How to Cut a Round Tube Correctly

How to Cut a Round Tube Correctly

Mild steel round tubes have carved a niche for themselves in diverse industries owing to their strength, malleability and cost-effectiveness. They can be manipulated into functional structures and aesthetic pieces of art with the help of several core techniques, which include cutting, welding, and shaping. Each of these fundamental processes has its own unique set of challenges that must be overcome to maximize efficiency and quality during fabrication. Cutting is one of the first and most crucial stages in transforming mild steel tube into desired shapes and structures. It is important to understand how to cut a round tube correctly, in order to minimize waste and ensure that the finished product maintains structural integrity.

A round tube cut involves the use of a rotary cutting blade that rotates around the circumference of the tube to remove material from the edge of the tubing. This method can be used on both straight and coiled tube stock and is ideal for high-production applications. The rotary cutting blade eliminates the need for a kerf, which is produced when a straight cutting blade cuts into a piece of metal. This type of tube cut produces a slightly rounded end on the tube's cut edge, which is necessary to allow it to fit over other parts of the tubing's assembly.

To perform a round tube cut, the tubing is held in place on backup rollers while the rotary cutting blade rotates around its diameter. During this process, the blade pushes away some of the tube's interior and exterior walls to the left and right of the blade, which is why it is important to cut with long strokes and avoid short, choppy strokes that may damage the tube or cause the rotary cutting blade to bend or break.

The resulting cut edge of a round tube can be rough, which should be smoothed and deburred before the tube is used in any application. This step can be done by hand with a pair of snips or a sharp blade, and it is also possible to purchase tube cutters that are designed specifically for this task. These tools will not only make the job much easier and faster, but they will also produce a smoother, more even edge than manual methods.

Another way to achieve a round tube cut is to use a band saw that is equipped with a circular cutter attachment. This machine can cut entire bundles of tubing into shorter lengths. However, a problem with this method is that the tubes may shift during bundle cutting, which can lead to out-of-square cuts. To reduce this risk, it is often helpful to tack-weld one end of the tubing before it is placed in the band saw.

A final option for producing a round tube cut is to use rotary cutting, which uses a helical blade to cut the tube from the inside out. This method can produce an extremely clean cut, but it can be difficult to control and is not suitable for all sizes of tubing. It is usually best used for tubing with a relatively thick wall thickness.