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Cutting disks

F

fuse

Sapling
Joined
Sep 4, 2025
Messages
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Location
Herefordshire UK
Name
Martin
LOCATION
Uk
I have a batch of 1" mild steel angle iron which is a problem cutting
It's nothing special but my chopsaw is struggling
IMG_20260428_112104467.jpgIMG_20260428_112037870.jpg
The disk is fine for one cut but burns and deflects on the next
I have some 1" box section within the same project and this cuts beautifully - it also appears to dress the disk so it can make another cut on the angle iron. This is the type I am using-any suggestion for an alternative?IMG_20260428_112212323.jpg
 
That is a bit odd. What is the lump on the horizontal leg of the angle? Are you cutting off a weld?
It's over 20 years since I was metalworking. Most of the brands we used I don't see on google. I do see Norton at Toolstation and they used to be good.
 
Yes its a weld but it does this on virgin sections too
It goes through the vertical better then finds the horizontal a problem.
Further force on the disk causes big deflection - too scary.
Ive tried a Erbaur and Norton
The material is from a couple of old road signs that a crew threw into my ditch a few years ago.I cleaned them up - surely they cant be some special alloy steel???
I find it odd too that the box section stuff is obviously softer but will temporarily restore the disk
I can use this as a workaround but Id like to get to the bottom of this.
I was wondering about the grade - the Axxxx number?
 
My guess is a low grade stainless steel. Try a light cut with maybe some wd40 sprayed on or get a stainless cutting disc. The flat has more heat build up and work hardens may be what is happening.
 
If it's mild steel, an ordinary hacksaw with a new blade will go through that stuff like a knife through beurre - Rob
 
Forty eight 10° cuts on the angle iron plus 24 on the box section
Lifes too short Rob😕
Its a partial repeat of the project I did a couple of years ago and invested in the chopsaw.
 
Ive since done a bit more cutting - I think its the scale from the mill.
Ive drilled the components now and had a similar experience with the drill bits
The box section doesnt have the scale and theres no issues putting holes through but the angle is resistant until you break though the skin,then its fine.
 
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Just a thought Martin... with you saying the blade goes through the vertical fine...

Could you try placing the pieces so your not laying any 'flat' part on the saw bed? So it's like a triangle? Poor description, 😞. Wide section sides resting on the bed and the fence...?

If possible, you'd not be trying to cut through the wide flat section... Sorry...
 
Yeah ,thanks Frank,I did try try that but the clamp jaw isnt a particularly precise design and the pieces jam under it doing when doing that so youre never sure of how secure it is and with a 12" disc deflecting its too scary even for a loony like me.
Also I needed the ends cut at 10° ( top photo)which that method interfered with.
I know what the issue is now so I have my ' dressing ' workaround for this material.
 
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Thanks for the update on what your having to cut it to - the "leg" bit - Martin.

I meant to add that clamping the metal would probably be an issue and a jig of some design would need to be made... safety and all.

Would be interested to hear how you resolve this with the workaround 🙏
 
I just cut through a scrap of the box section material after every two cuts of the angle iron.
It apparently 'dressed' the disc and exposed fresh grit.

That scale could be used on armour plate😉
 
When I get angle iron and structural steel flat bar (which both come with a similar thickness of mill scale), I tend to "just" remove all the mill scale before doing anything else with it. That's partly because I'm typically TIG welding them (so need a clean finish) but it also has the advantage of saving drill bits etc.

You can make life a lot easier by soaking them in citric acid for a while, but a thorough going over with one of these abrasive wheels or a coarse flap disc is usually necessary even after soaking (but much quicker and easier post acid). That's all a bit of a chore though so I can understand not wanting to do it.
 
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