Pendulum saws: features of choice, tips for self-assembly

Pendulum saw DeWALT DW872

professional tool
For bevel cutting, the machine stop is rotated at an angle of 45°, adjustment is made using a scale. On the working handle there is a disk start button. For safety, the saw is covered with a casing that opens as it approaches the workpiece. A special reflector will protect against sparks. For convenience, the machine is equipped with a soft start system, this avoids sudden voltage surges and protects the mechanism from shock loads. Which extends the service life of the tool.

Peculiarities:

Constant cutting depth without burrs.
Equipped with a 70 tooth titanium disc.
The working unit can be secured in the lower position.
The frame is made of steel.
Dust protection.
End angle up to 50°.

Options:

Engine - 2200 W.
The cutting width is 100 mm.
Revolutions (per minute) - 1300.
Cutting depth - 100 mm.
Disc - 355 mm.
Weight - 23 kg.
Dimensions - 525x430x280 mm.
Price - 56,700 rub.

Design features of the cutting machine

In order for the machine to serve for many years, it must be made of reliable materials. It is better to make metal structural elements from steel alloys, which are particularly hard. In this case, the operation of the finished equipment will be smooth and stable.

It is better to make the platform from heavy, rigid material - a lot here determines the subsequent position of the machine (whether it will be mobile or stationary).

To ensure reliable fastening of the workpiece, you can mount a more complex structure by including a vice as an element.

The disk may have an abrasive surface if it is intended to process the edges of the metal from burrs formed during cutting. This disc is convenient for processing chamfers.

What is this?

Miter saws "bison" zpt
The saw performs reciprocating movements during operation. The saber works exactly the same way.

A cutting pendulum electric saw is a fairly compact machine in size, where the cutting tool is a disk and is mounted vertically on a special pendulum.

The size of the device may vary depending on the model and power. The pendulum provides the ability to raise and lower the cutting blade when working on metal or wood.

The assortment is extensive, which allows the buyer to choose such popular saws as Makita, Zubr, PM 400, etc.

Device Features

Drawing of a typical saw device

Circular and pendulum saws have approximately the same principle of operation;
The main difference between the devices is that with a disk cutting tool and the motor are fixed motionless, while with a pendulum device they rise and fall due to the pendulum;
The cutting pendulum installation provides a high-precision cut at a right angle;
Additionally, tools such as PM 400, PM 55, Interskol, Zubr, Makita, KD 300, PM 70 and other representatives of the pendulum saw segment are capable of cutting at an angle;
Often, a cutting system for cutting wood or metal includes an abrasive disc;
The use of appropriate disks allows you to work efficiently. To process a particular product, you simply need to replace the blade;
The blade can also be universal, allowing you to cut all kinds of workpieces with one disc;
A modern cutting pendulum electric saw for cutting workpieces is distinguished by the fact that the cutting blade and disk can be replaced in the shortest possible time. This is what distinguishes the leaders of the segment in the person of PM 70, PM 55, KD 300, Zubr, Makita, Interskol, PM 400, etc.;
Each cutting tool must be equipped with protection systems. This is because the rotating cutting blade is potentially dangerous;
By choosing the desired size of the device, you can cut workpieces at home;
Manufacturers offer both household and industrial models.

Despite its fairly significant advantages, the pendulum cutting saw has several disadvantages.

For sawing, you have to apply significant force, as when using a grinder.
A cutting saw has certain restrictions on the width of the material being cut.
The device is not very productive, so it is often used as an auxiliary equipment in factories or home workshops.

The estimated price of devices for home use is from 12 to 40 thousand rubles.

How it works

To cut materials, you need to know exactly how a pendulum-type electric saw functions.

A pendulum saw can safely be called a circular saw. Here the circular machine is installed on a special frame;
The machine operates from the mains;
Factory models can be equipped with special turntables, due to which the device is used as a miter box. This function cannot be called necessary, but sometimes its relevance is in demand;
The electric cutting saw received its name due to the fact that the cutting blade is lowered by hand along a pendulum path onto the workpiece, and when the cutting is finished, it rises to its original position;
Depending on what blade is used, the size and power of the device, a factory-made or home-made electric saw can cut metal, wood, tiles, porcelain, plastic, glass, etc.;
Cutting discs are used to cut metal. They can be borrowed from an angle grinder;
If it is wood, a circular blade is used.

Peculiarities

The device is a design based on a special rotating disk. Using the device you can cut wood, steel, ceramic and other surfaces. Also very often, installers use it during concrete work with the foundation, for cutting reinforcing bars, in the manufacture of porcelain stoneware or when working with solid bricks. Such a tool is popular only on construction sites or in production, since at home there is no need to cut large materials in large quantities. The device should be used very carefully, and before starting work it must be properly configured, otherwise even an experienced operator may be injured.

Cutting machines are used for industrial purposes when it is necessary to quickly and efficiently cut reinforcing bars or boards. The tool for professional work has a large cutter diameter that can cope with cutting a huge number of objects.

Manufacturing companies also present on the market small-sized versions of the device, created specifically for domestic use. There are several stages of protection for operator safety. The main component of the device is the stationary base of the machine - this ensures perfect threading. The frame has a closed body - this guarantees protection of the worker’s hands from cutters and waste flying in all directions.

It is worth noting such important elements of the machine as a durable body and cutting disc. These designs can be divided into subgroups depending on the purpose and direction of rotation of the cutter:

vertical devices;
horizontal;
devices capable of cutting at different angles.

In large companies, electric automated machines are used in production, which are expensive. There are other options - these are small-sized devices that require the constant presence of an operator. Such models are most often found in enterprises. The main feature of the design is high quality and wear resistance. Manufacturers claim that such a device, with constant loads and careful use, will last about 15 years. The unit is capable of processing any surface at high speeds without creating defects or damage.

How to make it yourself

Best wood saw blades for circular saw

It is not necessary to spend significant amounts of money on purchasing an expensive pendulum cutting machine. Every master can make such a tool with his own hands. The basis for a pendulum saw for metal can be a conventional electric drill, grinder or electric motor. Even with minimal knowledge and skills in working with tools, you can easily assemble a homemade unit that will not be inferior in power and performance to factory models.

Before you start making such a power tool with your own hands, it won’t hurt you to first familiarize yourself with the drawings and instructions for assembling the machine. During operation, you must adhere to the following algorithm:

Prepare the engine from the angle grinder. The V-belt from the vehicle should be installed so that torque is transmitted from the engine to the spindle. To securely fasten the pendulum mechanism, you will have to make a metal frame. As a material for it, you can use a metal blank with a square cross-section or an attachment to an electric drill. The spindle body must be secured to one side of the frame by welding, and an electric motor must be installed on the other

Pay special attention to the size of the shaft, which must correspond to that shown in the saw assembly drawing. A groove should be made in the frame so that the rolling axis of the cutting disc can be inserted there. At the same stage, you need to weld the frame, but this must be done in such a way that the spindle, rolling axis and motor are parallel to each other. To make a protective case, you can use a sheet of tin

Additionally, a drive handle must be installed on the belt casing.

If you are interested in purchasing professional tools for long-term use, we advise you to choose from machines from reliable and trusted manufacturers. You should not buy cheap devices made in China. And a hand-held metal chain saw will do an excellent job of performing a small amount of work at home.

It is no coincidence that pendulum cutting saws are popular among professionals and amateurs. After all, this equipment has a lot of advantages, among which the most relevant for consumers are versatility, high accuracy and processing performance, and safety. All this makes such machines one of the most attractive for home craftsmen who need a simple tool to perform a small amount of work.

Of course, it is necessary to select this equipment with special care, paying attention not only to the price, but also to the key performance characteristics, as well as the manufacturer. If necessary, you can even try to make such a machine with your own hands, especially since this will require the most accessible tools and materials, minimal knowledge and experience in working with the tool

The main thing is to choose a suitable drawing and carefully study the order of the work and follow it exactly.

How to make a start button for a pendulum machine from an angle grinder

The angle grinder works when you press a button. Moreover, the spindle rotation speed depends directly on the pressing force of the button. This means that an adjustment mechanism is built into the button, the operation of which facilitates the operation of the tool. When operating an angle grinder on a stationary machine, it is necessary to consider the starting system so that you do not have to hold the handle with one hand and press the button with the other.

If the tool is equipped with a regular button, which automatically locks when it is turned on, as for example in the first version of the machine, then no difficulties arise here. First, the tool is turned on, and then you can perform work. However, most angle grinders are equipped with self-off buttons that must be held by hand while operating. There are two ways out of this situation:

Use ties (for example, plastic) or clamps of the appropriate diameter. They fix the button in the pressed position. In this case, it is also necessary to take into account the latch, which is responsible for turning the tool on automatically. Both the latch and the button must be tightened with a clamp, tie or other similar materials. In this case, the principle of operation of the device will be as follows - if you need to start the tool, you need to plug the plug into a socket or make a switch
It is rational to remake the starting system if the tool is planned to be used more often as a cutting machine than as a stand-alone angle grinder. To do this, it is necessary to route the wires from the angle grinder to a separate switch, which will turn the tool on and off if necessary.

The power button, if it is displayed, is best located on the handle. A homemade machine does not require large expenses for its production, which, in fact, is its main advantage.

How the mechanism works

Power tools for woodworking: overview, features and selection tips

The cutting tool of the saw is fed through a pendulum mechanism, that is, its movement is from top to bottom. Control can be either manual or mechanical. One of the advantages of such a machine is that you can change the cutting angle up to 45 degrees from the normal.

The circular saw acts as a working part of the machine

It is important to understand that the type of device may vary, for example, depending on the number of saws, there are single- and double-head saws

If we talk about a fully equipped machine, then during operation it is safe and comfortable to use. There is a special dust collector, the task of which is to collect waste abrasive elements and metal particles. The workpiece is securely fixed using a special clamp, thanks to which the blade will not move.

The cutting pendulum saw for metal has the following advantages:

a multifunctional tool in which it is quite easy to replace the saw blade;
the pendulum installation allows you to obtain an accurate and high-quality cut of the workpiece, especially when it comes to Makita tools;
fairly fast operating speed;
The tool is accessible and easy to install. At the moment, metal pendulum circular saws are available in almost all places where tools are sold. If desired, such a saw can be assembled independently;
easy maintenance, as well as replacement of device elements and cutting discs. The saw blade is especially easy to replace.

Power tools, accessories, both household and professional models - Makita offers a wide choice to the consumer.

Features of choosing a pendulum saw

You can choose a high-quality and effective tool of this kind based on the following criteria:

For what purpose is the tool selected? For example, if you don’t have to use a saw very often, you can choose simpler models that are less functional. If you need to do complex sawing work, then it is better to start with professional pendulum models.
Security level. As a rule, now each model is equipped with a protective casing that is capable of completely covering the working element - the disk - during operation.
Weight and dimensions. If the tool is heavy, it will be more difficult to work with it, since the master will simply waste energy faster.
Ergonomics. A pendulum saw should be comfortable to use.
Dust disk and its size. The disk is the cutting tool of the saw, and its size must be at least 20 cm in diameter.

If we start from the main characteristics of a pendulum saw, namely the width and depth of the cut, then it becomes clear what materials can be worked with on a particular unit. The diameter of the disc also plays a role, and the wider it is, the easier it is to work

Equally important is the design of the frame and the rotary block

Video:

How to choose a saw blade

To effectively select a working disk, it is necessary, first of all, to know exactly what material is to be processed. The key parameters of the dust disk are the following: outer and mounting diameter. The latter is usually 3 cm, and as for the external one, the dimensions vary depending on the required cut.

When choosing a disk, you should be careful, since some engines are designed for a specific disk. It is for this reason that in certain situations a large blade will be harmful to the saw.
What material the disc is made of, its geometry and sharpening of the teeth - the quality and success of the work itself depends on this.
Some types of teeth are optimal for cross cuts, others are convenient for making longitudinal cuts, and others are ideal if you need to achieve a neat and clean cut.
Certain discs have wavy lines and thin slots on their body, which compensate for temperature deformation and reduce noise during material processing.

Video:

Advantages and disadvantages

Assessing the advantages and disadvantages , it is worth noting that there are much more advantages. These include:

Functionality. By changing the working blade and operating power, such a saw can be used for cutting workpieces made of various materials.
Quality. Most of these tools are made for professional use. Therefore, the quality and service life of such saws is increased.
Accuracy. The workpiece is cut very accurately at the required angle of inclination, which cannot be done using another tool.
Speed of work. Thanks to the design of the machine, you can cut a lot of workpieces in a short period of time. At the same time, changing the angle does not require spending a lot of effort and time.
Easy to maintain. Changing working tools is quite easy, and the necessary parts can be easily found in almost any hardware store.

The only disadvantages include the high cost of the tool. But when used professionally, it is compensated by properties and characteristics. It should also be noted the low quality of discs made by unscrupulous manufacturers. Therefore, when purchasing consumables, it is recommended to pay attention only to trusted manufacturers.

DIY pendulum saw

A homemade pendulum saw made by a craftsman with his own hands: photo, detailed description, as well as a video showing the saw in operation.

I would also like to say something about the engine. I looked at examples of machines, most recommend installing 3 kW motors, ideally connecting to a 3-phase network or through a tank to a single-phase one.

I had a 1.2 kW 1450 rpm engine, I decided to use it to make a machine, increase the speed on the circle with pulleys, so as not to lose the already small power, I used a frequency drive.

The circle size is 230, with the possibility of installing 300.

The manufacturing process of a pendulum saw is shown in the photo.

The rotor shaft from a burnt out engine was used for the pendulum assembly. I made the supports for the bearings from a water pipe.

The shaft and support were made by a turner. The frame for the engine and shaft is welded from a 40 x 40 mm profile pipe.

The table is made of a corner 45 x 45 mm and a profile pipe 40 x 40 mm.

There are 75 mm wheels on two legs of the table, and adjustable supports on the opposite legs.

The table top is covered with 2 mm steel sheet, the protective casing is made of 1.5 mm sheet

I’ll dwell a little on the frequency converter, the price for them starts from $100, I didn’t look at the specifications, and I don’t need it, because I wasn’t going to buy a ready-made one. I made a homemade frequency generator, I won’t describe it, there are diagrams and a detailed description on the Internet. I’ll just show you a couple of photos of what the one I made looks like.

The frequency converter in the housing will be fixed under the saw table.

The protective casing cover is secured with extended nuts, which are used in conjunction with construction studs.

I am completely satisfied with the homemade pendulum saw, I don’t like the way the sparks fly when working, I need to do something clever with the spark receiver, as is done in the factory miter saws. The machine freely saws a D50 pipe with a wall thickness of 3 mm, while the engine copes without straining, there is enough power. Overall dimensions of the machine:

Length - 700 mm.
Width - 400 mm.
Height - 700 mm.

Author's video: work of a homemade pendulum saw.

engine's type

Modern pendulum saws operate on the basis of commutator and asynchronous motors. The first option has decent power, but contains carbon brushes that are subject to gradual abrasion. Asynchronous models last much longer and produce less noise. True, such motors may not be installed on all pendulum saws.

Mounting saw from 230 mm grinder

It is known that for convenient cross-cutting (facing) of a metal profile, assembly (cutting) metal saws with abrasive or metal discs with carbide-tipped teeth are used. Saws with abrasive discs are mostly common because the abrasive discs themselves are relatively cheap and widely available. Unfortunately, commercially available factory-made mounting saws, even from well-known brands, have some unpleasant shortcomings/shortcomings that you have to eliminate with your own hands.

I have already written in more detail about this in this topic. " >

Recently, a large grinder with a 230 mm disc has been idle. Work on single cutting of profiles or other medium and small work is much more convenient to carry out using a small and light angle grinder with a 125 mm disc. Much less weight, noise, vibration, less sparks, sludge, heating of workpieces, higher processing accuracy, and finally much higher safety. That is why the 230th angle grinder was left “out of work” in most cases. And since the saw head from the factory installation migrated to the Console circular saw, it was decided, based on a grinder with a 230 mm disc, to make a mounting saw that is in no way inferior, and even in some ways superior to the factory-made design. Moreover, it was decided to make a new original design for the table and the entire saw as a whole, and not to use, for example, the freed-up standard table from the Metabo CS 23-355 mounting saw. The new table has a durable and stable design, can be easily attached to a workbench using clamps or a bolt connection, and has the ability to easily install table extensions. These features are TOTALLY absent in the factory product. The tabletop was also covered with a much thicker material. The flange mounting of the pendulum stand to the table allows you to set the exact position of the disk plane parallel to the edge of the table. The flange attachment to the pendulum beam of the angle grinder fixation unit allows you to easily and accurately set the perpendicularity of the disk plane to the table surface. These features are also not available in factory installations. Also, thanks to the flange on the pendulum, it became possible to install various replaceable angle grinder fixing units for using any angle grinders. Bronze-graphite bushings and an axle from the car's pendulum arm assembly are used in the pendulum turning unit. This makes the critical unit practically “eternal” - since high-quality auto parts and lubricants are used. It is also easy to replace worn parts. In addition, the pendulum stand is shifted slightly to the left from the axis of the slot for the disk, so it is possible to cut off narrow strips (up to 30 mm wide) from the edge of large sheets of metal or other material. In general, the design of the device was developed with the expectation of further modernization - the use of large and powerful grinders with a reinforced gearbox, soft start, and speed control. In this version, it is planned to use a 355 mm abrasive disc with a 25.4/22.23 mm adapter ring. You will just have to additionally make a new protective casing on the angle grinder for this disc, best of all similar to the standard casing of a factory-made mounting saw. By the way, another significant advantage of the described device is that it allows you to use abrasive discs MUCH MORE EFFECTIVELY, down to a minimum diameter = 100 mm. The standard design of the Metabo CS23-355 mounting saw allows you to work with a disc worn out only up to 235 millimeters! The difference is simply GIANT!

The photo does not yet show a clamp/vise for pressing workpieces. This will be done a little later, most likely using the Clamptec quick-press type. The construction of the saw uses easily accessible and inexpensive materials and components - ordinary metal sheet, profile pipe, angle, strip, fasteners. In terms of financial costs for materials and components, the figure turned out to be around 800 rubles. This figure, of course, does not include the cost of the angle grinder itself and the clamp. I will post information on them later, when everything is finally clarified. More high-quality photos are posted in the photo gallery here ” >

What are they?

All electric pendulum saws can be divided into products according to the type of material being processed:

for metal;

cutting (universal).

Electric saws from the first category are capable of working with aluminum and other soft and harder materials. Some models come with a carbide blade and even a rotary table, making the task much easier. You can buy a product for cutting with a large broach. A tool for metal eliminates the thermal effect on this material, thus mechanical cutting does not affect the composition of the alloy, and therefore the characteristics of the metal do not change.

The power of the pendulum saw and the type of disk that sits on it determine what kind of metal the tool can work with. Non-ferrous and ferrous metals can be processed. If we talk about the scope of application, metal saws are used for cutting:

corners;
rods;
fittings.

There are lower power pendulum saws available for sale that are used for cutting wood. Such units are classified as one of the types of circular saws. They are used for trimming timber or cutting wood at right angles. During operation, such a tool swings like a pendulum, hence the name.

During operation, the operator has the opportunity to follow the cutting line, which is very important if no preliminary markings have been made. Disadvantages include limited cutting width and the need for additional effort by the operator

The design uses cutting elements with a diameter of 50 to 65 cm.

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Exploitation

Before use, the machine must be installed on a raised table or workbench, this is necessary for the comfort of its use. It is also necessary to make room for cutting, carrying material and storing workpieces.

The Makita LC1230 saw is compact; its installation requires a small area, but do not forget about moving the material and workpieces; as a result, the working area of the cutting saw is a rectangle of 2x4 meters. With a material length of 2–3 meters.

Cutting with a pendulum saw is not a difficult task, but nevertheless requires attentiveness and accuracy. Thus, sparks and hot metal particles flying from under the saw pose a particular danger. Partially, the collar installed on the saw body saves you from them. But nevertheless, we should not forget about personal protective equipment.

Constant work related to cutting metals and wood materials requires the use of a cutting machine. With the help of an electric tool, it is possible to quickly and efficiently cut metal structures. A disc cutting machine is used to form blanks for profile pipes, channels, rods and other rolled metal parts.

The equipment is used in large production enterprises; band and hacksaw machines are used for mass work. The complexity of the metal structure of special machines makes it impossible to use them in limited areas. The cutting machine can be used under any conditions, which makes it popular. A circular saw is responsible for cutting work.

Safety precautions at work

A pendulum saw is a tool that has a cutting block and operates at high speed. Therefore, in order to avoid injury during work, it is necessary to follow safety measures.

Before turning on the tool, you must check it and the electrical cord for external defects, as well as the rated voltage of the network.
The device should be placed in a well-lit and ventilated room, away from fuels and lubricants.
It is necessary to install disks of the appropriate mounting diameter on the saw.
Do not use discs that are mechanically damaged or poorly sharpened.
If the blade jams, the saw must be turned off by turning off the start switch.
Do not touch the rotating disk, much less try to stop it.
The cutting unit must be protected by a special casing.
You should use personal protective equipment, such as glasses, gloves, earplugs.
Do not stand in front of the cutting line while working.
The disc is not allowed to go beyond the edge of the table.

Compliance with these minimum requirements will help prevent injury.

Assembly saws

A special subtype of pendulum cutting machines is characterized by a simplified design and increased mobility. Assembly machines do not have a mechanism for turning the saw itself and cut the workpiece only along the normal.

The device in this case is as simplified as possible: a saw, a pendulum, a frame. Discs for cutting metal are usually abrasive; carbide is less commonly used.

The drive on a disk, in professional cutting machines, is usually belt driven, this allows you to reduce the load on the engine and avoid sudden jerks.

Due to the lack of rigid fastening of the pendulum and the workpiece, when working with cutting-off assembly machines, the following nuances must be taken into account:

Use a clamp to secure the workpiece while cutting.
At the moment of starting, the torque of the disk gives a strong push to the saw, take this into account.
When cutting with a mounting machine, a burr is formed on the workpiece, which must subsequently be removed.

Drive unit

It is most convenient to use a belt drive as a drive mechanism. To do this you will have to find two pulleys of the same diameter. One of them is mounted on the motor shaft, the second - on the drive shaft of the cutting disc. The disk shaft is mounted on two bearings. It is best to use the scheme when the drive mechanism is located on the left of the disk mounting cloud. It’s more convenient to work this way, and safety rules are followed. The disc fastening nut will not be at risk of loosening.

To tension the drive belt, the engine is mounted at the rear of the pendulum with 4 bolts located in longitudinal slots. It can shift in the direction of the central axis of the machine (perpendicular to the axis of rotation of the motor shaft) by 5-7 centimeters. This will maintain the required belt tension and prevent it from slipping. It will also be easier to replace the belt if the previous one becomes unusable.