Sofia Martinez
Notching plastic pipe involves cutting an opening into the side or end of a tube to create a joint. There are various methods and tools available for notching, each with its advantages and disadvantages. The most suitable method depends on the specific requirements of the project, such as the desired notch shape, the raw material, and manufacturing considerations, and personal preference. This introduction will explore the different techniques and tools used for notching plastic pipe and provide an overview of the attachment process.
Characteristics and Values Table for Notching Plastic Pipes
| Characteristics | Values |
|---|---|
| Tools | Hole saw, drum sander, abrasive-belt notcher, chop saw, tubing notcher, hand notching, laser notching |
| Process | End notching, side notching, end milling, multi-notch |
| Considerations | Notch shape, raw material, manufacturing considerations, tolerance, production rate |
| Templates | Print tube coping template at 100% printer scale, use plot point increments for larger pipes, use angle increments for printing templates |
| Setup | Line up, set tooling, set angle, make the cut, clean up |
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What You'll Learn
Hand notching: requires finesse but can be learned quickly
Hand notching is a skill that requires finesse but can be learned quickly. It is a process of cutting and notching tubes by hand, which can be more efficient than using a tube notching tool as it eliminates the time-consuming setup process. While the setup for a notch cut may be quick with a machine, the time taken to line it up, set the tooling and angle, make the cut, and clean up can be a lengthy process.
Hand notching is particularly useful for multi-angle or multi-plane notching, which most tube notching systems cannot handle. It is also a good option for notching tubes with complex angles. The more you practice hand notching, the better and faster you will become.
There are several methods and tools for notching tubes by hand. A simple and inexpensive method is to use a hole saw, which can be used on-site with just a simple jig to obtain the required shape. However, this method has some disadvantages, including inconsistent repeatability, a rough finish, and a limited size range. Another inexpensive method is to use a drum sander or abrasive-belt notcher, but these processes are labor-intensive and generate dust, sparks, and heat.
For more complex notches, a CNC mill can be programmed to create nearly any shape imaginable, but this method can be time-consuming depending on the shape and size of the notch. Laser notching is another emerging technology that is efficient, accurate, clean, quiet, and flexible, but the main drawback is the cost of the machine.
Regardless of the method chosen, there are some important considerations to keep in mind when hand-notching tubes. Firstly, the face line and throat line are reference lines used for placement and depth of cut, respectively. Secondly, the rule of thumb for measuring the notch is that only about one-third of the tube will overlap the other at any angle, as long as the tubes are the same diameter. Finally, for larger pipes, you may need to use plot point increments to display notch line offset measurements and measure and mark the notch accordingly.
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Hole saw: a simple, inexpensive, and portable option
Hole saws are a simple, inexpensive, and portable option for notching plastic pipes. They are a good choice for job site work. Hole saws use a rotating tool to remove the material and create a notch. The tool diameter determines the notch radius.
To use a hole saw, first make sure that your notcher is correctly assembled. Check that the spindle travels smoothly, as friction can cause excessive wear on the bushings. Once your notcher is set up, insert your first piece of tubing and set the speed. Lubricate the hole saw and the bushings with cutting oil as you work. Keep the spindle support positioned as low as possible to aid accuracy. The angle of your clamp will depend on the notch you want to make, so it may be helpful to practice on some scrap material first.
When you're ready to make the notch, remove the locking pin and engage the drill. Proceed to cut the workpiece, watching your notch take shape. Once you're happy with the cut, shut off the drill and insert the locking pin before removing the notched tubing.
Hole saws have some disadvantages, including inconsistent repeatability, a rough finish, a limited size range, and the inability to notch shapes other than a circle. They may also struggle with larger tubing sizes. Additionally, drill bits in the centre of the arbor can snap, and "spin-on" hole saws may not be suitable for larger tubing.
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Drum sander: an inexpensive option that generates dust, sparks, and heat
A drum sander is a cost-effective option for notching pipes and tubes. However, it is a labour-intensive process that generates dust, sparks, and heat. This makes it less suitable for high-volume production.
Drum sanders use a rotating tool to remove material from the pipe or tube. The tool diameter determines the notch radius. The main advantage of a drum sander is its low cost, but it has several drawbacks. Firstly, it generates dust, sparks, and heat, which can be hazardous and require additional safety precautions. Secondly, it is a labour-intensive process, which can slow down production rates. Finally, the abrasive-belt life depends on the finish and part material, and the part may need to be cleaned to remove abrasives before welding.
When using a drum sander, it is important to consider the type of material being used for the drum. While PVC pipe is commonly used due to its low cost and ease of availability, it has a low HDT (Heat Deflection Temperature) and is prone to deforming under pressure and modest heat. This can affect the performance and longevity of the drum sander. As such, wood is often preferred for the drum material as it can handle heat better and is stiffer, making it easier to maintain its shape.
To use a drum sander for notching plastic pipes, the pipe is first attached to a rotating tool, such as a lathe. The pipe is then rotated and a sanding or abrasive belt is applied to the pipe to remove material and create the desired notch. The pipe may need to be rotated multiple times to achieve the correct notch shape and size. It is important to consider the notch shape, raw material, and manufacturing considerations such as tolerance and production rate when using a drum sander for notching pipes.
Overall, while a drum sander is an inexpensive option for notching plastic pipes, it has several limitations, including the generation of dust, sparks, and heat, which can impact its suitability for certain applications.
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CNC mill: an accurate but expensive option
CNC mills are a more expensive option for notching plastic pipes compared to other methods such as hole saws, drum sanders, and abrasive-belt notchers. However, they offer several advantages that make them a popular choice in certain applications.
CNC mills can be programmed to create notches of various shapes and sizes with high accuracy and tight tolerances. This versatility allows fabricators to use them for a wide range of products, from bicycle frames to aerospace parts. The process is also clean and safe, as it does not produce dust or sparks.
One of the main drawbacks of using a CNC mill is the cost of the machine itself. Additionally, the process may leave chips in the tube, requiring cleaning before welding. The cycle time, or the time it takes to complete one notch, can also be a disadvantage, especially for high-volume production runs.
However, if a CNC mill is already available, the end milling process can be relatively inexpensive. The machine's ability to create complex shapes and its high accuracy make it a valuable tool for certain projects, such as those requiring precise notches or unique shapes.
Overall, while CNC mills are an expensive option for notching plastic pipes, they offer advantages in terms of accuracy, versatility, and cleanliness. For specific projects requiring complex or precise notches, a CNC mill can be a valuable investment, but for simpler applications, other methods may be more cost-effective.
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Chop saw: requires practice but can be used without a notcher
Using a chop saw to notch plastic pipe is a precise method that requires some practice. It can be done without a notcher by following these steps:
First, determine the tube size and joint angle. This information is crucial as it will guide the accuracy of your cuts. Next, calculate what will be known as the "base angle". This is the angle of both cuts if the joint was 90 degrees. For example, for two 1.75" tubes at a 90-degree joint, the base angle or the angle of both cuts is 28 degrees.
Now, set up your chop saw vise at a 45-degree angle. Place the tube in the vise and clamp it securely to avoid any slippage. Cut the corner of the tube, then flip the tube 180 degrees and cut the other corner. You will now have two notches. Fine-tune these notches with a file or disc sander to achieve a perfect fit.
For joints that are not 90 degrees, you will need to adjust the angles of your cuts. For instance, if you desire a 15-degree joint with a 1.75" tube, subtract 15 degrees from one cut and add 15 degrees to the other, all while starting with the base angle of 28 degrees for a 1.75" tube.
It is important to note that the chop saw method is limited by the maximum angle of the chop saw itself. Additionally, this method may require some trial and error, and adjustments can be made with a grinding wheel if needed.
The chop saw method offers speed and accuracy for notching plastic pipe without the need for a dedicated notcher. With practice and understanding, it can be a valuable technique for your projects.
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Frequently asked questions
Pipe notching is the process of cutting an opening into a pipe or tube to create a joint.
You can use a tubing notcher, which uses a hole saw with a solidly mounted shaft and an adjustable clamp to hold the pipe in place. You can also use a chop saw, band saw, or a sawzall.
First, you need to figure out the angle that you need to cut. Then, use the angle finder on the tool to set the correct angle. Hold the tubing in place with the clamp and use a drill to turn the hole saw.
Set the chop saw vise at a 45-degree angle and cut the corner of the tube off. Flip the tube 180 degrees and cut the other corner off. You will then need to use a file or disc sander to create a perfect notch.
Notched pipes can be welded together to form a joint. Before welding, you may need to clean the pipe to remove any dust or chips created during the notching process.
