Hole cutting in steel Help

[SBW]

Hi I am posting on behalf of a friend; he would like to cut holes of diameter 50mm in a sheet of steel of approx 3mm thickness. As the holes are to accommodate test meters in a standard instrument panel I doubt if it will be constructed from hard steel so neatness and ease of process will be the order of the day. Any advice will be gratefully appreciated.
Thank you
Barry

 

[wingcoax]

it depends on how many holes. If not many then use a good quality hole saw. If a lot it may pay to get a hydraulic punch.

 

[Lectrician]

I agree.

Sterratt holesaw and some lube, on a slowish speed with a firm pressure. Use a decent drill that does not slug up when you apply pressure.

 

[bernardgreen]

Hole pundh and die is the easiest option for clean swarf free cutting. ( A pilot hole is needed and that will produce swarf. )

http://uk.rs-online.com/web/p/punch-die-combinations/0543787/ is specified for 1.6 mm steel but with care will probably cut thick.


Or google for one that is designed to cut 3 mm.
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[ericmark]

Hole punch or rota broach will cut clean precise holes but a saw type hole cutter will often cut holes larger than the cutter should with a gland they are near enough but for a meter I would go for a 48mm cutter and finish with a file as often only one mm land on a meter and it would be so easy for the hole to end up too big.

 

[streetlighter]

At ELEX last week i picked up a set of holesaws made by armeg specially designed for drilling sheet steel like trunking and enclosures. they have a hex shank and can be used with an impact driver and a smaller pillot drill and finer teeth than normal whole saws also a rim to stop them going in further than about 10mm.
I have a set 16,20,25,32mm im not sure what sizes they will go upto

 

[Mursal]

As above, or a series of 3mm/6mm holes just on the waste side of the line. Break the waste piece out and round file to finish. The bezel edge on the gauge will cover any discrepancies.

"A friend", likely story .............

 

[stillp]

Hole pundh and die is the easiest option for clean swarf free cutting. ( A pilot hole is needed and that will produce swarf. )

http://uk.rs-online.com/web/p/punch-die-combinations/0543787/ is specified for 1.6 mm steel but with care will probably cut thick.


Or google for one that is designed to cut 3 mm.
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If it would cut 3 mm steel Bernard, they'd say so! I suggest hiring a hydraulic hole punch if there are several holes to be cut, otherwise stitch drill and file smooth, as mursal suggested.

 

[flyingsparks]

SBW I have PM you with details of a local business who can laser cut this for you. Give them a try for a quote. That's going to be the easiest and nearest solution.

 

[JohnW2]

If it would cut 3 mm steel Bernard, they'd say so!

IME, they're rarely that modest - they'd probably say that it could cut through 4 or 5mm

Kind Regards, John

 

[bernardgreen]

IME, they're rarely that modest - they'd probably say that it could cut through 4 or 5mm

I guess they will specify a thickness that can be cut through several times before the tool blunts out. It was a Q-Max cutter that managed a couple of holes in metal thicker than the specified maximum before it blunted out.

 

[JohnW2]

I guess they will specify a thickness that can be cut through several times before the tool blunts out.

Yes,if theyare reputable/ressponsible manufactorers. Others may quote the thickness it will cut through once, and never be usable again!

It was a Q-Max cutter that managed a couple of holes in metal thicker than the specified maximum before it blunted out.

I may be wrong, but I have a feeling that it was Q-Max ones I used to use back in the 60s for cutting (countless) holes for valveholders and panel meters. They were only ever used on aluminium or soft alloys, but, nearly 50 years on, some of them are still working fine!

Kind Regards, John

 

[SBW]

Thank you to all of the above posters, for the quality replies, a virtual wealth of information
I have passed the replies over to my friend so he can evaluate them.
Thank you
Barry