Quote:
Originally Posted by fox46
Hmm, it sure seems to have worked out well for the OP...
I reiterate- just because a tool will do the job doesn't make it the right tool!
A chop saw is NOT the right tool. Chop saws designed for structural tube are called cold saws and typically cost $1000+, have an automatic feed, and run at low RPM to prevent accidents such as the OP's photo. The capabilities of a consumer grade chop saw and aluminum end at things like window screen frames. THIS is a chop saw for structural tube ie: cold saw:
I contest anyone that states a reciprocating saw is more dangerous than a chop saw. How many people do you know have lost fingers to chop saws vs reciprocating saws??
A reciprocating saw will be challenged to make a perfectly straight cut but what are you doing that requires a perfect cut? Welding? Fill it. Anything that requires more precision than a saw cut should be rough cut and then machined.
Acceptable saws to cut structural aluminum:
-Reciprocating saw with bimetal blade
-Bandsaw (vertical) with appropriate blade and blade speed for metal
-Bandsaw (horizontal)
-Cold saw
-Hacksaw
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We use a chop saw designed for cutting Metal that has a purpose built blade for aluminum on it. How is this not the right tool?
Yes, a cold saw would be nicer, but it's still on our wish list.
The OP likely was doing something improper and/or using the wrong kind of saw/blade.
We get square cuts off our saw, it's a huge time savings not having to mill ends. I'm in the business of maximizing my students time doing cool stuff (fun machining) and minimizing the lame stuff (hey lets face 200 tubes this season because our saw can't cut straight!). Suggesting we weld nonsquare tubes and just fill the edge is really a poor approach to the manufacturing process.
All the students and mentors cleared to use our saw have been trained, and they use it safely and without issue. Fingers shouldn't be involved in the process at all. Material should be clamped.
For ~$500 we got a saw that was able to cut up to 4" solid with square edges, you'd be looking at likely $5k+ for a cold saw with such capability (which is our next move, we really want one). A horizontal band saw that can compete in speed and squareness isn't really an option either.
Many of out industry professional sponsors running small to large shops run similar saws for certain cuts as opposed to their band saws for the same reason we do.
A reciprocating saw will do the job, but that doesn't make it the right tool
