Guide to cutting aluminum with a circular saw
Most types of aluminum offer excellent workability and weldability, making the material suitable for a wide range of applications. The most suitable way to cut this material is still with a band saw, but aluminum can also be cut with a circular saw—you just need to choose the right one. However, when a circular saw is your only option for cutting aluminum, follow these steps for safe cutting.
Choosing the right blade for cutting aluminum
Standard carbide-tipped wood-cutting blades can still work for aluminum, but they require additional precautions. The tips are more likely to grab the aluminum or break. Almost all major manufacturers of metal-cutting circular saw blades produce blades specifically designed for cutting non-ferrous materials, so simply choose the right blade for its purpose.
When comparing options, look at the number of teeth on the blade. Thicker material requires fewer teeth, while more teeth allow smoother cuts on thinner aluminum. Therefore, use a circular saw blade with more teeth for thin aluminum sheets, and a blade with fewer teeth for thicker material.
Lubricate the blade for extra protection
The biggest risk when cutting aluminum with a circular saw is the blade grabbing the material. If the blade gets stuck, there is a risk of injury. Regardless of blade type, lubricate the blade to prevent material from sticking and reduce binding. Lubrication also protects the blade and prevents overheating, reducing the risk of broken teeth.
The easiest way to lubricate a circular saw blade is with blade wax. Wax contains specially designed compounds for smoother and faster cuts. Simply rub it onto the teeth of the blade. You can also use WD-40, but you may need to apply it more often. Compared to wax, WD-40 does not keep the blade lubricated for as long.
Always secure the material and wear proper protection
After selecting the right blade and lubricating it, you must secure the aluminum. When cutting, a crosscut saw clamps the material, while a circular saw can pull it. Use multiple clamps to secure the material.
At least two industrial C-clamps are sufficient. Look for strong cast-iron clamps to firmly hold aluminum sheets or plates. Do not wear gloves when working with a circular saw, as the blade can catch the glove.
In addition to gloves, avoid loose clothing and remove jewelry and rings. You do not want anything getting caught in the blade. However, you must wear eye protection.
When cutting metal, including very thin aluminum, always wear safety goggles or a face shield. Masks and shields also help prevent inhaling debris during cutting. Although lubrication helps protect blades from overheating and breaking, accidents can still happen.
Summary
Cutting aluminum with a circular saw requires several specific steps. Make sure you have the right blade. Carbide blades can work, but they are more likely to grab the material. If possible, buy a blade specifically designed for cutting aluminum and other non-ferrous materials.
Always lubricate the blade, even if it is designed for aluminum cutting. Secure the material to the workbench before cutting. Also wear a face shield. With these precautions, you should have no problems cutting aluminum with a circular saw.
