The Ultimate Guide to Cutting Copper: Best Tools for Every Job

Though cutting copper looks simple, the proper selection of tools and methods can distinguish between an immaculate cut and an unsightly one. Whether you are an experienced contractor or just starting your first DIY project, managing the peculiarities of how to cut copper is of utmost importance for precision and speed. This manual aims to teach users all the tools to cut copper pipes and tubes, from simple hand-operated tools to sophisticated powered ones. Ultimately, you will learn to distinguish between different kinds of copper work to guarantee success, regardless of how large the project is. Now, look at the essential tools and skills that will improve your craftsmanship.

What are the most effective tools for cutting copper pipe?

These tools are often suggested when a person needs to cut copper pipes:

1. Pipe Cutter – Pipe cutters are the most reliable tools for cutting copper pipes, as they can quickly and more accurately cut pipes. A pipe cutter has a cutting blade and an adjustable grip, ensuring uniform cuts.
2. Hacksaw – Hacksaws are a good substitute that can multitask. They are more mechanically robust, making them easier to cut, and can produce better results without a pipe cutter. In addition, they are also more easily obtainable.
3. Tubing Cutter – Primarily intended for copper, a tubing cutter accomplishes a quick and smooth cut by clipping the tube while turning the tool. It works perfectly for deeper but smaller-diameter pipes and provides extreme accuracy.

Out of all the tools, pipe and tubing cutters achieve the best results concerning accuracy and simplicity.

How does a tubing cutter work for copper pipes?

The tubing cutter necks the surface of the copper-end pipe by placing the copper pipe within the tool and securing it tightly. After this, the tool is rotated around the pipe while the tool’s rotating cutter is tightened further with every full rotation. The outer layer of the pipe is cut into and scored, and pressure is applied thoroughly and constantly until the material splits in a smooth and even fashion. It cuts from a particular side, ensuring the tool’s inner layer remains undamaged. These basic facts make it apparent that the design of a tubing cutter minimizes the risk of pipe deformation to a great extent and cuts with precision.

When should you use a hacksaw to cut copper pipe?

A hacksaw is the most recommended tool for cutting copper pipes in places with narrow spaces where a tubing cutter cannot be used. With hacksaws, copper piping of any size can be carved without special attachments. These tools are helpful for demolition or repair work in tight spaces or for already installed pipes in difficult-to-reach areas.

When using a hacksaw, angle cuts must first be done with excellent straps, ensuring that the toothed hacksaw blade does not draw in the pipe, making deformities. Using blades with 24 to 32 teeth is the best recommendation when using saws for piping. Blades like these ensure the edges are smooth and pipes do not take deformations. The hacksaw method is indeed more labor-intensive than a tubing cutter but is extremely useful when expecting high-precision cuts and lacking other means. Without proper attaching cutting tools, hacksaws are incredibly reliable for pipes that need specific dimensions due to their design. For safe installation, pipes must always be deburred after cutting, severely increasing the risk of a hacksaw if proper care is not taken.

Are power tools suitable for cutting copper pipes?

Power tools such as rotary tools, reciprocating saws, or angle grinders can perform the task well when cutting copper pipes, especially when the work needs to be done quickly and accurately. These tools are especially useful for bigger jobs where manual cutting would take too long. One benefit from them is the ability to get clean, smooth, and accurate cuts that significantly make edge preparation and post-cutting deburring unnecessary when cutting brass.

A study notes that rotary pipe cutters driven by cordless drills enable accurate cuts and minimal vibrations that help preserve the pipe’s form. In addition, reciprocating saws with metal cutting blades can cut copper pipes of different thicknesses and diameters, making them versatile. Industry specialists recommend using a blade dedicated to metal because it is more efficient than standard blades and increases the lifespan of the tool and the blade.

Safety measures must be prioritized even though power tools offer the most convenience. When pipes are cut with tools or power saws, dismembered parts can become airborne. Experts recommend wearing goggles and gloves. The operator must also securely clamp the pipes to keep the cut accurate. In the long run, power tools are considered user-friendly and reliable, so they are worth the investment for professional installers and contractors.

How do you choose the right tool for cutting sheet copper?

What are the benefits of using tin snips for thin copper sheets?

Due to their great affordability and ease of usage, tin snips are one of the most commonly used tools for cutting copper sheets. Thin sheets of copper can be easily cut with hand-operated shears suitable for cutting soft metals like copper snips. This tool provides users with clean cuts that do not harm the material. People can find all sorts of different tin snips – straight-cut, left-cut, and right-cut – so one device can be used to accomplish a various range of purposes so long as cutting lines and curvature shapes are needed.

Furthermore, about other benefits, a critical advantage of tin snips is the ability to reduce material waste. The gradual profile of the blades means that thin or jagged edges are less likely to be a problem. Hence, this quality has important implications for industries striving for material efficiency. Lastly, tin snips are incredibly lightweight and can be carried around easily, which is a huge benefit for people on job sites where heavy machinery would be challenging to move. Recent industry data suggests that copper sheets which are 24 gauge (0.5 mm) thick are ideal for cutting with tin snip, hence proving suitable for softer materials.

Nonetheless, it is essential to choose the appropriate type of tin snip for the work task at hand. Straight-cut snips are best for straight cuts, while left or right-cut snips are better for circular or more complex shapes. Tin snips are economical tools for working with thin copper sheets. When maintained and sharpened regularly, they can last a long time and work well, thus appealing to professionals and do-it-yourselfers.

When should you opt for an electric shear to cut copper sheets?

Electric shear-cutting machines are the go-to tool for significant projects where detail and pace are necessary simultaneously. Such tools are specifically built to be more aggressive than manual tin snips because they can manipulate heavier volumes of material. Electric shears easily cut through the material without any deformation when cutting copper sheets over 24 gauge (0.5 mm). They are highly beneficial in volume production as well as mass construction works.

Electric shears are known for giving a very clean and precise cut due to their power, allowing no distortion on the cut surface. This is essential in systems where copper sheets are used for ducts in HVAC or with bespoke metalwork craftsmen. Getting the same quality cut with manual tools would require a great amount of energy and lead to operator fatigue. With electric shears, the user is less fatigued, and there is a boost in work performance.

The latest innovations in electric shear design have improved their efficiency and range, providing a new alternative for making precision cuts on copper. For example, many new models are made more user-friendly, with features such as precise speed controls and interchangeable blades, allowing for greater use across different projects. According to industry reports, materials as thick as 18 gauge or 1.2 mm can be cut with electric shears, making them much simpler to use when dealing with heavy copper sheets or needing multiple cuts.

When looking for electric shears, professionals need to think about the electric shears they need and the scale of the project. While some of these tools might be costly initially, the long-term benefits can outweigh the initial costs with better performance and reduced labor.

How effective are rotary tools for intricate copper sheet cutting?

When applied to intricate designs, copper sheet cutting is best accomplished by rotary tools because of their adaptability and accuracy. Such tools can be implemented with cutting wheels and carbide engraving bits designed for metals, allowing users to delicately cut sheets as thin as 24 gauge thick (0.5 mm) of copper. Moreover, many rotary tools come with the added benefit of variable speed features, which increases the operator’s control over the entire operation by tailoring the tool’s performance to the sheet’s dimensions and cutting complexity.

Rotary tools are also exceptional when a detailed cut needs to be achieved, where clean, accurate cuts with little to no material distortion are expected. Research suggests that tools fitted with high-speed steel and diamond-coated bits tend to perform best on copper, as they experience less wear, increasing lifespan. However, for the user to achieve the desired results, working in a more controlled environment as opposed to open space will be needed, with proper safety standards in place, such as stabilizers that will lessen the movement of the copper sheet and protective eye gear. While these tools are highly dependable for accuracy-based projects, other tools, such as electric shears, would be better suited for large-scale areas or thicker sheets.

What are the best tools for cutting thick copper pieces?

How does an angle grinder perform when cutting thick copper?

Equipped with the right cutting disc, an angle grinder can easily slice thick copper pieces. Shearing copper is better accomplished with a diamond blade, as these are designed to have both durability and high levels of precision. The effectiveness of an angle grinder depends on the power rating of the tool, as well as the size of the copper sheet or pipe. An angle grinder with a motor power of 7 to 10 amps and a 4.5 to 7-inch disc diameter is well suited for thicker copper materials.

Optimum speed varies from anywhere between 8000 to 12000 revolutions per minute, but the exact value depends on the specifications of the cutting disc. The user must maintain smooth and even motion to ensure no overheating of the copper takes place, and that smooth and clean cuts are produced. Pausing regularly or using a coolant can effectively lower the temperature of the alloy being cut. This helps ensure the material does not suffer thermal damage.

It is critical to observe safety measures whenever angle grinders are being used – especially in a metal shop. Dust and metal shavings can harm the operator’s health; therefore, protective gear such as gloves, a face shield, and goggles is paramount. Also, the copper piece must be secured in a clamp while cutting it with an angle grinder to avoid injury and ensure an accurate cut. To conclude, although the angle grinder can save time for shops that cut thick copper pipes, proper precautions must be taken during the operation of the tool for proper safety, especially with high-speed cutting actions.

Is a reciprocating saw (Sawzall) a good option for thick copper?

The reciprocating saw, or Sawzall, is a good option for cutting thick copper as long as the right blade and cutting technique are used. Various types of saws are made to cut a range of materials, including metals, and these tools are extremely useful. It is advisable to employ a blade designed specifically for these jobs, such as a bi-metal blade or one intended for non-ferrous metals like copper. When using a blade for thicker copper, teeth per inch (TPI) settings of 10-18 are recommended.

The reciprocating saw works through denser materials quicker than traditional saws, making it more efficient. However, the workpiece must be securely fastened to a strong clamp, as the back-and-forth motion is very quick for the saw to be effective. Also, the speed of the blade can create vibrations, which can lead to rougher cuts or create hazards in a work environment. That said, if one carefully adjusts the speed and limits the movement to avoid overheating the blade, it will last longer.

Reciprocating saws offer great versatility and good cutting power, but their effectiveness is sometimes undermined by how aggressive they can be. As a result, rough edges are common, signifying that finishing by sanding or filing will be necessary after cutting. Still, with the right blades and stabilization methods, a reciprocating saw becomes a very efficient tool for cutting through large copper pieces. It is easier than precision blades and cutting techniques would allow.

What role do carbide-tipped blades play in cutting thick copper?

Here is a rewrite of the following text: Carbide-tipped blades are useful while cutting thick copper since they are durable and can be used for extended periods without losing sharpness. In my opinion, they effectively deal with cutting copper materials while ensuring that the cuts are accurate and that the standard wear and tear is managed less.

How can copper be cut without deforming or damaging the material?

What techniques help prevent burrs when cutting copper?

In the cutting operation of the copper workpieces, burr management involves the use of proper technique, tools, and work parameters which allows one to make cuts with virtually no burr formation. As an example, the choice of tool blade is very important. Copper is best cut using carbide-tipped HSS blades or saw blades with fine teeth because the slow feeding rate with these blades results in very little heat production and burr formation. Furthermore, slower cutting speeds reduce excessive heat build-up, which is exponentially higher when cutting softer materials such as copper.

In addition, the setup also includes the appropriate clamping and holding of the copper workpiece. The material must be fixed in place to limit vibration and movement while being cut, which helps manage the burrs as well as improve the uniformity of the edges. Furthermore, high-quality cutting oils and lubricants specially designed for softer metals reduce friction and heat and improve the cutting quality.

Improvements such as light deburring are also important to remove small imperfections present after cutting. Techniques such as polishing and thorough sanding using sandpaper ensure that the edges are smoothened to the desired level. It is proven through studies that proper selection of cutting tools with lower speeds, as well as post-processing treatments, aid in the reduction of burrs and preserving the copper workpiece. This incorporation of techniques helps specialists deliver high-quality work while minimizing damage and reducing rework.

How can you ensure clean cuts on thin copper sheets?

To achieve neat cuts on thin copper sheets, use appropriate cutting tools made explicitly for metalwork, like precision shears and tungsten carbide-tipped blades. These techniques will require the sheet to be held down during the cutting process so that it does not shift and pull through at a small and even pace so as not to tear. Furthermore, lubricating the tool’s edge can assist in lowering friction, which can lead to even better results. Finally, washing or lightly sanding the edges to remove excess material will ensure a smooth final look.

What are the best practices for cutting small copper pieces?

The recommended practices during the cutting of small copper pieces include the following:

1. Picking the Appropriate Tool: It is best to work with jeweler’s saws, metal snips, and precision cutters designed for copper work. These tools give better control and provide cleaner cuts.
2. Consider Securement of the Material: The copper piece should be firmly clamped onto a sturdy surface so it does not move while cutting, which is also a safety measure.
3. Perform with Moderate Tempo: The cuts should be made with controlled and steady movement to maintain precision and prevent material deformation.
4. Polishing the Skirts: After cutting, examine the edges. If any are sharp or uneven, use a fine file or sandpaper to smooth them.

If these practices are followed, refining and cutting small copper pieces safely and precisely is possible.

Which power tools are most versatile for various copper-cutting tasks?

How does a Dremel tool perform for detailed copper-cutting work?

A Dremel tool is perfect for copper-cutting delicate details in a workpiece thanks to its accuracy and adaptability. Given the right cutting wheel, it can provide smooth, precision cuts that are great for delicate artistry or minor changes. The tool is handheld, compact, and has variable speeds, making it easier to work while still carving without breaking the material. Attachments to the tool must be carefully selected, and safety measures must be followed to achieve the best outcome with minimum risk of danger.

What advantages does an oscillating multi-tool offer for cutting copper?

Using an oscillating multi-tool can be a great advantage when cutting copper. Thus, it can be helpful for professionals as well as do-it-yourself enthusiasts. Below are some of the positives highlighted in detail.

Having these tools in a metal shop increases the methods by which one can cut the copper, thus increasing the options in a project.

Multi-tools serve various purposes nowadays because most tools come with multiple blades and attachments. This makes cutting through copper pipes, sheets, or even fittings much easier. Such tools find plumbing, electrical works, and even custom fabrication applications.

Precision Cutting

Due to their small size and oscillating cutting action, these tools can provide great precision within spaces that more significant tools may prove ineffective.

Minimal Heat Generation

Unlike other cutting tools, oscillating multi-tools generate minimal heat during operation. This means there are fewer chances of warping or damaging the copper material while cutting. This is particularly important for aesthetics and applications that must balance structural requirements.

Accessibility in Confined Spaces

Because of its small size and the way it can fit into tight corners, the oscillating multi-tool is handy when working with copper installations inside walls, ceilings, or any other confined place.

Reduced Debris

Compared to more abrasive cutting tools, the oscillating method generates significantly fewer sparks and material splinters, contributing to a cleaner and safer working environment.

Variable Speed Options

With oscillating multi-tools, it is possible to achieve optimal control according to the thickness and type of copper material, as these tools come with adjustable speed options.

The durability of blades can be crucial due to the toughness of materials such as copper or brass.

Long-term operating costs are reduced due to minimal replacements needed, as the blades used for copper cutting are usually designed with durability in mind, extending their lifespan.

User-Friendly Operation

The ergonomic design of the tools ensures that user fatigue is reduced during prolonged use and also allows for smooth, steady, and accurate handling.

Oscillating multi-tools are ideal for a range of projects involving copper materials. They enable the user to enjoy improved versatility, precision, ease of use, and, most importantly, reliability for professional-grade cutting when dealing with brass and copper materials.

Is a jigsaw a good all-around tool for cutting different copper forms?

A jigsaw can be a useful power tool for cutting copper elements. However, its efficiency depends on several criteria, including the thickness of the copper and the type of jigsaw blade used. The jigsaw’s configuration enables it to be fitted with the necessary blades for the intricate cuts and curves that are characteristically complex. Thus, a blade finer for metal with minimum teeth is preferred for best results, as it reduces wear and tear and makes the edge smoother.

That said, there are places where using a jigsaw as a tool for cutting copper has limitations. The tool easily cuts through thin copper sheets without putting in much effort; however, the same is not applicable for thicker copper pipes or bars, as it would require much more effort from the jigsaw motor and might lead to significant wear on the jigsaw blade, thus deteriorating its performance. However, jigsaws are known to vibrate while in use, and while this is a valuable feature, it can be detrimental as the jigsaw clamps the material.

Recent developments in the control of jigsaw technology, such as incorporating variable speed settings and anti-vibration features, have enabled those tools to be reliably used even for metal cutting. In addition, industry data suggests that using specialized blades made of high-grade metal can increase the tool’s life and cutting effectiveness in harsh operations. Nevertheless, where the accuracy of the cut is critical or when recurrently different types of copper profiles need to be machined, it is reasonable to expect using more dedicated tools like a metal bandsaw or a rotary cutter, which are more durable and reliable in severe conditions.

What safety precautions should be taken when cutting copper?

What personal protective equipment is essential for copper cutting?

When cutting copper, one must take personal precautions to avert accidents and harmful exposure.  Below is the recommended personal protective equipment (PPE):

Safety Glasses or Goggles

Copper cutting produces fine particles and shards that can severely damage the eyes. For proper eye safety, goggles or safety glasses that meet the standard specifications of ANSI Z87.1 are advised.

Cut-Resistant Gloves 

When dealing with sharp edges of copper or utilizing cutting implements, durable gloves must be worn to avert cuts and abrasion while operating in a metal shop environment. EN 388 qualified cut-resistant gloves, particularly level 4 or 5-rated gloves, provide the best hand protection.

Respiratory Protection

Using power tools to cut copper may produce loose particles and release fumes, particularly during overheating scenarios. To discourage the inhalation of these dangerous fumes or dust, it is advisable to wear respirator masks with minimal N95 protection.

Hearing Protection 

Power tools like grinders or jigsaws may produce noise levels higher than 85 decibels, which, considering prolonged exposure, may impede hearing. In high-noise environments, earplugs/muffs with a noise reduction rating of 25 dB or more are necessary.

Protective Clothing 

When cutting, skin can be injured by sparks and flying debris, which can be avoided with long-sleeved, flame-resistant clothing made with fabrics like Nomex and treated cotton. Such materials provide ample protection from burns and overexposure.

Steel-Toed Boots

The risk of foot injury when dropping heavy tools or copper sheets is elevated in a metal shop. Standard steel-toe boots and slip-resistant shoes dramatically reduce this risk.

Once proper PPE is put to use, workplace safety risks improve over 60%. Sticking to the essential safety measures will protect the worker and increase efficiency and confidence when handling and cutting copper.

How can you minimize copper dust exposure during cutting?

Reducing copper dust exposure when cutting copper is necessary for air quality and workers’ occupational health. Control measures of airborne particulates can be combined in one method, which is more effective:

Local Exhaust Ventilation (LEV)

Cutting dust is captured at the source due to the installation and use of an LEV system closely located near the cutting zone. The LEV system is outfitted with HEPA filters that provide clean air circulation by filtering out 99.97% of small particulates classified as 0.3 microns or larger.

Wet Cutting Techniques

Opting for wet cutting rather than dry cutting will minimize dust production and significantly lower airborne levels. Introducing water or cooling fluid can lower dust by more than 90%, helping significantly reduce inhalation risks.

Respiratory Protective Equipment (RPE)

Dust breathing protection must be employed when working in areas where dust cannot be removed entirely. NIOSH-approved N95 or higher respirators are recommended, as they strongly filter fine dust particles. More robust dust exposure scenarios may require powered air-purifying respirators (PAPRs).

Routine Cleaning Methods

Keeping the workspace clean routinely prevents dust from freely circulating. Dry sweeping should be discontinued, and higher-efficiency vacuum systems must be employed, as they help prevent particles from being resuspended.

Workplace Monitoring and Training

The air pumped by the workplace is monitored periodically to check if dust has exceeded the permissible exposure limits (PELs) set by OSHA and compliance monitoring. Moreover, training of the workforce on the possible control of dust has proved to be helpful.

With these practices being best incorporated into the operations, the industries can mitigate the health effects of copper dust and adhere to acceptable limits. These preventive measures benefit not only the workers but also the environment by ensuring the efficacy of the production area.

What are the best practices for handling sharp copper edges after cutting?

1. Wearing suitable Personal Protective Equipment (PPE) is essential: Use correctly selected cut-resistant gloves and safety glasses to cover the hands and eyes while dealing with sharp edges.
2. Deburring Edges: Always try to use a deburring tool or smooth it out by sanding paper immediately after cutting to minimize the chances of getting hurt.
3. Employ proper Handling Methods: Ensure that cut pieces of copper are firmly gripped. Do not drag your hands along the edges of the pieces to avoid cuts.
4. Store securely: Ensure that the cut edges of copper pieces face downwards to the storage area so that the sharp edges do not come in contact with the rest of the things in the storage.
5. Facilitate Training: All employees who work with Copper should be thoroughly acquainted with safe working techniques and the significance of tools and PPE.

These methods can minimize these types of workplace injuries or the use of fitted edges with sharpened copper.

Frequently Asked Questions (FAQs)

Q: Which tools are best for cutting copper sheet metal?

A: The thickness of the sheet varies according to the best tools used to cut copper sheet metal. You should use either tin snips or aviation shears for the thinner sheets. On the other hand, thicker sheets can be easily cut using a jigsaw fitted with a metal cutting blade or a circular saw with a carbide-tipped blade. You are responsible for protecting yourself before visiting the workshop by wearing safety goggles and proper metalworking safety gear.

Q: What is the best approach for cutting a copper pipe?

A: The pipe cutter is the most accurate option for cutting a copper pipe since it produces a straight and smooth cut while keeping the pipe round. However, if you are dealing with pipes of a larger thickness, more robust tools are needed, such as a bigger pipe cutter or even a hacksaw with fine blades. Remember that all cutting edges should be deburred to ensure correct fitting.

Q: Can I cut copper with a hacksaw?

A: You can use a hacksaw to cut copper, especially for pipes or larger slabs. When cutting softer copper pieces, select a saw with finer teeth—approximately 32-toothed hacksaw blades tend to do the job smoothly. Use a clamp or a vice to firmly hold the copper piece before sawing while exerting constant, moderate force throughout the sawing process. It’s advisable to first draw the cut line before proceeding with the saw for better accuracy, using a ruler as a guide.

Q: What would be the best cut for thinner sheets of copper?

A: The most effective tools for thinner sheets of copper remain Aviation shears or tin snips. These scissor-shaped tools allow for precise cuts and can endure strict guidelines. Heavy-duty scissors can also be used for greater ease with substantial sheets. A straight-edge guide paired with a sharp utility blade can also work effectively to achieve very long, pristine, exact cuts.

Q: What should I look for when selecting a metal cutting blade for power tools?

A: Opt for blades that are purpose-built for non-ferrous metals like copper. Tools like circular saws and jigsaws require specially crafted metal cutting blades. Carbide-tipped blades are more effective as they provide clean cuts and have extended usability. – circular saw blades should have a minimum of 60-80 teeth, while jigsaw blades should have 21-24 teeth per inch for best results. The quantity of teeth on the blade, along with its material and type, will influence the cutting efficiency and overall performance of the tool.

Q: Are there any power tools meant for cutting copper?

A: Although there aren’t too many tools explicitly made for copper cutting, various power tools are great. For example, Milwaukee and a few other brands manufacture circular and reciprocating saws made explicitly for cutting metals, and copper works perfectly for these. A nibbler drill attachment can be helpful for sheet metal applications, as well. Most of these tools are used by plumbers and electricians with copper fittings.

Q: How do you avoid the distortion of copper when cutting it into sheets?

A: To avoid the distortion of copper while cutting it into sheets, you must utilize sharp tools to support the sheet correctly. If you’re using power tools, set them to high speed to lower the heat produced. Apply them with hand tools, and ensure the sheet is firmly clamped. You can use a lubricant or coolant for thicker sheets to minimize heat. Additionally, avoid distortion and leaving a rough edge that can be filed or sanded close to the sheet’s desired end size and shape.

Q: Which safety measures should I observe while cutting copper?

A: To adjust copper, wearing protective spectacles to shield the eyes from flying metal pieces is advisable. Put on gloves to protect the hands from any cuts. If using a power tool, ear defenders are necessary. Since copper cutting generates a lot of dust, good ventilation should be maintained. Try to use clamps or a vice to firmly hold the workpiece in place so it does not move out of position. While working with power tools, ensure adherence to the rules laid by the manufacturer. Also, avoiding loose garments while operating power tools that can rip them apart is recommended.

Reference Sources

1. Wear Behavior of Uncoated and Coated Tools In AMPCO (Cu-Be) Alloy Milling Operations

• Authors: V. Sousa et al.
• Date of Publication: August 23, 2021
• Journal: Applied Sciences
• Citation: (Sousa et al., 2021)

Summary:

• This study focuses on the performance of tools, both uncoated and coated, during the milling of AMPCO (Cu-Be) alloy, which is known for its superior mechanical properties and ability to withstand wear.

Findings:

• Coated tools proved to perform superiorly in abrasive processes compared to uncontrolled tools during longer cutting lengths.
• The study found that wear mechanisms were distinct in controlled and uncontrolled tools, with controlled tools sustaining fewer adhesive separate damages.

Methodology:

• Various machining experiments were conducted, and diverse feed rates and cutting lengths were used. The surface roughness of the machined part was measured, and the cutting force values were saved. After the experiment, the wear modes were studied.

2. Oxidation-enhanced wear behavior of WC-FeAl cutting tools in dry machining of oxygen-free copper bars

• Authors: Furushima R et al.
• Date of Publication: 15 March 2017.
• Journal: Wear.
• Citation: (Furushima et al., 2017, pp. 104 – 112)

Summary:

• The research explores the oxidation behavior on the wear rate of WC-FeAl cutting tools during the dry machining of oxygen-free copper bars.

Key Findings:

• The findings indicated that oxidation enhanced wear under certain conditions, ultimately increasing the cutting tools’ wear rate.
• It follows that tool material selection is crucial for improved dry machining work performance.

Methodology:

• The authors undertook several cutting tests, measuring the wear rates and examining the wear mechanisms using microscopical techniques.

3. A Comparative Assessment of the Performance of TiN, TiCN, and AlTiN Coated Carbide Tools during Dry Micro-Milling of Items Made of Aluminium, Copper, And Brass At Stlow Spindle Speeds.

• Authors: M. Jahan et al. (et al. so cite others when needed)
• Published on: 22nd March 2018
• Journal: International Journal of Machining and Machinability of Materials
• Citation: (Jahan et al., 2018, p. 141)

Summary:

• This study analyzes, through a comparative lens, how effective dry micro-milling of copper, aluminum, and brass with carbide tools is based on their specific coatings (TiN, TiCN, and AlTiN).

Key Findings:

• Across all materials, including copper, where tools were used, TiN-coated tools had the lowest wear rate and the highest-quality surface finish.
• The study proved that the choice of coating plays a considerable role in the tool’s effectiveness in micro-milling processes.

Methodology:

• In this research, several dry micro-milling tests were conducted at low spindle speeds, and several metrics, including surface finish and tool wear, were collected and analyzed.

4.  Leading Copper CNC Machining Service Provider  in China