Cut to Length machine recommendation
Close
Login to Your Account
Results 1 to 12 of 12
  1. #1
    Join Date
    May 2015
    Country
    UNITED STATES
    State/Province
    North Carolina
    Posts
    72
    Post Thanks / Like
    Likes (Given)
    6
    Likes (Received)
    12

    Default Cut to Length machine recommendation

    I need a recommendation for a machine to cut High-Carbon Steel to length. The profiles are rectangular (.125" x 1" or smaller). Hardness is in the 40's, Rockwell C. Precision must be +/-.001". Ballpark estimate for cut time is 20 seconds.

    I can use search engines just fine, but I was wondering if anyone had any actual experience with various machines that might help us make a decision. I'm not limiting this to a particular type or brand - it could be a traditional cutoff grinding wheel, a circular saw, a CNC grinder, a Wire EDM, you name it. We need something that can run day and night for years and still work in the long run.

    Any recommendations would be much appreciated.

  2. #2
    Join Date
    Aug 2004
    Country
    UNITED STATES
    State/Province
    Virginia
    Posts
    2,973
    Post Thanks / Like
    Likes (Given)
    247
    Likes (Received)
    1400

    Default

    Cold saw in my opinion.

  3. #3
    Join Date
    May 2010
    Location
    Cambridge, MA
    Posts
    1,871
    Post Thanks / Like
    Likes (Given)
    83
    Likes (Received)
    1093

    Default

    For small cross section area like that, use a shear. It will make an instantaneous clean cut with no scorching of the material.

    For round rod, you can just buy a Diacro. For rectangular bar maybe use something like the Edwards Multishear. This thing is awesome, for only $1600 you can shear up to 1/4" x 6" bar stock and it has dies to do angles too.

    Multi Shear | Edwards Manufacturing

  4. #4
    Join Date
    May 2015
    Country
    UNITED STATES
    State/Province
    North Carolina
    Posts
    72
    Post Thanks / Like
    Likes (Given)
    6
    Likes (Received)
    12

    Default

    We do use a shear. But then we have to precision grind the ends. If this is the only option I'm all for it, but if there's a way to get the cut precise within tolerance the first time, I'd prefer that.

  5. #5
    Join Date
    Aug 2009
    Location
    Oakland, CA
    Posts
    424
    Post Thanks / Like
    Likes (Given)
    0
    Likes (Received)
    215

    Default

    If you need clean burr free ends you will be best served by an ECM (electrochemical cutoff machine). They're sort of half way between EDM and a saw. Electrochemical Grinding (ECG)

  6. #6
    Join Date
    Oct 2021
    Country
    UNITED STATES
    State/Province
    Ohio
    Posts
    27
    Post Thanks / Like
    Likes (Given)
    9
    Likes (Received)
    9

    Default

    I don't know much about different types of machines, but I'm an EDM operator, and EDM is so convenient. With one macro program you could cut an entire bar of steel, just set and forget for a couple minutes. Only thing is it leaves a slightly burned finish, unsure how much the aesthetic matters for what you do with the steel. The finish is easily polished with a hone stone, but then there's that added time factor.

  7. Likes petersen liked this post
  8. #7
    Join Date
    May 2015
    Country
    UNITED STATES
    State/Province
    North Carolina
    Posts
    72
    Post Thanks / Like
    Likes (Given)
    6
    Likes (Received)
    12

    Default

    TKassoc, ECM looks very interesting. I haven't heard of that before. Thanks for the tip.

    Ishira, the burned finish does matter. I think that would be a deal breaker. Do all EDM's leave this burn, or could we avoid it by getting a more expensive machine?

  9. #8
    Join Date
    Oct 2021
    Country
    UNITED STATES
    State/Province
    Ohio
    Posts
    27
    Post Thanks / Like
    Likes (Given)
    9
    Likes (Received)
    9

    Default

    All EDMs.. should..(?) leave the burn finish, due to the nature of the cut, however a second pass over the material has cleaned it up in my own experience, and just takes a couple extra seconds to do. I can figure out how to post images on here a bit later today, and send you what steel looks like EDM'd with a second cleanup pass. I have a piece on hand I just did the other day. Looks pretty nice, I think.

  10. #9
    Join Date
    May 2015
    Country
    UNITED STATES
    State/Province
    North Carolina
    Posts
    72
    Post Thanks / Like
    Likes (Given)
    6
    Likes (Received)
    12

    Default

    That would be helpful, thank you.

  11. #10
    Join Date
    Nov 2014
    Country
    UNITED STATES
    State/Province
    Florida
    Posts
    6,380
    Post Thanks / Like
    Likes (Given)
    2552
    Likes (Received)
    3158

    Default

    Quote Originally Posted by Ishira View Post
    All EDMs.. should..(?) leave the burn finish, due to the nature of the cut, however a second pass over the material has cleaned it up in my own experience, and just takes a couple extra seconds to do. I can figure out how to post images on here a bit later today, and send you what steel looks like EDM'd with a second cleanup pass. I have a piece on hand I just did the other day. Looks pretty nice, I think.
    Should be important to note... Depending on machine, the Charmilles had special finishing passes for a *polished* finish.

    * entirely dependent on what you are looking for, but as Ishira noted, a finish pass will leave a pretty nice finish regardless, just a light touch with a fine stone will take that even further.

  12. Likes Ishira liked this post
  13. #11
    Join Date
    Oct 2021
    Country
    UNITED STATES
    State/Province
    Ohio
    Posts
    27
    Post Thanks / Like
    Likes (Given)
    9
    Likes (Received)
    9

    Default

    Quote Originally Posted by Mike1974 View Post
    Should be important to note... Depending on machine, the Charmilles had special finishing passes for a *polished* finish.

    * entirely dependent on what you are looking for, but as Ishira noted, a finish pass will leave a pretty nice finish regardless, just a light touch with a fine stone will take that even further.
    ^
    Definitely look into the different brands and speak with some applications engineers if EDM is the route you choose. There's a couple major manufacturers and each one is competitively different! We use Fanuc in our shop, so that is the machine type I know best, and I could tell you nothing about the others and their nuances, haha.

  14. #12
    Join Date
    Jun 2012
    Country
    UNITED STATES
    State/Province
    Michigan
    Posts
    14,391
    Post Thanks / Like
    Likes (Given)
    4902
    Likes (Received)
    5204

    Default

    traditional cutoff grinding wheel would likely leave a bug at the exit..and the wheel is likely to lose width, to grow the part length.


Tags for this Thread

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •