The 40×40 mm profile tube is one of the most popular sizes in construction, furniture manufacturing and frame manufacturing. But even the highest quality material can be ruined by improper cutting. Uneven edges, burrs, and deformation are common problems that complicate welding and spoil the appearance. This article contains a detailed guide on cutting 40×40 professional tubes using a grinder, metal scissors and a saw, as well as practical tips on how not to deform the edges.
The goal: to get a smooth, perpendicular cut without burrs and flattening — for high-quality welding and a neat appearance.
What do you need to know before cutting?
- Wall thickness: for 40×40 mm, usually 2.0–3.0 mm. The thicker it is, the harder it is to cut, but the lower the risk of deformation.
- Material: steel St3sp or 09G2C — affects the choice of disc and cutting mode.
- Accuracy: for welded structures, the deviation from 90° should not exceed 1-2°.
Tip: before cutting, clean the cutting area from rust and dirt — this will prolong the service life of the disc.
It is more reliable to buy a 40 40 pipe conforming to GOST from the manufacturer directly at the factory.
Method 1: Cutting with a grinder (USM) — fast and accurate
The grinder is the most common tool. Suitable for any amount of work.
What will be needed:
- Angle grinder (125 or 150 mm)
- Metal cutting disc (1.2–1.6 mm thick)
- Vise or clamps
- Marking (square, tape measure, marker)
Step by step:
- Measure the desired length and make a mark around the perimeter of the pipe.
- Draw the cutting line along all four sides using a square.
- Secure the pipe in the vise strictly perpendicular.
- Slowly and smoothly start cutting without pressing on the disc.
- Do not overheat the metal — take pauses when cutting for a long time.
Life hack: make an incision on one side, then flip the pipe over and finish on the opposite side — this way there is less risk of burrs.
Do not use a sanding disc instead of a cutting disc! It is thicker and creates strong vibration, which deforms the edges.
Method 2: Cutting metal with scissors — without sparks and noise
Suitable for thin pipes (up to 2.5 mm) and small volume.
Types of scissors:
- Manual — for 1-2 pipes, they require effort.
- Electric (guillotine) — fast, precise, without deformation.
Advantages:
- There is no overheating of the metal
- Smooth cut without burrs
- Safe and quiet
Tip: when cutting manually, make incisions one at a time on each side — this way the pipe will not flatten.
Limitation: it is difficult to cut pipes with a thickness of more than 2.5 mm with scissors. Don't try it.
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