A hacksaw is a type of hand tool designed specifically for cutting through materials such as plastic, steel, and other metals. They are a variant of the traditional hand saw, typically used for cutting wood, and have become a staple tool for professionals and hobbyists alike.
Hacksaws supply firm and precise cutting power, ideal for a wide range of projects and applications. Physically, they are characterised by their distinctive adjustable frame shaped like the letter ‘D’, which holds the blades under tension.
What is a hacksaw?
A hacksaw is a fine-toothed saw, originally and mainly made for cutting metal. The equivalent saw for cutting wood is usually called a bow saw.
Most hacksaws are hand saws with a C-shaped walking frame that holds a blade under tension. Such hacksaws have a handle, usually a pistol grip, with pins for attaching a narrow disposable blade.
The frames may also be adjustable to accommodate blades of different sizes. A screw or other mechanism is used to put the thin blade under tension.
On hacksaws, as with most frame saws, the blade can be mounted with the teeth facing toward or away from the handle, resulting in cutting action on either the push or pull stroke.
In normal use, cutting vertically downwards with work held in a bench vise, hacksaw blades are set to be facing forwards.
What a Hacksaw Is Used For?
A hacksaw is mainly used for cutting thin metal such as aluminum, brass, steel, or copper. Hacksaws are also used for cutting plastics such as PVC, PEX, or ABS on pipes or on sheet goods made of PVC, polystyrene, and more.
A hacksaw is typically used to cut materials that are harder than wood but should not be used for cutting stone.
Parts of a Hacksaw
A hacksaw consists of two main parts: the metal frame with a handle and the removable blade.
Hacksaw Frame
A hacksaw frame is C-shaped with a handle at one end. The hacksaw blade runs across the open end of the frame. Most hacksaw frames are 6, 10, or 12 inches in length.
Hacksaw Blade
A hacksaw blade is a thin band of metal ranging from 6 to 12 inches long. The blade mounts to the frame on pins. After it has dulled, a hacksaw blade is difficult to sharpen. It’s typically disposed of and replaced with a new blade.
Once the blade is drawn tight in the frame, the thin metal gains enough strength to be used as a saw.
Hacksaw blades have between three and 32 teeth per inch (TPI). Most blades range from 18 to 32 TPI. Blades that have more teeth per inch are used for cutting finer materials.
Types Of Hacksaws
To serve a multitude of industries and applications, hacksaws are made in different sizes and shapes. The main categories of hacksaws are:
#1. Full-Sized Hacksaw.
Full-sized hacksaws, also referred to as senior hacksaws, are huge, multipurpose, easy-to-use instruments that quickly cut through hard materials. They work with blades that have 12, 18, 24, and 32 teeth per inch.
#2. Junior Hacksaw.
Smaller versions known as junior hacksaws are employed when space is at a premium or when fine cutting is necessary.
They are not appropriate for cutting harder materials because of their soft, half-sized blades. Junior hacksaws are small hand tools that are very portable.
#3. Mini Hacksaw.
Small hacksaws are lightweight, portable types made for cutting in tight areas and reaching difficult-to-reach places like home plumbing. Typically, they have extremely small D frames and long, ergonomic handles.
#4. Power Hacksaw.
Electric motors are typically integrated into power hacksaws, also referred to as electric hacksaws, to power their blades; however, they can also be connected to external motors or engines. Powered hacksaws often raise their blades automatically on the return stroke.
Power hacksaws are usually stationary tools, however, there are also portable versions available. Another typical addition to assist in keeping the blades from overheating while in use is a cooling pump.
Types of Hacksaw Blades
The following are the main types of hacksaw blades:
- Course Grade Hacksaw Blade
- Medium Grade Hacksaw Blade
- Fine Grade Hacksaw Blade
- Superfine Grade Hacksaw Blade
- Ail Hard Blade
#1. Course Grade Hacksaw Blade.
Hacksaw blade of this grade is used for cutting thickness of mild steel, copper, aluminum, and brass, etc. It contains 14 to 18 teeth per inch.
#2. Medium Grade Hacksaw Blade.
Hacksaw blade of this type is used for cutting all kinds of metals such as cast iron, tool steel, aluminum, brass, high carbon steel, etc. From 20 to 24 teeth per inch are cut in this hacksaw blade.
#3. Fine Grade Hacksaw Blade.
This type of hacksaw blade is mainly used to cut thin pipes, sheets, tubes, etc. It has 24 to 30 dents per inch.
#4. Superfine Grade Hacksaw Blade.
For cutting extraordinary solid metals and thin metal sheets, a thin type of hacksaw blade is used. There are 30 to 32 dents per inch in this type of hacksaw blade.
In all the hacksaw blades of various grades mentioned above, teeth are cut on one or both edges. These blades are hardened in two different processes and these depend on their nature.
#5. Ail Hard Blade.
Blades of this nature are hardened and tempered only except for the ends having holes. These are used for cutting articles cast iron or mold iron etc.
#6. Flexible Blade.
In blades of this nature only the cutting teeth and nearby part it hardened and tempered. But this process becomes elastic and there is less risk of their being broken in the event of a shock. These blades are used for cutting thin sheets, pipes, curves, etc.
What are the different types of Hacksaws?
- Some hacksaws can hold both 10-in. and 12-in. blades
- There are 6-in. hacksaws available
- Handle styles vary
- Compact/mini hacksaws consist of just a handle and a blade, similar to a knife
- Tensioner mechanisms vary
- Some hacksaws can pivot the blades to a 45° angle to allow for flush cuts.
How to Use a Hacksaw?
- Mount Blade on Frame. With the frame’s thumbscrew retracted, insert the blade into both of the frame’s retaining pins. Tighten the thumbscrew clockwise until the blade is tight and does not wobble side-to-side. Use a rag to rub two or three drops of machine oil across the blade.
- Clamp Work Material. Clamp the work material into a vise. Or, use clamps to hold the material to the work table.
- Hold Hacksaw Correctly. Hold the hacksaw with one hand on the grip and the other hand at the far end of the frame.
- Create Notch. Press forward on the saw an inch or two to create a starting notch in the material.
- Cut Material. Saw the material by moving forward and back in full strokes. Press firmly down on the forward stroke, but not so much that you twist the blade. Ease up on the pressure for the backward stroke.
How to Change a Hacksaw Blade
Changing a hacksaw blade is a straightforward process, regardless of whether you are using a senior or junior model. Below is a handy step-by-step guide detailing the process:
- Depending on the model of hacksaw you have, either apply the fasten-release mechanism or turn the wing nut to loosen the current blade
- Carefully slide out the current blade
- Insert the fresh blade onto the retaining pins within the handle
- Either tighten the wing nut or reapply the fasten-release mechanism
- Conduct a test cut on a piece of scrap metal to ensure the new blade is safe and properly secured
How to Maintain a Hacksaw
Regularly maintaining your hacksaw and keeping it in good condition will not only ensure a quality cut but it will also lessen the safety risk associated with using the tool. When conducting hacksaw maintenance, consider the following fundamentals:
- You should regularly inspect hacksaw blades for signs of damage including warping or blunting.
- If blades do show signs of wear and tear, replace them.
- Apply oil or lubricant to the blade to prevent overheating when cutting.
- Minimize the risk of breakage when cutting harder materials by cutting more slowly.
- Regularly clean hacksaw blades to keep them in good condition for longer.
Hacksaw Tool Applications
As previously mentioned, hacksaws are ideal for cutting plastic and metal. Hacksaws with low TPI can cut wood well, but a regular handsaw or traditional frame saw are better suited for wood.
Hacksaws are not a good option for cutting stones. For stone, use a circular saw with a diamond blade.
Some common applications of hacksaws are:
- Cut galvanized or steel pipes: Using a hacksaw is faster than taking the time to set up a powered saw.
- Metalworking: Useful when bar stock needs to be cut quickly.
- Plumbing: Plumbers use hacksaws to cut metal and plastic piping.
- Wrought iron and cast iron: Hacksaws are strong enough and have enough applied pressure to cut through these hard metals.
- Construction: Hacksaws are useful in many ways, for example, cutting rebar.
- Bolt and screw trimming: Use a hacksaw to quickly solve the issue of bolts and screws being too long.
- Woodworking: As mentioned above, hacksaws are not the most suitable saw for woodworking, but they can be used.
- Frozen meat: Hacksaws are excellent for cutting large slabs of frozen meat.
FAQs.
What is a hacksaw used for?
Hacksaws were originally and principally made for cutting metal, but can also cut various other materials, such as plastic and wood; for example, plumbers and electricians often cut plastic pipe and plastic conduit with them, while surgeons can use unpowered saws as bonesaws.
What can a hacksaw not cut?
A hacksaw is typically used to cut materials that are harder than wood but should not be used for cutting stone.
Is it OK to use a hacksaw on wood?
A hacksaw is a type of hand tool designed specifically for cutting through materials such as plastic, steel, and other metals. They are a variant of the traditional hand saw, typically used for cutting wood, and have become a staple tool for professionals and hobbyists alike.
Why is my hacksaw blade upside down?
Hack saw is always meant to cut on the push. If its cutting on the pull the blade is backwards. Most saws have fixed blades and a handle, that determines which way the cut. Hand wood saws have teeth that cut on the down stroke.
When should you use a hacksaw?
A popular tool among plumbers and electricians, a hacksaw is primarily designed for cutting through metal, like copper pipes or conduit. However, it can also be used on plastic, like PEX or PVC, making a hacksaw an invaluable tool for anyone that regularly works with these materials.