Stainless steel is naturally strong and very durable. It is widely used across many industries. However, cutting it is not always easy. Steel is hard and heat-resistant. When cutting, its high tensile strength, low conductivity, and high hardness make it challenging to cut. With traditional methods, you may not get the expected result. That’s where stainless-steel laser cutting comes in.
Traditional methods require a large setup and yet cannot offer increased precision. This results in uneven edges, warped, or distorted parts. These defective parts won’t assemble properly. Therefore, finding the best way to cut stainless steel is critical.
Recently, laser cutting stainless steel sheets has gained more popularity. It is fast and offers the highest accuracy of any other commonly used methods. Besides, it also produces less HAZ and creates smooth edges. Laser cutting typically reduces the need for post-processing or finishing.
This article explores various methods for cutting stainless steel. We compare the performance of each method based on your project needs. After reading, you will understand which method might be suitable for your project. Ultimately, the best method depends on your specific project requirements.
Understanding the Challenges of Cutting Stainless Steel
Before we learn about various steel-cutting methods, it is crucial to understand how steel behaves under different conditions.
Cutting stainless steel is trickier than cutting mild steel or aluminum. During the process, it’s tough to cut. The main reason behind it is its physical and thermal properties. Therefore, when cutting stainless steel sheets, tool selection and process control are critical.
High Material Hardness
Stainless steels are significantly more robust than most common metals. Therefore, cutting increases tool wear. The blades and punches used to cut it may dull more quickly. In addition, cutting it requires a higher cutting force. It requires higher power systems.
High Strength and Toughness
Steel also has high tensile strength, which typically resists deformation. As a result, achieving a clean cut is difficult, and the material may spring back.
Low Thermal Conductivity
Compared to other metals, steel has lower thermal conductivity, which means that heat remains in the cutting zone. It can eventually cause overheating, which may damage the metal surface.
Work Hardening Effect
Steel hardens when stressed or heated, a phenomenon known as work hardening. Each cutting pass can harden the material. It may increase the cutting resistance. This is a significant issue when cutting stainless steel sheets in multiple passes.
Heat Affected Zone
Thermal cutting, such as plasma or gas cutting, can create large HAZ areas. It often results in structural changes and reduced mechanical properties. It also affects the corrosion resistance of the metal parts. With traditional methods, controlling the HAZ during stainless steel cutting is much more challenging.
Burr Formation and Edge Quality
When you cut steel, burrs often form. Regardless of the method, some burr formation is typical. As a result, the edges become rough or uneven, potentially requiring additional deburring. It adds time and cost at the end. With traditional methods, achieving high edge quality is difficult.
Distortion and Warping
Heat and mechanical stress can also deform the material. A thin steel sheet is more prone to distortion. Due to warping, parts won’t fit perfectly during assembly. Ultimately, this can lead to scrapped or reworked parts.
Precision and Tolerance Control
In metalworking, minor errors are pretty common. Compared to other metals, steel is difficult to correct. With traditional cutting methods, maintaining the tight tolerance is challenging.
Popular Methods of Cutting Steel
You can generally cut steel in various ways. Each method differs in speed, precision, cost, and edge quality. Not all the methods may suit your project needs. The proper process depends on steel thickness, the accuracy you need, and your production volume. To find out the correct method, you should understand how each technique works.
Mechanical Cutting Methods
Most traditional SS cutting techniques are mechanical-based. These methods use physical force to separate the steel parts.
Mechanical cutting methods typically use a specialized cutting tool. It presses or moves against the steel until separation occurs. Common mechanical cutting methods include shearing, sawing, punching, and milling.
Shearing is suitable for straight cuts on the steel. It is a prevalent choice for sheet metal fabrication. In addition, it is ideal for cutting sheets into smaller sizes. With it, you can easily process thicknesses up to 8mm or 9mm. However, thicker thicknesses of 10-20mm or more are much more challenging to manage.
Sawing is widely used for cutting stainless tubes, bars, pipes, and profiles. Band saws and circular saws are the two most popular cutting devices used in workshops. In contrast, punching creates holes and simple shapes in steel sheets.
CNC milling is a much more advanced technology. It makes precise cutting and allows you to cut slots, pockets, and complex features.
Plasma Cutting Stainless Steel
Plasma cutting steel is one of the common thermal cutting processes. It uses an electric arc and ionized gas to cut through metal. It is widely used to cut steel plates and thick sheets. It’s more likely to be seen in industrial environments rather than in local workshops.
Plasma cutting typically works by sending an electric arc through a gas stream. The gas becomes ionized, forming plasma. This plasma then reaches very high temperatures. The plasma reaches a temperature high enough to melt the steel along the cutting path. To blow away the molten material, a high-speed gas flow helps.
Plasma cutting stainless steel is also widely used in metal fabrication. It is ideal for making structural parts, frames, and heavy components.
Waterjet Cutting Stainless Steel
Waterjet cutting is neither a thermal process nor a mechanical process. It uses high-pressure water mixed with abrasives to cut steel. The jet erodes the material along the path. Throughout the process, no heat is generated, eliminating thermal distortion.
Waterjet cutting is also suitable for cutting stainless steel of various thicknesses. You can create clean edges with good accuracy. However, this setup is messy and requires very high operating/labor costs.
Laser Cutting Steel
Laser cutting is a modern method for cutting stainless steel that offers the highest accuracy. In today’s world, laser cutting is replacing many traditional methods. It is fast, cost-effective, and more efficient and consistent than other technologies.
Laser cutting of SS Sheet is widely used in industrial manufacturing. However, it’s also finding its way into smaller workshops and even hobbyist projects. It is a versatile cutting method ideal for all-purpose steel thicknesses.
Laser cutting works by focusing a high-energy laser beam onto the steel surface. The intense heat melts or vaporizes the material at the cutting point. An assist gas, in this case, plays a crucial role in blowing away the molten metal out of the kerf. This results in a narrow and controlled cut. Laser cutting SS sheet allows consistent quality across complex designs and fine details.
There are different types of laser-cutting machines for steel. CO2 laser machines are typically not suitable for metal cutting. They are the more favored choice for non-metals. Fiber laser cutting machines are the most common choice for steel. It offers higher efficiency and better performance. Typical power ranges from 1kW for thin sheets to 20kW for thicker sheets. Cutting a steel sheet requires a larger work bed.
A typical laser head cannot reach these extended areas. Thus, it must be integrated into a system that follows the design path. In this case, CNC integration is a key part of stainless steel laser cutting. The laser head follows CNC-programmed paths. With laser cutting software, you can control the cutting speed, power, and gas flow.
What is the Best Way to Cut Stainless Steel?
The best way to cut stainless steel mainly depends on the quality of the final parts. Whether the part will be used in precision applications or structural parts. Therefore, selecting the best cutting method entirely depends on your project needs. You must consider the precision, speed, and edge quality.
Most modern industries rely on precision components. They often demand clean cuts and tight tolerances. Stainless steel laser cutting, in this case, meets these needs better than most alternatives. The following comparisons explain why laser technology is often the best choice for cutting stainless steel.
Laser Cutting vs Plasma Cutting
Plasma cutting uses extreme heat to melt the metal for cutting. The cut is fast but less precise. Due to intense heat, the edges create a large HAZ and produce more burrs. As a result, edges become rough and need extra finishing.
Stainless steel laser cutting offers a narrow kerf and smooth edges. You can control and localize the heat input based on the steel thickness and types.
Laser cutting SS sheet produces consistent results and offers the lowest possible distortion. With laser cutting, you can also produce clean cuts on thin sheets. However, for thicker plates or sheets (≥10mm – 20mm), you will need high-power systems, which may be costly. In this case, plasma cutting is better for thick plates.
Laser Cutting vs Waterjet Cutting
Waterjet cutting is a non-thermal process of cutting stainless steel. It creates no heat, which avoids distortion. However, there are some limitations where laser cutting shines. Waterjet cutting needs higher operational costs. Besides, its cutting speed is slower.
Laser cutting stainless steel works much faster. It works exceptionally well on thin materials. Unlike waterjet cutting, a laser cutting setup is clean and requires little labor.
Laser Cutting vs Mechanical Cutting
Mechanical cutting might be cheaper than all the methods explained. However, mechanical cutting also has some limitations, where laser cutting offers better solutions.
In mechanical cutting, cutting tools often wear quickly. Besides, burrs and edge damage are pretty common. Above all, traditional methods struggle with complex geometries.
Stainless steel laser cutting is a non-contact process. There is no tool wear or worry about complex shapes. You can automate the whole process and monitor it for quality control.
Laser Cutting vs Traditional Shearing
Traditional shearing is better suited to simple cutting, such as a straight cut. It is widely used for making sized plates from a large coil of steel. This method usually makes deformed edges.
Stainless steel laser cutting offers much greater flexibility. You can create curved lines, holes, and intricate designs, virtually any design you need. It also ensures less material stress. For custom parts and high-quality finishes, laser cutting is a better solution.
Why Laser Cutting is Better than Other Cutting Methods?
Laser technology made metalworking straightforward and reliable. Its unmatched speed, accuracy, and repeatability revolutionized industrial growth. Compared with traditional methods, laser cutting stainless steel reduces waste and requires less finishing.
Precision and Accuracy
Laser cutting works by deploying a tiny laser beam. At the focal point, the intense heat melts and removes the metals. As a result, it can provide extremely high precision. Besides, with software, you can control the laser beam’s focusing and intensity. With traditional methods, this level of control is difficult.
Clean and Burr-free Edges
Laser-cutting stainless steel also produces smooth and clean edges. With laser cutting, burr formation is typically minimal or eliminated. As a result, it reduces the need to finish tasks.
Reduced HAZ
Stainless steel laser cutting also generates a very small HAZ. However, you must ensure proper laser power intensity and speed. A slower speed often produces a large HAZ, while a faster speed may not produce a perfect cut.
Since laser cutting produces less HAZ, it limits thermal distortion. Eventually, it preserves the material properties.
High Speed and Productivity
Laser cutting the SS sheet is fast and efficient. You can achieve high cutting speeds, even for complex parts. Besides, it also reduces cycle times and increases your project productivity.
Cutting Complex Shapes
One of the most significant advantages of using laser cutting is the ability to process complex shapes. Whether you need curves, fine details, or small holes, laser cutting can cut accurately.
Automation Integration
Another significant advantage is the ability to integrate laser cutting with automation. You can use CNC controls to move the laser gun based on your design files. Besides, on the production line, you can also integrate loading, unloading, and nesting capabilities.
Summary
Cutting stainless steel requires the correct method to achieve good quality and efficiency. Each cutting technology has its own strengths and limitations. However, the best choice depends on thickness, accuracy, speed, and budget. The table below summarizes the differences among the stainless steel cutting methods discussed in this article.
| Cutting Method | Cutting Speed | Precision | Edge Quality | HAZ | Cost |
| Mechanical | Moderate | Low | Rough | None | Low |
| Shearing | Fast | Low | Deformed | None | Low |
| Plasma Cutting | Fast | Moderate | Rough | Large | Moderate |
| Waterjet Cutting | Slow | High | Smooth | None | High |
| Laser Cutting | Very Fast | Very High | Smooth | Minimal | Higher |
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