How do power saws cut metal or other materials?

Power saws used in machine shops employ three primary methods to cut through metal and other materials: true cutting, grinding, or friction-created melting.1

• True Cutting: This method utilizes tools with teeth, such as reciprocating hacksaw blades, band saws (endless flexible steel bands), or circular disk cutters. These teeth are typically "set" or bent to alternate sides, ensuring the cut groove (kerf) is wider than the blade to prevent binding.12
• Grinding: Abrasive cutoff saws use thin, bonded abrasive wheels operated at high peripheral speeds to wear away material, which is particularly effective for hardened steel bars and thin tubes.1
• Friction-created Melting: Friction-sawing machines operate at such high speeds that the heat generated by the friction of contact is sufficient to melt and remove the metal. This technique is commonly used for cutting structural steel shapes like I-beams and channels.1

These machines are essential for industrial applications, allowing for precise cutting of bars, plates, and complex contours.13