Can You Cut Aluminum With Wood Blade?

Cut aluminum with wood blade. When it comes to working with materials, there are many options. Always utilize the proper tools made for the specific job. It’s one of the reasons that so many people reject using a wood knife on aluminum, which is a much stronger metal than wood. However, if you take the appropriate measures, it is certainly possible to utilize a wood blade.

Wood Blade On Aluminum

assorted axe and knives

The teeth on the blade are the most important factor. The smoother the cut, the more teeth (higher TPI), which is determined by the number of teeth on the blade. Lower TPI blades have larger teeth and deep gullets. These will grab the aluminum channels‘ edges and draw the workpiece towards the blade.

When cutting into aluminum that is less than 1/16 inch thick, you will want to use a blade with more than 10 teeth per inch in diameter. If you have a 12-inch miter saw, for example, use a 120-toothed blade.

  • 10 (TPI) x 12 (blade diameter in inches) = 120

Many businesses, in fact, make such wood blades with a lot of teeth, up to 200, solely for that purpose.

If the aluminum is thicker, such as 1/8th inch, you will need a blade with 10 teeth per diameter inch. The number of teeth is reduced to only 8 per diameter inch for 1/4th-inch thickness aluminum. For aluminum that is thicker than a quarter-inch, the limit is 6 teeth per inch.

Cutting Aluminum With A Circular Saw

turned-on circular saw

Selecting A Blade For Aluminium Cutting 

Woodworking blades with carbide tips function effectively, although they need special handling. The points are more prone to grab onto aluminum or break off. Almost all major blade manufacturers produce blades specifically for cutting non-ferrous materials. In reality, most businesses have distinct grades of carbide expressly made for cutting aluminum alloy.

Look at the tooth count of the blades when comparing alternatives. The thickness of the material requires fewer teeth, but more teeth are required to produce smooth cuts on thinner aluminum. Use a blade with more than 10 teeth per diameter inch if the metal is less than 1/16th-inch thick. Several firms make blades with 200 teeth specifically for cutting extremely thin aluminum.

For cutting material up to 1/8 inch thick, a 10-inch x 100 tooth or 12-inch x 120 tooth blade with ten teeth per inch is ideal. For materials up to one-fourth inches thick, use 8 teeth per inch. Use a blade with only 6 teeth per dia inch for heavier aluminum sheets.

Lubricate The Blade For Increased Protection

Aluminum is a very soft material and can be cut with a circular saw without too much difficulty. The greatest hazard of utilizing a circular saw to cut aluminum is that the blade will catch on the material. You risk harm if the blade catches on the substance. People have lost digits as a result of this problem. To keep the blade from gumming up with debris or getting caught on the material, use lubrication. The lubrication also protects the blade from overheating, reducing the chance of chipped tips.

A wax stick is the most convenient method to apply lubrication. These sticks contain compounds that aid in the creation of smoother, faster cuts. The blade’s teeth are simply brushed with the substance. WD-40 can also be used to keep blades lubricated. However, at times you might require to apply the oil a number of times. In comparison to saw wax blade sticks, WD-40 does not keep the blade lubricated for as long.

Always Clamp The Material And Wear Protection

You will need to tighten the aluminum after selecting the proper blade and lubrication. The material is clamped down by a miter saw as you cut, while a circular saw can pull. Use several clamps to keep the material safe. 

At least two solid C-clamps should be sufficient. Heavy-duty cast iron clamps are preferable for a good grip on aluminum sheets or plates. When working with a circular saw, do not use gloves. The guide rail’s blade may snag the glove if you are wearing one.

Gloves aren’t required, but avoid wearing loose-fitting clothes and removing jewelry and rings. You don’t want anything to get caught in the blade. Wearing eye protection is a must, though.

Cutting Aluminum With A Miter Saw

Yes, a miter saw may be used to cut aluminum. Although there are many devices that can be utilized to cut aluminum, a Miter Saw is excellent if not the best tool for cutting aluminum. It has a design that allows you to clamp the metal and make precise cuts with the handle that holds the spinning blade due to its efficiency. As a result, while using a miter saw, you may safely and efficiently cut aluminum.

Miter saws can cut various materials, including aluminum. In fact, you may even chop steel and other metals with a miter saw. However, certain factors must be considered before you begin cutting metal, such as the amount of metal you wish to remove and the job’s requirements. You’ll also need to think about the type of blades you’re using. So, which blades do you require?

Select The Right Blade

To begin, you must first check to see if the blades you want to install have the correct tooth count. Also, discover the aluminum’s thickness. A 200-tooth HSS blade is ideal for cutting extremely thin aluminum.

Mount The Blades

To replace the blade, you must first remove the old one. Remove the old blade and replace it with a new one using the blade guard open.

Clamp The Aluminum

The first step is to secure the metal in such a manner that it does not move about significantly, as this may cause the blade to grab the material and harm it completely. So make sure your aluminum material, bar, or other metal piece is securely clamped, and ensure you always wear safety goggles when cutting.

Cut The Aluminum With The Miter Saw

After you have double-checked everything, move on to the cutting procedure.

To cut with the miter saw, align the workpiece and the blades in accordance with the planned cut or measure marks. Typically, one hand is kept on the aluminum. The handle of the miter saw is lowered with the other hand until it coincides and cuts the material.

Use a lubricant to make the cutting go more smoothly when you begin. Cut the large items into medium ones, then fine them based on the project needs.

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