How to cut aluminum with no fire, electricity, or debris.

[ColinPearson]

Hey folks... I'm looking for a tool that SHOULD exist, but I don't know if it does nor what it's called if it's out there. I need to cut some aluminum plate, 3/16" material. Heat, abrasives and electrical tools are all out due to client restrictions. We are cutting a hole in the roof of an aluminum tank and nothing is allowed to fall into the tank.

It's a little much cutting to do with a chisel, but that's possible if we need to. So, what I'm picturing is like a lovechild between a sleever/crowbar and a P-38 can opener. Something with a pointed end that could be jabbed through metal (or through a hole started with a chisel) and also a cutting edge where the leverage of the bar would let you cut. Jab/pry/repeat.

Anyone see a contraption like that before? thanks and have a great weekend!

 

[EdStainless]

power shears. Think of hydraulic powered tin snips.

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P.E. Metallurgy, consulting work welcomed

 

[IRstuff]

I doubt that you'd find anything short of a 5-lb maul and chisel that could be "could be jabbed through metal" that's 3/16" thick, without deforming the metal. if you can chisel a large enough opening you can get a metal shear in to cut the aluminum:

https://www.mcmaster.com/metal-shear/cutters/high-force-sheet-metal-cutters/

Not sure how well any of these do against 3/16" aluminum, since the maximum thickness called out is only 1/16"

If you can convince your client to allow power, then

https://www.mcmaster.com/metal-shear/cutters/powered-sheet-metal-cutters/,

some of which can cut 3/16" alumnimum.

This one is air-powered, but only to 1/8"

https://www.mcmaster.com/3837A3/

TTFN (ta ta for now)
I can do absolutely anything. I'm an expert!

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[itsmoked]

Use a wax dam and a strong base.

Keith Cress
kcress -

http://www.flaminsystems.com

 

[CWB1]

Depending on the kerf allowable, shears or a nibbler are the first two that come to mind. Both are available unpowered, electric, and hydraulically powered.

 

[BrianE22]

Can you cut "almost" through? If you could thin out the metal then it would be easier to pry out.

 

[berkshire]

Following up on BrianE22s post,
You could try a router set to almost, cut through, then pry the metal up like opening a pull tab on a tin can. Try this first on scrap metal away from the tank to get the best settings.
B.E.

You are judged not by what you know, but by what you can do.

 

[mfgenggear]

boy what a FUBAR
it would almost be easier to cut the whole top off then remove it
then cut the opening, reclean the whole tank remove all debris
then re-weld it.
sounds more difficult, but easier in the long run.
some thing missed in fabrication?

 

[Strong]

Consider an air impact splitter (bushing or muffler) chisel. This chisel probably would not require a starting hole that would cause falling chips. I recommend conducting a demonstration test on similar metal for cutting capability and to check for falling metal particles. May need to try more than one method/tool to demonstrate feasibility and convince customer.

Walt

 

[berkshire]

Strong,
Most air impact splitters are fabricated for thinner metals maxing out at 16 to 14 Ga However the idea could be scaled up and a custom splitter fabricated, Be aware the if the splitter is overloaded the penetrating tongue will snap off ( Ask me how I know about this.) If this happens on the tank the piece could be retrieved with a magnet on a line, but I do not think this is what the OPs customer wants.

You are judged not by what you know, but by what you can do.

 

[Compositepro]

Use a router to mill a groove to 90% depth of the plate, then finish with an impact splitter.

 

[Strong]

"Be aware the if the splitter is overloaded the penetrating tongue will snap off"
Yes, that is why it should be used after a metal router reduces the thickness. The router depth and width should be tested with the selected air-impact splitter for compatibility on a representative specimen, especially with the apparent concern over metal chips and broken tool pieces falling into the tank.

Walt