Set-up cutting

equipment
Cutting Equipment
• In Shielded Metal Arc Welding (SMAW), cutting equipment is used for
tasks such as preparing materials for welding, trimming excess welds,
and separating pieces. The cutting equipment ensures that the
workpieces fit correctly and are prepared to receive the welds. Here
the different cutting equipment used in smaw.
A hacksaw is a fine-toothed saw, originally and
mainly made for cutting metal. The equivalent saw for cutting
wood is usually called a bow saw. Typical full-size hacksaw
frame, with 12" blade. Most hacksaws are hand saws with a C-
shaped walking frame that holds a blade under tension.
Hacksaw design and function

• Handle: Most hacksaw handles

are pistol type, as seen in Figure
2, or straight type.
• Frame: Frames can be adjustable
to fit different blade lengths or
fixed to fit only one blade length.
• Blade: The blade tightly fixes to
the frame, making it strong
enough to cut through metal.
Setting up a cutting hacksaw in conformity with occupational health and safety
standards involves a series of steps to ensure the safety of the operator and the
proper functioning of the tool. Here's a detailed guide to achieve this:

1. Pre-Operation Safety Checks:

•Inspect the Hacksaw:
• Ensure the hacksaw frame is in good condition (no cracks or damage).
• Check that the saw blade is properly secured and tightly fitted.
• Ensure the blade is not worn out or damaged. If damaged, replace it with a new one.
•Wear Appropriate PPE (Personal Protective Equipment):
• Safety glasses or face shield to protect from flying debris.
• Work gloves to protect hands from sharp edges.
• Hearing protection (if needed, especially when cutting metal).
• Dust mask (if cutting materials that may generate fine particles).
• Sturdy footwear to protect feet from falling objects.
•Work Area Safety:
• Ensure the work area is well-lit and free of clutter.
• The workbench should be stable and free from hazards.
• Secure the material to be cut using clamps or a vice. Ensure that it is steady and does not move during
cutting.
• 2. Proper Blade Installation:
• Correct Blade Tension:
• Ensure that the hacksaw blade is properly tensioned, not too tight to avoid
breakage or too loose to cause poor cutting performance.
• Proper Blade Orientation:
• The teeth of the hacksaw blade should point away from the handle (towards
the cutting edge) for efficient cutting.
• Blade Type and Size:
• Use the appropriate type of blade for the material being cut (e.g., a fine-
toothed blade for metal, a coarse-toothed blade for wood).
2.Oxygen-Acetylene Torch
In oxy-fuel cutting, a torch is used to heat metal to its
kindling temperature. A stream of oxygen is then trained
on the metal, burning it into a metal oxide ..
Oxygen-Acetylene Torch Parts:
Torch Body: The main structure that
houses the various components and
directs the flow of gases.
Gas Valves: These control the flow of
oxygen and acetylene gases.
Torch Tip: The nozzle through which the
gases are mixed and directed to produce
a flame.
Adjusting Screws: Allow fine control of
the gas flow.
Trigger Mechanism: Initiates the flow of
gases when pressed.
Function: Oxygen-Acetylene Torch is primarily used for
cutting metals by creating a high-temperature flame. The
mixture of oxygen and acetylene burns at a high
temperature to melt and cut through the metal.
Setting Up the Torch:
-Position the Cylinders:
• Place the oxygen cylinder on the right side and the acetylene cylinder
on the left side (as per standard safety protocols).
• Ensure the cylinders are placed upright and secured properly to
prevent them from tipping over.
• Use a cylinder cart or secure straps to keep the cylinders stable.
-Connecting the Hoses:
•Oxygen Hose: Connect the oxygen hose (usually green) to the oxygen regulator,
ensuring a tight fit to prevent leaks.
•Acetylene Hose: Connect the acetylene hose (usually red) to the acetylene
regulator, again ensuring a secure fit.
•Tighten the connections with the appropriate wrenches, but do not overtighten,
as this can damage the fittings.
 Angle Grinder
An angle grinder, also known
as a side grinder or disc grinder,
is a handheld power tool used
for grinding (abrasive cutting)
and polishing.
3. Angle Grinder
Parts:
• Motor: Powers the grinder to rotate
the disc at high speeds.
• Grinding Disc or Cut-off Wheel: The
abrasive disc or wheel that does the
cutting or grinding.
• Guard: Protects the user from flying
debris.
• Handle: Provides a grip for
controlling the tool.
• Switch: Turns the tool on and off.
Function:
Angle Grinder is used for cutting, grinding, and polishing
metal. In SMAW, it is often used to remove excess
material, bevel edges, or smooth out welds.
Safe Operation of the Angle Grinder
• Grip the Grinder Properly: Always use both hands when operating the
grinder—one hand on the main handle and the other on the auxiliary
handle.
• Maintain Control: Ensure you have a firm grip and stable footing before
turning on the grinder. Stand in a position that allows you to maintain
control at all times.
• Use Proper Body Position: Stand to the side of the grinder to avoid direct
contact with sparks or debris. Keep your body and face away from the
cutting line.
• Let the Tool Reach Full Speed: Allow the grinder to reach its maximum
speed before contacting the material.
• Apply Moderate Pressure: Do not force the grinder. Apply just enough
pressure to keep the tool cutting or grinding efficiently. Excess pressure can
cause the grinder to overheat or kickback.
• Monitor the Work Area: Always be aware of surroundings to ensure no
one is in the direct line of sparks or debris.
Post-Use Safety
• Turn Off the Grinder: Once the work is completed, turn off the
grinder and wait for the disc to come to a complete stop before
setting the tool down.
• Disconnect Power Source: If using an electric grinder, disconnect it
from the power supply when not in use. For cordless grinders,
remove the battery.
• Clean Up: Remove metal dust, debris, and any other waste created
during the process. Dispose of the waste properly.
• Store the Grinder Safely: When finished, store the grinder in a safe
place, out of the reach of unauthorized users or children.
Chop Saw (Metal Cut-off
Saw
Function:
The Chop Saw is used to
cut metal pieces to size
before starting the
welding process. It uses
a rotating blade to make
straight cuts through
metal.
4.Chop Saw (Metal Cut-off Saw
Parts:
• Motor: Powers the circular blade.
• Circular Blade: The sharp metal-cutting
blade used for cutting through thick
materials.
• Blade Guard: Provides safety by covering
the blade.
• Base: Holds the material being cut in
place.
6. Perform Safety Checks Before Cutting
• Check Blade Rotation: Ensure that the blade is rotating in the correct direction
(follow the arrows on the saw).
• Ensure No Obstructions: Make sure that there are no loose items or tools near
the saw.
• Test the Saw: Run the saw briefly without cutting to ensure it's functioning
properly and there are no unusual sounds or vibrations.

7. Operating the Saw Safely

• Turn On the Saw: Turn the saw on and allow it to reach full speed before starting
the cut.
• Keep Hands Clear: Keep your hands and other body parts away from the cutting
area and moving blade at all times. Use a push stick or other tool to guide the
material if necessary.
• Slow, Steady Pressure: Apply slow, steady pressure to guide the material into the
blade. Avoid forcing the material through the saw.
• Monitor the Work Area: Stay alert and aware of the cutting operation. Never
leave the saw running unattended.