Making the Cut: Pick the Right Cutting Technology for Pipe, Tube or ...

Tubing, pipe, or profiles are extruded, sized, cooled, and processed in a continuously moving process, so it’s important to choose a cutting technology that keeps pace and is appropriate for the size of the product and characteristics of the materials that you’re cutting. This article will discuss available cutting technologies and provide some insights on how to handle typical problems associated with each.

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Fly-Knife Cutters: 

Fly-knife cutters are very popular, made to cut smaller, softer tubing and profiles quickly and cleanly, using one or more blade types in a chopping or slicing motion. The simplest fly-knife cutters employ a blade mounted on a flywheel that provides cutting inertia. Fly-knife cutters are driven by a motor that transmits rotational force through planetary reducing gears. The gears increase the torque and cutting force of the blades, while also isolating and protecting the motor and motor shaft from the shock of cutting.

Fly cutting blades work by “displacing” material, literally pushing all of the material to one side of the cut or the other, so no material is lost. When extrusions are small, thin-walled, or soft, a fly cutter blade may slice through in a single cut.

To hold the product and blade steady during cutting, bushings are positioned on either side of the cutting blade. The extruded tube, pipe or profile slides through the cutter bushings and the blade makes a straight cut between them. The space between the two bushings is adjusted relative to the thickness of the blade. Ideally, the spacing should allow for a very slight “drag” on the side of the blade when it cuts through the product. This “drag” fit prevents blades from flexing or curving under stress and keeps the fly cutter properly aligned, cut after cut.

Guillotine or Traveling Guillotine Cutters:

Similar to their name, guillotine cutters use a vertical blade to slice or chop downward through extruded products. These cutters are often seen as fitting “in between” fly-knife cutters and traveling-saw cutters (see below), where they fill a more specialized niche: cutting very soft or sticky extrusions (e.g., thermoplastic elastomers, polyurethanes) that could “gum up” rotating fly knives or saw blades. While smaller guillotine cutters can process small-diameter products very quickly, larger-diameter products may be guillotine-cut on a moving table because cuts take longer and the extruded product is continually flowing.

Saw Cutters: 

Traveling-saw cutters are used on larger pipes or extrusions that are made of relatively hard, thick, or brittle materials, such as rigid PVC. Essentially, these are large circular saws adapted for cutting plastics. To ensure straight cuts of a continuously flowing extruded product, saw cutters are often mounted on traveling tables that move at the speed of the extrusion line. The extrudate is momentarily clamped to the table so that all three elements—extrusion, saw and table—move together while the cut is made. Then the table saw retracts to make a new cut. Unlike the other cutting types, which displace extruded material to either side of the cut, saw cutters remove a narrow swath of the material, creating “sawdust” which must be collected using a vacuum system.

Planetary Cutters:

Planetary cutters make extremely high-quality cuts—square, distortion- and particle-free—on high-value rigid tubing products used in medical, high-purity, or automated-assembly applications. Closely resembling a plumber’s pipe-cutting tool, planetary cutters hold a circular cutting wheel on the inside of a rotating ring that surrounds the pipe. The ring spins around the circumference of the tubing, pressing the cutting wheel inward so that it gradually splits the tube apart without any loss of tube material. Like other cutters, planetary cutters are often mounted on moving tables so they can make square cuts on moving product.

Cutting-related problems may show themselves very clearly but defy initial efforts at problem solving, since multiple variables are often the cause.

Common Cutting Problems & Solutions

Picking the right cutting technology for your application is step one. After that you’ll likely encounter problems that require you to implement a troubleshooting strategy. Let’s take a look at common issues with each of these various cutting technologies, and what you should look for to solve them.

Fly-Knife Cutting Problems

Angel hair or fines on knife surface: When cutting softer materials such as flexible PVC, fly-knife cutters tend to pull or carry out fine pieces of material as they exit the cut. To eliminate formation of these fines in “on-demand” cutting situations, the blade may be heated when it is at its home position between cuts. A heater can be added at the blade’s home position, with temperature setpoints based on the material being cut.

Material buildup on knife surface: Cut quality begins with periodic sharpening and change to a new blade when needed. Blade life varies based on material hardness, presence of filler, and the rate of cuts/minute.

In most situations, processors can get multiple shifts out of a sharp blade. But even with a sharp blade, any buildup of material on the sides can reduce cut quality, because that buildup tends to grab and stick to the extruded product as the cut is made. Material buildup typically occurs after a few hours of cutting softer, stickier materials.

There’s no perfect solution to this problem: In some cases, it is possible to equip the cutter with a felt pad—usually wetted with alcohol—that gently wipes the cutting blade on every revolution. Another solution is to add an engineered system to spray a controlled amount of isopropyl alcohol on the blade prior to each cut. The same system can also spray nearby cutter bushings to protect against buildup and rub-off of particulates onto the finished product. Spray systems don’t eliminate the need for periodic removal and thorough cleaning of particulate from blades, bushings, cutting chambers, and drip trays; but they do reduce cleaning frequency while maintaining better cut quality.

Extrudate sticks in cutter bushings: It’s not uncommon for warm extrudate to bind or stick somewhat as it passes through steel cutter bushings. If extrudate binds significantly, it can affect the smooth operation of the line and cause cut consistency and quality problems. There are a few ways to address this problem:

1. Add lubricant: Many cutters offer optional lubricant reservoirs that use pulses of compressed air to inject small amounts of lubricating fluid into diagonal, forward-facing holes located on the top of cutter bushings. Alcohol is the most common lubricant, particularly in medical applications, though water-soluble silicone may also be used.

2. Use lined cutter bushings: Cutter bushings with inner linings or sleeves of acetal or PTFE material can ease movement of the extrudate through the bushings. Note that when such sleeves or liners are used, they must allow for clearance of 1/4 in. to ½ in. at the interior ends of the bushings, so that only clean steel edges butt against the cutting blades.

3. Try air-feed bushings: Use a controllable stream of air or lubricant that enables extrudate of a tacky material to slide easily through the cutter bushings. Use of such bushings creates a more consistent feed that allows the processor to hold much tighter length tolerances.

Material Chipping or Cracking: When fly cutting semi-rigid to rigid materials like rigid PVC or PP, you may see “breakaway” cuts—with edges that have broken, cracked, or chipped off before the cut was completed. Obviously, you’ll want to address this problem very quickly, since it’s going to cause reject parts or require secondary finishing operations. While there’s no simple answer to this problem, a couple of approaches can be successful:

1. Reduce cutter speed: There is a rule of thumb for cutting (especially fly cutting): For the cleanest cuts, cut softer materials at higher rpm and harder materials at lower rpm. So, if cutting semi-rigid or rigid extrusions results in chips or cracks, start by slowing down the rpm of the blade to reduce or eliminate the problem. Sometimes, especially with rigid PVC, using a slightly duller blade actually provides a better cut.

2. Cut extrudate at higher temperatures: Chipping or cracking can also be related to the temperature of the extruded product. Many processors get better results by cutting at higher temperatures so that the material is a bit softer and less likely to fracture. The optimum way to do this is to bring the extrudate out of the cooling process and into the cutter while it still retains some process heat, at a temperature of about 120-140 F. Using retained process heat is better than the alternative, reheating fully-cooled products, because process heat is more evenly distributed and costs nothing extra. But no matter how you warm the product, cutting extrudate that is warmer often enables the blade to travel cleanly through, free of cracks.

Traveling-Saw Cutting Problems

Burrs/uneven cuts: Burrs can result from a combination of factors, but often involve problems in blade selection or blade rpm. If your cutter has a variable-speed motor—something that is strongly recommended for top-quality cutting—try changing speeds first: Go faster for softer materials, and slower for semi-rigid or rigid materials. If your cutter has a fixed-speed motor, your immediate options are limited to changing blades. If these options don’t get you the quality and consistency you need, the ultimate solution may be to upgrade to a planetary cutter.

Cut-length tolerances: Variability in cut lengths can be caused by a couple of subtle problems, usually associated with the traveling table. Many saws, and certainly older saws, are equipped with standard pneumatically driven traveling tables that can be tricky to adjust when a precise match with extrusion line speed is required. Fluctuations in air pressure can cause less precise operation. For these reasons, many processors are opting for servo-controlled traveling tables because they provide a much higher degree of precision and repeatability in tracking extrusion line speed. Servo-controlled tables can often eliminate the need for secondary cutting or finishing operations altogether.

Variations in square: Square cuts are key to holding length tolerances and allowing assembly of parts farther on in the manufacturing process. Aesthetics in finished assemblies are dependent on cut quality. Proper product guides and clamps are what solves these types of issues.

Planetary Cutter Problems:

In general, planetary cutters are the most trouble-free type of cutter. If you can’t obtain the consistent cut quality you need with a fly-knife cutter or a saw, your solution is likely to be a planetary cutter. They provide precise, clean, and particulate-free cuts and can often eliminate the need for secondary cutting or finishing operations, so they are an excellent solution for cutting extrusions that feed into automated assembly processes.

In general, planetary cutters are the most trouble-free type of cutter.

But there are some trade-offs: planetary cutters typically cost more, take longer to make cuts, and max out at lower line speeds than other cutter types. However, where cut quality is the primary concern, many processors are glad to adjust to lower line speeds in exchange for superior cut quality and virtual elimination of secondary cutting operations.

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Guillotine cutter problems

Blade buildup and cleaning: Though the motion of a guillotine blade differs from that of a fly-knife cutting blade, the common problems are quite similar, including buildup of fines on the blade, the necessity for proper blade cleaning and lubrication, and the selection of the ideal blade for the job.

Variations in cut length and square: Like the fly-knife and traveling-saw cutters to which they are functionally related, guillotine cutters are subject to variations that affect cut lengths and the square of cuts. Generally, these are caused by inadequate or improperly adjusted product guides or clamps, or fluctuations in the movement of traveling tables.

Like many other challenges in extrusion processing, cutting-related problems may show themselves very clearly but defy initial efforts at problem solving, since multiple variables are often the cause. By breaking down the issues—first by the type of cutting technology involved, and then according to the details of the problem you’re observing— you can often see the issues clearly enough to begin solving them, or to make the case for the upgrades you need to maintain top-quality cutting operations.

About the Authors: Ernie Preiato is v.p. extrusion sales for Conair.  Contact: 631-723-; ; conairgroup.com.

Today’s pipe cutting projects, ranging from DIY plumbing to industrial manufacturing, demand specific tools based on pipe material, diameter, wall thickness, and working environment. From traditional manual tools to advanced laser systems, this guide compares eight effective pipe cutting tools to help you make an informed choice for your specific needs.

8 Best Tools for Steel Pipe Cutting

I. Steel Pipe Laser Cutting Machine

Modern laser cutting technology represents the pinnacle of precision pipe cutting solutions. These sophisticated machines utilize high-powered laser beams controlled by computer numerical systems (CNC) to deliver unmatched accuracy and efficiency in pipe cutting operations.

Advantages:

• Ultra-precise cutting with minimal material waste
• Exceptional cutting speed for high-volume production
• Ability to perform complex cuts and intricate designs
• Clean, burr-free edges requiring minimal post-processing
• Automated operation reducing labor costs
• Environmentally friendly with minimal waste generation
• Consistent quality across large production runs

Disadvantages:

• Significant initial investment required
• Requires specialized technical expertise
• Regular maintenance and calibration needed
• Large space requirements for installation

Best Applications:

• Large-scale industrial manufacturing
• Mass production facilities
• Complex pipe fabrication projects
• High-precision component manufacturing

II. Metal Cutting Bandsaw

A metal cutting bandsaw represents an essential industrial solution, offering a balance between precision and efficiency. These machines use a continuous metal band blade to cut through steel pipes.

Advantages:

• Can cut up to six tubes simultaneously
• Delivers clean, straight cuts with minimal burrs
• Suitable for projects of all sizes
• Relatively quiet operation
• No blade lubricant required
• Excellent for high-volume production

Disadvantages:

• Requires dedicated space for stationary models
• Cannot perform cuts on already-built structures
• Initial cost higher than manual tools
• Limited to straight cuts only

Best Applications:

• Production facilities
• Metal fabrication shops
• Construction material preparation
• Industrial manufacturing

III. Cold Saw

The cold saw specializes in precision cutting while keeping both blade and material cool during operation, resulting in superior cut quality.

Advantages:

• Produces clean, burr-free cuts
• Minimal heat generation during cutting
• Extended blade life due to cooling action
• Can cut multiple pipes simultaneously
• Leaves smooth finish requiring little post-processing

Disadvantages:

• Higher initial cost than conventional saws
• Requires fixed installation
• Slower cutting speed compared to alternatives
• Limited mobility

Best Applications:

• Precision metal fabrication
• High-end manufacturing
• Projects requiring exact measurements
• Professional metalworking shops

IV. Portable Bandsaw

A compact, handheld version of its larger counterpart, the portable bandsaw combines mobility with precision for on-site cutting needs.

Advantages:

• Excellent mobility and versatility
• Suitable for existing structures
• Moderate noise level
• Ergonomic design
• Effective in hard-to-reach areas
• Lightweight and easy to handle

Disadvantages:

• Can only cut one tube at a time
• May result in crooked cuts without proper support
• Limited cutting capacity
• Battery life constraints for cordless models

Best Applications:

• On-site construction work
• Maintenance and repair
• Tight space operations
• Field work

V. Reciprocating Saw

The reciprocating saw offers a powerful solution for quick cutting needs, especially in demolition or renovation scenarios.

Advantages:

• Highly portable
• Versatile cutting capabilities
• Good for tight spaces
• Quick cutting speed
• Cordless options available
• Cost-effective

Disadvantages:

• Less precise than other methods
• High vibration and noise
• Difficult to maintain straight cuts
• Frequent blade changes needed
• Not suitable for finish work

Best Applications:

• Demolition work
• Quick rough cuts
• Emergency repairs
• Renovation projects

VI. Angle Grinder

An angle grinder equipped with cutting discs provides a versatile solution for pipe cutting, particularly effective for smaller diameter pipes.

Advantages:

• Highly versatile tool
• Quick cutting speed
• Portable and easy to use
• Affordable
• Can make flush cuts
• Works in tight spaces

Disadvantages:

• Generates sparks and debris
• Less precise than dedicated pipe cutters
• Frequent disc replacement needed
• Safety concerns
• Noisy operation

Best Applications:

• Small diameter pipes
• Quick cuts
• General construction
• Home DIY projects

VII. Manual Tube Cutter

Traditional manual tube cutters offer a simple yet effective solution for precise cuts on smaller pipes, making them ideal for plumbing work.

Advantages:

• Clean, precise cuts
• No power required
• Highly portable
• Silent operation
• Minimal maintenance needed
• Very safe to use
• Cost-effective

Disadvantages:

• Labor intensive
• Limited to smaller pipe diameters
• Time-consuming for multiple cuts
• Not suitable for heavy-duty work
• Requires physical effort

Best Applications:

• Small plumbing projects
• DIY work
• Precision cutting needs
• Light commercial use
• Maintenance tasks

VIII. Hacksaw

The traditional hacksaw remains a reliable and accessible tool for basic pipe cutting needs.

Advantages:

• Very affordable
• Simple to use
• No power needed
• Highly portable
• Minimal maintenance
• Works anywhere
• No special training required

Disadvantages:

• Very labor intensive
• Slow cutting speed
• Can produce uneven cuts
• Limited to smaller pipes
• Physically demanding

Best Applications:

• Basic DIY projects
• Emergency repairs
• Small-scale work
• Budget-conscious users
• Simple cutting tasks

Comprehensive Tool Comparison

Tool Type Cutting Speed Material Compatibility Precision Cost Range* Ease of Use Mobility Noise Level Maintenance Needs Laser Cutting Machine Very High (5/5) All metals, thick & thin (5/5) Excellent (5/5) $$$$ Complex (2/5) Fixed (1/5) Low (4/5) High (1/5) Metal Cutting Bandsaw High (4/5) Most metals (4/5) Very Good (4/5) $$$ Moderate (3/5) Limited (2/5) Moderate (3/5) Moderate (3/5) Cold Saw Moderate (3/5) All metals (5/5) Very Good (4/5) $$$ Moderate (3/5) Fixed (1/5) Moderate (3/5) Moderate (3/5) Portable Bandsaw Moderate (3/5) Most metals (4/5) Good (3/5) $$ Good (4/5) Excellent (5/5) High (2/5) Moderate (3/5) Reciprocating Saw High (4/5) Most metals (3/5) Fair (2/5) $$ Very Good (4/5) Excellent (5/5) Very High (1/5) Low (4/5) Angle Grinder High (4/5) Most metals (3/5) Fair (2/5) $ Good (4/5) Very Good (4/5) Very High (1/5) Moderate (3/5) Manual Tube Cutter Low (1/5) Thin-walled only (2/5) Very Good (4/5) $ Very Good (4/5) Excellent (5/5) Silent (5/5) Low (4/5) Hacksaw Very Low (1/5) Most metals (3/5) Good (3/5) $ Very Good (4/5) Excellent (5/5) Silent (5/5) Very Low (5/5)

*Cost Range Legend:

• $ = Under $100
• $$ = $100-$500
• $$$ = $500-$5,000
• $$$$ = Over $5,000

Additional Comparison Factors:

Power Source Requirements:

• Electric (High Power): Laser Cutter, Metal Cutting Bandsaw, Cold Saw
• Electric (Standard): Portable Bandsaw, Reciprocating Saw, Angle Grinder
• Manual: Tube Cutter, Hacksaw

Best Use Case Scenarios:

• Industrial Production: Laser Cutter, Metal Cutting Bandsaw, Cold Saw
• Construction Sites: Portable Bandsaw, Reciprocating Saw, Angle Grinder
• Small Projects/DIY: Manual Tube Cutter, Hacksaw

Cut Quality Characteristics:

• Laser Cutter: Perfect edges, no burrs, heat-affected zone
• Bandsaws: Clean cuts, minimal burrs
• Cold Saw: Very clean cuts, minimal deformation
• Power Tools: Rougher cuts, may need finishing
• Manual Tools: Clean cuts but requires skill

Production Volume Capacity:

• High Volume: Laser Cutter, Metal Cutting Bandsaw
• Medium Volume: Cold Saw, Portable Bandsaw
• Low Volume: Reciprocating Saw, Angle Grinder
• Very Low Volume: Manual Tube Cutter, Hacksaw

Making the Right Choice: Key Considerations

Project Scale

• Large Industrial: Consider laser cutting machines or metal cutting bandsaws
• Medium Commercial: Cold saws or portable bandsaws are ideal
• Small Projects/DIY: Manual tube cutters or hacksaws will suffice

Budget Considerations

• High Budget: Laser cutters, cold saws
• Medium Budget: Bandsaws, power tools
• Limited Budget: Manual tools, basic power tools

Usage Frequency

• Daily Use: Invest in professional-grade power tools or industrial machines
• Occasional Use: Mid-range power tools
• Rare Use: Manual tools or basic power tools

Precision Requirements

• High Precision: Laser cutters, cold saws
• Medium Precision: Bandsaws, manual tube cutters
• Basic Precision: Reciprocating saws, angle grinders

Conclusion: Choosing the Right Steel Pipe Cutter

The ideal choice for cutting steel pipes ultimately depends on your specific needs, working environment, and budget constraints. Here’s a simplified guide for different scenarios:

For Industrial Applications:

• If precision and high volume are priorities, and budget allows, the laser cutting machine is unmatched
• For regular production needs, a metal cutting bandsaw or cold saw offers the best balance of efficiency and cost
• When working on-site, a portable bandsaw provides the necessary mobility without sacrificing too much precision

For Professional Contractors:

• Portable bandsaws and reciprocating saws offer the mobility needed for field work
• Angle grinders work well for quick cuts and tight spaces
• Manual tube cutters are excellent for precise, clean cuts in plumbing applications

For DIY and Small Projects:

• Manual tube cutters provide the best value for occasional use
• Hacksaws are perfectly adequate for basic cutting needs
• An angle grinder can be a versatile addition to your toolbox

Remember that investing in quality tools appropriate for your specific needs will save time, reduce waste, and produce better results in the long run. Consider factors such as frequency of use, required precision, mobility needs, and available budget when making your final decision.

To get the most out of your chosen tool, always follow manufacturer guidelines, maintain your equipment properly, and prioritize safety in your working environment. With the right tool and proper technique, you can achieve professional-quality cuts regardless of your chosen method.

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