrous metals (high-alloy steel, which has a thickness of up to 50 millimeters, brass, copper , aluminum and titanium).

To mechanize the procedure, metal cutting devices were developed - semi-automatic and portable machines of various modifications. Semi-automatic machines work with inactive and active gases, while portable machines use exclusively compressed air.

Metal cutting with plasma at home is carried out using hand-held devices, the set of which includes a cutting plasma torch, a manifold, a cable-hose package and a lighter designed to excite the cutting arc. Such kits allow you to perform a limited amount of work with equipment loading no more than 50%. Therefore, it is recommended to equip them with welding converters and rectifiers during operation.

The essence of technology

The beginning of the metal cutting procedure is the moment when the plasma arc is excited. Having started cutting, you should maintain a constant distance between the metal surface and the plasma torch nozzle, which is 3 - 15 millimeters.

Strive to ensure that the current is minimal during operation, because as the current increases and the air flow increases, the service life of the electrode and plasma torch nozzle decreases. But the current level should ensure high cutting performance. The most difficult operation is punching holes, since a double arc may form and the plasma torch may fail.

Remember that the tool for cutting metal when punching should rise above the surface of the part by 20 - 25 millimeters. The plasma torch is lowered into the working position after the sheet is pierced through. If you are punching holes in sheets that are thick, it is recommended to use protective screens that have holes with a diameter of 10-20 millimeters. Screens must be placed between the plasma torch and the product.

When cutting aluminum using an argon-hydrogen mixture to increase the stability of the arc, the hydrogen content should not exceed 20%. Copper cutting is usually performed using hydrogen-containing mixtures. Brass needs a nitric oxide mixture or nitrogen. After cutting, copper must be cleaned to a depth of 1-1.5 millimeters. But this requirement is not at all necessary for brass.

Laser cutting of metal

Laser cutting is a fundamentally new type of metal processing, which is characterized by extremely high accuracy and productivity. Such cutting machines have revolutionized the world of metalworking, making it possible to create complex metal structures simpler, faster and more affordable. Laser cutting is now confidently replacing other types of processing of metal workpieces and is becoming increasingly popular.

The essence of technology

Technology laser cutting Do-it-yourself metal today is one of the most progressive technologies in creating various parts from sheet materials. The procedure is good for its versatility, because it allows you to work with any materials - metallic and non-metallic origin.

The laser beam is a narrowly directed light beam of small diameter, which has high intensity. If the laser beam is aimed at metal surface or other solid object, the product will reach a high temperature. It is enough for the metal to begin to melt at the point of contact. But at the same time, areas of the surface that are adjacent to the beam remain hot, but are not damaged.

By moving the beam along the surface, you can create a very thin, high-quality line of cutting metal with perfectly thin edges, despite the thickness of the metal being processed. The area of the laser beam that hits the plane is literally calculated in square microns. But at the same time, during laser cutting, the energy density that is directed to the metal is excessively high, which causes the appearance of a heating area.

As a result, the metal melts locally, which is accompanied by the removal of molecules of the substance. Laser cutting machines are ordinary coordinate tables that are interfaced with a head, which is controlled by the machine’s microprocessor and which moves according to a given program over the surface of the sheet being processed.

Laser cutting machines for special purposes can be produced, for example, they are popular in Lately laser machines for pipes that are suitable for any profiles. In this case, you can carry out processing along the entire length of the part at once. This is enough effective method, which provides tight control of cutting geometry when using a laser machine.

Advantages of laser technology

The undoubted advantages of laser technology include:

complete absence of physical deformations and defects during operation of the machine;
the ability to operate the machine with ductile metals;
absence on the surface finished product microcracks;
precision processing accuracy of a laser machine;
high speed;
small cutting thickness;
waste-free machine;
high level of automation of the laser cutting process;
reasonable cost of metal cutting.

Using laser cutting

Working on a laser machine involves burning sheet material through a laser beam. Due to the absence of direct contact between the part and the cutting head, the equipment allows you to safely process fragile products, successfully cope with carbide material, and easily provide high-speed cutting of thin sheet steel.

The technology is also considered beneficial in situations where products are produced in small batches, because the costs of producing expensive molds for casting are eliminated. The equipment is capable of handling steel of any condition and quality; it works well with aluminum, aluminum alloys, copper, and brass.

A very significant nuance of such a technological process is the simplicity of working with flat and three-dimensional parts, as well as complex contours.

Laser cutting is one of the technologies in which the cost of a product when creating complex products almost does not depend on the size of the batch that is processed by the machine. That is why laser cutting technologies are widely used in private construction and household, while the time until the final result is obtained is minimal.

Guillotine metal cutting

For high-quality and fast cutting of metal, special sheet shears - guillotines - are used. The name of such metal-cutting machines comes from the similarity of the work of scissors with a medieval execution weapon. But today guillotine shears are used for harmless purposes.

Selecting sheet shears

The main criteria for choosing a guillotine are the type of production: piece or serial, the thickness of the metal sheet, the length of the metal slitting line and mechanical strength. Consumers, depending on their goals, can choose simple manual or electromechanical guillotines. Many models of sheet metal shears are additionally equipped with industrial electronics and options that increase metal cutting productivity.

Despite the abundance of drive types, all guillotine models have the same operating principle. To begin with, the sheet to be cut is placed on the work table along the set stops between the lower and upper knives. It is first necessary to press a sheet of metal against the guillotine table using a pressure beam. Then the upper knife moves and the metal is cut. Then you can transport finished parts from the metal cutting zone.

The precision of cutting metal sheets using guillotine shears is ensured by the sheet pressing mechanism. Cutting, as a rule, is carried out according to markings or a stop: it is customary to install precise back rulers on guillotines, which allow achieving high precision of the cutting procedure. Some models are equipped with a return tray to collect cut metal.

When choosing a specific model of scissors, you need to carefully think through the list of required functions, because the advantages of the work do not always consist in a large number of them, while the price of such a machine directly depends on this indicator. For work at home, a guillotine with a set of only the necessary functions is quite suitable; multifunctional scissors are required in large industries.

Types of guillotines

According to the principle of the device, sheet shears can be manual, pneumatic, hydraulic, mechanical, automatic, and also combine several combinations at the same time. Manual and pneumatic guillotines are among the simplest and are used for straight cutting of metal sheets.

Hydraulic shears with an electromechanical drive are easy to operate and have a high level of labor, which can be noted in the video about cutting metal. Cutting accuracy is ensured by adjusting the position of the knives. Hydraulic guillotine shears with automatic or manual adjustment of the gap that forms between the knives are extremely popular.

Using guillotine shears

Guillotines are designed for cutting metal sheets of different thicknesses in the transverse and longitudinal directions. Some types of sheet metal shears are capable of cutting round, square or corner metal. The main characteristics of guillotines, which are used for cutting metal, are the length and maximum thickness of the cut.

The use of guillotines allows you to obtain an accurate cut of the material without nicks or dents, and does not damage the equipment polymer coating and metal coloring. Depends on technical capabilities Guillotine shears are used in mass and individual production.

After reading our article, you have become familiar with the main types of sheet metal cutting. Recalling once again - guillotine, laser, plasma and gas cutting. Each of them has its own advantages and disadvantages. Remember that each type of metal cutting involves the use of special equipment and tools, which requires the consumer to have certain skills and strict adherence to safety precautions.

Sheet metal cutting can be characterized as a technological process, as a result of which metal product is divided into parts, acquiring specified shapes and sizes.

The article describes the processing of sheet metal, talks about methods of cutting metal, describes roller shears, automatic lines, etc., and also discusses special equipment for processing sheet metal (machine, cutter, etc.).

Cutting methods are divided into two main groups: mechanical and thermal.

Before choosing a specific type of cutting, you need to know the advantages of each type, the essence of the process, and in what cases a particular type of cutting is used.

The basis of mechanical cutting is cutting tool, having characteristics of strength and hardness higher than those of the metal being processed.

This processing method is also called cold. Mechanical processing includes guillotine, band saw, water jet and grinder cutting.

Cutting with scissors and grinder

To cut metal using this method, special guillotine shears are used, which can be used for thin sheet metals (profiled sheets, galvanized).

The cutting element is a knife. Guillotine shears can be mechanical, automatic, pneumatic, or hydraulic.

Manual and pneumatic guillotine shears have the most low prices of all types of equipment designed for straight cutting of metal.

However, an inexpensive tool has low productivity, so you have to put in a lot of effort.

Therefore, most often preference is given to special power tools or industrial equipment, which work much easier and faster.

An electric tool is an angle grinder (angle grinder).

This is due to the fact that abrasive wheels reduce the protective characteristics of the metal. When cutting with a grinder with your own hands, you must follow safety precautions: your eyes and hands must be closed.

The main danger when working with an angle grinder is the flying of fragments.

Effective cutting with a grinder is carried out by the heel of the disc - the near one bottom circle. The tool must be turned off every 5 minutes to avoid overheating.

If you are cutting long pipes with a grinder, you need to start from the hanging edge. Thick parts are cut straight with a grinder.

Guillotine shears work according to to the following principle: The cutting sheet is placed on the table between the knives.

The metal must be pressed against the table with a beam, and then the upper knife must be moved.

Guillotine shears provide precise cutting of metal, which is explained by the clamping mechanism. Guillotine shears are designed for longitudinal and transverse cutting of sheet metal. This slitting device is the most popular.

Another type of tool is applicable for square, round and angular metal, due to the fact that the knife is positioned at any angle. The main characteristics of the device are the length and thickness of the cut.

Guillotine shears provide an even cut without roughness; the knife does not spoil the paint and polymer coating and the characteristics of the product being processed.

There are also disc shears for longitudinal cutting, which is carried out with rotating round knives.

The lower and upper disc knives rotate in different directions at the same speed. The movement of the workpiece is ensured by friction against the knife.

Sheet metal cutting disc shears are primarily used for roofing works for longitudinal processing.

Disc shears work like this: the sheet to be processed is placed on the machine and inserted between the support and clamping rails.

Then the sheet is fixed with clamps and the disc shears move along the cutting line. When the disc shears begin to rotate, the knife cuts the product.

Disc shears are easy to use when slitting metal yourself (especially if the cutting lines are pre-marked). The knife produces precise and high-quality cutting.

This tool is intended for longitudinal cutting only. Automatic lines are quite popular.

Automatic lines consist of a feeding device, an unwinding device, a material feeding mechanism, cutting block and control panel.

Automatic slitting lines have the main advantage: there is no need to involve people, since all operations on the line are carried out under the control of one person.

Roller shears are often used. The roller knife is used for straight and shaped cutting. The roller knife is suitable for cutting round, oval, and square shapes.

Band saw cutting

For such cutting, roller shears are not suitable, but a machine with a band cutter that has teeth is used, the distance between which is selected based on the quality of the material being processed.

Cutting has excellent characteristics: high productivity, good finishing, thin cut not exceeding 2 mm.

This machine is capable of processing any alloys. One of the advantages is that cutting can be done at any angle.

The machine also has disadvantages: the inability to perform figure cutting.

Waterjet cutting is used for materials of varying hardness: concrete, stone, different types metal, etc. the basis of this method is the use of a mixture abrasive materials and water.

The machine supplies the mixture with a high pressure pump, reaching highest speed, which ensures cutting.

This method is one of the most promising; it allows thin metals to be cut without abrasive materials, only with water.

Thermal types

Thermal cutting of sheet metal is based on thermal action, after which the cut area melts and burns. The main methods are gas, plasma and laser cutting.

Gas cutting

Cutting and bending using oxygen and flammable gases has affordable prices. The method is not applicable to all materials. Can also be performed figure cutting.

The condition for high-quality cutting is the combustion temperature of the metal exceeding the melting point.

The principle of the technology is this: the surface is heated to 3000°, which depends on the metal being processed.

This temperature is achieved using a mixture of combustible gas and oxygen.

For a high-quality cut, the volume of gas supply and the speed of the cutter must be correctly adjusted.

This method is mainly used for installation work, in the production of metal structures.

The method is not without its drawbacks, which include the large width of the seams and subsequent processing.

Also, when the surface is heated unevenly, deformation and deterioration in the quality of the metal occurs.

An advantage is the ability to process products up to 20 cm thick, with a cut of 2.5 mm.

Plasma cutting

Plasma cutting of sheet metal is modern method, in which a plasma jet is used instead of a cutter.

The basis of the method is the use of gaseous substances in a high-temperature plasma state obtained under the influence of an electric arc discharge.

Cutting can be done in two ways: jet and arc. When processing with an arc, the sheet is included in the circuit, an arc is formed between the metal and the electrode. In jet machining, a cut is formed between two electrodes.

Homemade devices can act as a plasma cutter

The plasma flow occurs on a plasma torch that has an electrode that forms an electric arc.

Plasma cutting is used for cutting and bending different metals up to 20 cm thick.

Thanks to high temperature there is no thermal effect on areas located near the cut, which prevents deformation of the sheet and does not impair the characteristics of the metal.

This is especially important when working with stainless steel. Curly cutting can also be performed.

Do-it-yourself plasma cutting and bending hand-held devices, in which the start of cutting is the moment the plasma arc appears.

During the process, a distance of up to 15 mm must be maintained between the plasmatron nozzle and the metal.

Laser cutting

A laser machine for cutting and bending metal is the latest equipment. Laser cutting of sheet metal is based on the thermal energy of a narrowly focused laser beam.

The main advantages of the technology include accuracy, cleanliness of processing, and thin cuts.

The method is used for jewelry and other products that require complex shaped cutting and bending. It is advisable to use the method for metal with a thickness of no more than 15 mm.

Equipment prices are not the lowest due to the newness of the technology.

The essence of the method is as follows: a high-intensity laser beam is aimed at the metal, heating the product.

After which the surface begins to melt at the point of contact, and the adjacent areas also heat up, but do not deform or lose their characteristics. As the beam moves, it creates a thin cutting line with smooth edges.

Laser cutting tools are represented by coordinate tables interfaced with a head controlled by microprocessors.

Laser machines perfectly process fragile products and carbide materials.

Sheet metal processing is carried out different ways(roller knife, machines, cutters, etc.), from which you can choose suitable option cutting and bending with your own hands. And homemade devices can be used for bending.

Metal cutting is one of the most popular and widespread methods of processing such material. In this case, it is mandatory to use special tools that provide the ability to cut sheet metal, since it is unrealistic to do this without the use of additional devices.

Cutting technology consists in the fact that a workpiece made of a particular material is exposed to the cutting edge of a tool. The sharp cutting edge of the tool moves along the surface of the metal, cutting it. During this process, the cut layer undergoes plastic deformation.

Metal cutting at home

Sheet metal cutting

The main tools for cutting at home are cutters, discs, and drills. The use of such tools makes it possible to give the part the required shape, polish the metal surface, bringing it to the required dimensions.

When using such methods, a knife or other machine acts on the surface of the metal. In this case, it is very important that its cutter has a higher hardness than the workpiece, otherwise no cutting will occur.

The most common method of cutting metal in a home workshop is mechanical cutting. This method of processing the material is quite economical and can provide a very smooth edge to the workpiece. Its only drawback is that it usually only allows for straight-line cutting of metal.

Roller knives for metal

Very often in the modern metalworking industry, roller knives are used for cutting sheet metal. The work of such a tool consists of the work of its two main elements - cutting discs. Rotating in different directions, these roller discs are pressed into the material, cutting it. Due to the friction of the metal and the knives among themselves, the workpiece moves along the tool.

The most common are roller knives for metal, which consist of two rollers. This tool has two rotating disks - lower and upper. Nowadays there are three types of knives:

with parallel position;
with one inclined;
with several slopes.

The first group of such cutting tools is mainly intended for cutting material into strips.

The second group is intended for cutting metal into strips, as well as for round and ring workpieces.

The third group is mainly used for cutting annular, round and curved workpieces with a small radius.

All of these knives are well suited for quickly cutting sheet metal. In this case, the cut edge of the material does not require any additional processing.

Homemade roller knives

Design of a homemade roller knife

The cost of even the simplest models of roller knives is now very high. Therefore, it makes sense to purchase such a tool only if such sheet metal processing will be carried out very often. Otherwise, for one-time or periodic use, such a purchase will not justify itself from a financial point of view.

In such a case, more the right decision will try to make such an instrument with his own hands.

There can be a lot of designs of roller knives, so making a knife yourself will not be difficult. But the main part of the tool - the cutting knives - must be made of the highest quality and durable alloy, the strength of which exceeds the material being cut. Otherwise, the quality of the cut edge will be very low and additional processing will be required.

Usually, even in factory models of roller knives, the resource is within 25 km of sheet metal 0.5 millimeters thick. If you cut sheet metal with greater thickness, then the service life of the tool will decrease. But after this, the rollers can be sharpened, as a result of which the tool will be ready for use again.

As for the service life of homemade roller knives, it directly depends on the quality of the material from which the cutting parts of the machine are made.

What can knives be made from?

Roller blade made of bearings

When handmade The main problem with such a tool is to choose suitable material, which will cut metal workpieces.

So, if it is necessary to cut not the most durable sheet metal - aluminum, galvanized steel, etc., a good solution would be to use ordinary bearings, the ends of which must first be sharpened.

To cut such knives into metal, one of the rollers, the drive one, must be installed on a handle with which you can press the knives to the material. After this, all that remains is to pull the metal, holding the handle of the homemade machine pressed to the base.

The larger the diameter of the bearings, the higher the cutting speed of such a hand tool.

Thus, now you can find many designs of homemade roller cutting shears. The most difficult thing is to find parts that can be used as knives. To make it more convenient to use a do-it-yourself machine, it can be additionally equipped with guides that will allow you to cut the workpiece smoothly.

In this case, the finished tool, if necessary, can be installed on any metalworking equipment, for example, on a sheet bending machine.

Review and comparison of factory models

DIY roller knife

Cutting metal at home is a rather tedious process. And its quality often leaves much to be desired, forcing additional processing of the resulting edges. The situation can be largely corrected by using special devices, including those made by hand. We will talk about one of these devices, namely the roller knife, today.

Roller knives for metal

The roller knife is gaining more and more demand and popularity today. This is due not only to the high productivity of such a device, but also to its fairly simple design. The principle of operation of the mechanism is simple - two cutting disc rollers rotate in different directions, pressing into the surface of the metal and thus cutting it. Friction between the metal and the knives ensures unhindered movement of the workpiece along the tool.

In the vast majority of cases, roller knives for cutting sheet metal include two rotating rollers - an upper and a lower one. Depending on the variation of the cutting element used, such tools can be classified as follows:

Parallel position knives - used for cutting metal into strips, while providing very acceptable quality;
Edges with one inclined - this group allows not only longitudinal cutting of material, but also cutting out ring and round workpieces;
Knives with several inclined - such devices make it possible to effectively cut round, curved or ring-shaped workpieces with a small radius.

It is worth noting that all of the above variations cope perfectly with cutting sheet steel, while the cut edges do not require additional attention and subsequent processing.

Homemade roller knives

With all its undoubted advantages, even the most simple model A roller knife has a pretty decent price. This is the reason why it is inappropriate to purchase it for one-time work or periodic use. However, the optimal solution from a financial point of view still exists - a roller knife can be made with your own hands at home.

The design of such a device can be very different. The most common variations are presented below (photo, photo 2). But in any case, the main part remains unchanged - the cutting knife. It should be made from the most durable and reliable steel alloy, the strength parameters of which must necessarily exceed those of the material being cut. If this condition is not met, the quality of the cut will be low, which will require additional processing of the cut edges.

Practice shows that the working life of factory-made knives is about 25 km of sheet steel, provided that its thickness is 0.5 mm. With greater thickness, the resource will be correspondingly lower. However, the tool can be sharpened without any problems and continue to function effectively.

If we talk about the resource homemade knives, then it is directly dependent on the material from which the cutting parts of the unit are made.

What can a knife be made from?

The options can be very different; here you need to pay attention to what exactly you plan to cut. So, if it is not the most durable sheet steel in its structure, including aluminum, galvanized metal and other similar materials, the most ordinary bearings will be a completely suitable solution. True, for this you will have to pre-sharpen their ends.

To carry out cutting, one of the rollers, the one that will play the role of a drive, is installed on the handle, due to which the knife will be pressed to the metal. Please note that the larger the diameter of the bearings, the faster the material can be cut.

So that the cutting process takes place with maximum comfort and accuracy, the device can be additionally equipped with guides - this will not be particularly difficult, but in the future it is guaranteed to serve well.

The resulting tool is quite versatile and can be used in conjunction with a wide variety of metalworking equipment, including sheet metal bending machines, which can also be made independently at home.

homemade roller knife for metal

Roller knife. DIY metal scissors. (part 2). Review. DIY metal scissors. Do-it-yourself sheet bending machine setup. BENDER. Manual roller mini sheet bender. Operation of an eccentric manual press with a semi-automatic stamp. DIY roller knife for sheet bending. To be continued. Homemade pipe bender for 550 rub. Tricky drive. Twist it screw piles motor drill. Comparison of roller knives for Tapco and Van Mark bending machines. Editing a convex profile on grindstone. Disc shears SPPR-A 1250/1.5. Machine for sharpening scissors. Inside view. Roller sheet bender. Sorex roller knife repair | Cutting knife.

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Advantages of using roller knives

Sheet metal is cut different ways and tools. One option is to use a roller knife. The device is used in industrial or home environments. There are factory-made models on the market, but making a roller cutter for sheet metal with your own hands is a feasible task. This possibility is determined by the volume of processed material and economic expediency.

Description, principle of operation

A roller knife for metal is a device designed to separate sheet metal into two parts. The principle of operation is based on the destruction of the strength bonds of the processed material in a local area.

The force on the metal is carried out along two parallel planes. The force vectors are directed towards each other. Example: household scissors or industrial guillotine.

In roller shears, the power parts are made in the form of two disks. The internal (facing each other) cutting surfaces are in the same plane. The edges of the rollers extend (displaced) to a small distance in perpendicular to the plane. When moving (rotating), the device slides onto the metal sheet.

A sheet sandwiched between two disks experiences two forces at the point of contact. Shear deformation and separation of the material occurs. The discs, performing a translational-rotational movement, shift the point of contact in the direction of the cut. In this way, the process of continuous processing of sheet iron is carried out.

Design

According to the type of cut line created, the device is divided into:

Parallel arrangement of cutting planes. Allows you to create an even, straight cutting line. Used to produce strips of metal.
One inclined plane. Two lines are made - straight and curved.
Two inclined planes. Create curved and circular cutting lines.

The last two options are used to create shaped semi-finished metal products. The first option is the most common due to its simple design and configuration.

A roller blade is rarely used on its own. To create straight cutting lines and the ability to work with dimensional products, you must have reference points. Therefore, the cutting tool acts as a technical addition to any stationary machine. For example, a sheet bender.

A device for cutting metal consists of:

bed with guides (supporting surfaces);
fixation of the processed material;
disk knife.

The design of the roller knife includes:

body with built-in or overhead handle;
cutting discs;
adjustment device (tuning) - designed to adjust the gaps and the disks themselves along several planes.

The knife elements (except for the discs) are geometric shapes that are quite simple in shape. They are made from semi-finished steel, sheet, angle, channel or other metal profile.

The cutting element is made of durable tool steel. Factory models have a resource of 25-30 km when processing sheets 0.5 mm thick.

The adjustment system is a combination of oval holes, metal spacers and set bolts.

For a craftsman who has the skills to process metal parts, making such a device will not be difficult. Using the example of specialists who created a roller knife on their own, the time costs were within 5-10 days, including adjustment and configuration.

Advantages

A disc knife is an alternative to manual metal shears or an industrial guillotine. Compared to them and other devices, it has a number of significant consumer properties:

small dimensions and weight;
simple design;
easy setup and adjustment;
ease of use;
ability to work with a wide range of sheet materials: steel, roofing iron, aluminum, copper.

The edges of the processed semi-finished product, after exiting the machine, have a clean cut, without deformation or burrs.

Application

The main purpose of the device is to process sheet metal material with a thickness of no more than 10 mm. For example:

working with roofing iron when constructing a roof or fence;
production of semi-finished products - strips for the production of ventilation from galvanized steel;
res of stainless steel for creating countertops or cabinets for kitchen equipment.

The equipment has found application in auto repair shops for the manufacture of body or cabin elements. Factory cabinets and shelving are assembled from cut metal.

Industrial design or own design

Circular knives for cutting metal are produced industrially, but you can make them yourself. To decide whether to create a tool manually, you need to consider a number of factors:

Intensity of equipment operation. For an enterprise that produces goods in serial and medium-sized batches, it is better to purchase an industrial design. Combined with the quality of the workmanship, you will have the ability to fine-tune the instrument. An additional plus is the ergonomic design, which improves ease of use.
Required cut quality. At home, creating a device that provides accuracy of tenths of a millimeter is quite a difficult undertaking.
Economic component. An industrial product costs 20-70 thousand rubles (knife only). The real costs of making your own instrument (except for labor) rarely exceed 5 thousand rubles. Moreover, this amount includes the supporting part (machine).
Time factor. Designing and manufacturing the knife will take up to two weeks. Factory product can be purchased in one to two hours. Your own knife will cost less, but there is a proverb that came from abroad: “time is money.”

Hence, solving everyday problems or a small workshop is a tool created on your own. Intensive operation: daily cutting length is more than 20-50 meters - it is necessary to purchase industrial equipment.

Do-it-yourself manual sheet bending: video and drawing

Where do they get metal parts? various forms? The answer is that they buy them ready-made or make them themselves. Finished metal parts are much more expensive than the cost of a metal sheet, and to make them yourself, you need a special machine. You can make a sheet bending machine with your own hands, having some tools, materials and, of course, those same “golden hands” available. The videos and drawings presented in our article will also be useful to you.

Isn't it easier to buy a sheet bending machine?

The most pressing question is sheet bending machine price. The cost of factory sheet bending equipment is high. Such an expense is only advisable if you purchase such a machine to earn money, otherwise it will not pay for itself.

In addition, most of the machines of this type are designed to bend sheets up to 3 m wide. Such a unit cannot be called universal, firstly, it will not fit into any garage, and secondly, the mechanical drive is inconvenient for delicate work, and hydraulics complex and expensive. Thirdly, the energy costs for manufacturing small parts are not worth it.

The only option left is with a manual drive, which you can make yourself!

The simplest do-it-yourself sheet metal bending machine

Building a homemade manual sheet metal bender will save you money and will be a real boon whenever you need it. deal with sheet metal. Fortunately, on the Internet you can find the most different drawings with descriptions. All offered models are different, but you can find something common in the design of all variants of any sheet bending machine:

By the way, all parts do not have to be made of metal, You can also use wood. The wood is strong enough to process thin aluminum or iron sheets. Regular wood for this, of course, it is a little soft, it is better to take hard woods like oak, ash, walnut, etc. But as a last resort, pine material is also suitable for the simplest garage sheet bending machine.

As a basis take the presented drawings:

We strengthen the tree with metal corners or sheets of metal;
Where real strength is required are the hinges for the machine, with the help of which its bending link moves;
If the bending link is a decent size, then you won't even need a weight frame to apply the required pressure to the thin sheet of metal;
The crimping punch should be fixed with wing nuts, the main thing is to put washers under them;
To work with sheets of different thicknesses, you can make blanks of several punches with grooves of different thicknesses;
To bend metal sheets at 90 degrees, you need to equip a limiting surface with an inclination of about 5 degrees. Otherwise, it will be impossible to make a perfectly right angle.

Secret! To make precise bends, you need to make a notch at the intended bend location, which will direct the process in the right direction.

Do-it-yourself manual sheet bender for thick sheets

For the manufacture of parts from thin sheet metal, the simplest option made of wood and minimal metal elements. Whereas for processing thick sheets, powerful channels and angles will be needed. The design elements are the same as in the previous bending machine: base, clamp, lever and crimping ram.

Material for manual sheet bending:

Channel No. 6.5 or No. 8 is suitable for the base;
For clamping we take channel No. 5;
For the punch you need a corner No. 5 with the thickest walls;
For a lever handle, fittings with a diameter of 15 mm are suitable;
10 mm rod, sheet metal for the “cheeks”.

Although the design does not differ in principle from the first option, you cannot do without a welding machine.

Let's get started with the work:

Final processing of parts

Some people recommend simply going over the clamp with a file or, even more outlandishly, with a grinder. However, you must be aware that such processing of the clamping plane will not give ideal accuracy - acceptable The unevenness of this element is only 0.2 mm. You cannot achieve such precision with a file, and if the processing is poor, your sheets will be wavy after bending.

For home use This will still work, but if you decide to do any work professionally, then this is unacceptable. There is only one way out - give the clamp for milling, but this must be done after final assembly. When all the nuances that could appear have already appeared, then milling will really help to even everything out to a decent result.

As you can see, wonderful manual sheet metal bending machines can be made in a garage. Choose the option you need and do it yourself simple machine for thin metal l for a more serious machine made of channels and angles for working with thick sheets. Drawings with step by step description and a video master class will help you. We advise you to heat the sheets at the bending points to make the work even faster and easier.

Sheet metal is cut using different methods and tools. One option is to use a roller knife. The device is used in industrial or home environments. There are factory-made models on the market, but making a roller cutter for sheet metal with your own hands is a feasible task. This possibility is determined by the volume of processed material and economic feasibility.

The force on the metal is carried out along two parallel planes. The force vectors are directed towards each other. Example: household scissors or industrial guillotine.

In roller shears, the power parts are made in the form of two disks. The internal (facing each other) cutting surfaces are in the same plane. The edges of the rollers extend (displaced) a small distance in a perpendicular plane. When moving (rotating), the device slides onto the metal sheet.

Design

According to the type of cut line created, the device is divided into:

Parallel arrangement of cutting planes. Allows you to create an even, straight cutting line. Used to produce strips of metal.
One inclined plane. Two lines are made - straight and curved.
Two inclined planes. Create curved and circular cutting lines.

The last two options are used to create shaped semi-finished metal products. The first option is the most common due to its simple design and configuration.

Compound

A device for cutting metal consists of:

bed with guides (supporting surfaces);
fixation of the processed material;
disk knife.

The design of the roller knife includes:

body with built-in or overhead handle;
cutting discs;
adjustment device (tuning) - designed to adjust the gaps and the disks themselves along several planes.

The knife elements (except for the discs) are geometric shapes that are quite simple in shape. They are made from semi-finished steel, sheet, angle, channel or other metal profile.

The cutting element is made of durable tool steel. Factory models have a resource of 25-30 km when processing sheets 0.5 mm thick.

The adjustment system is a combination of oval holes, metal spacers and set bolts.

Advantages

A disc knife is an alternative to a manual or industrial guillotine. Compared to them and other devices, it has a number of significant consumer properties:

small overall dimensions and weight;
simple design;
easy setup and adjustment;
ease of use;
ability to work with a wide range of sheet materials: steel, roofing iron, aluminum, copper.

The edges of the processed semi-finished product, after exiting the machine, have a clean cut, without deformation or burrs.

Application

The main purpose of the device is to process sheet metal material with a thickness of no more than 10 mm. For example:

working with roofing iron when constructing a roof or fence;
production of semi-finished products - strips for the production of ventilation from galvanized steel;
cutting stainless steel to create countertops or kitchen cabinets.

The equipment has found application in auto repair shops for the manufacture of body or cabin elements. Factory cabinets and shelving are assembled from cut metal.

Industrial design or own design

Circular knives for cutting metal are produced industrially, but you can make them yourself. To decide whether to create a tool manually, you need to consider a number of factors:

Intensity of equipment operation. For an enterprise that produces goods in serial and medium-sized batches, it is better to purchase an industrial design. Combined with the quality of the workmanship, you will have the ability to fine-tune the instrument. An additional plus is the ergonomic design, which improves ease of use.
Required cut quality. At home, creating a device that provides accuracy of tenths of a millimeter is quite a difficult undertaking.
Economic component. An industrial product costs 20-70 thousand rubles (knife only). The real costs of making your own instrument (except for labor) rarely exceed 5 thousand rubles. Moreover, this amount includes the supporting part (machine).
Time factor. Designing and manufacturing the knife will take up to two weeks. A factory product is purchased in one to two hours. Your own knife will cost less, but there is a proverb that came from abroad: “time is money.”

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