Many factors are involved in choosing a particular method or technology for cutting tube or pipe. The basic factors that affect the cut are the tube or pipe material, wall thickness, squareness of ends, end-conditioning requirements, and secondary process requirements.Other factors that play a role include production volume, cutting efficiency, overhead costs, and special requirements of the tube or pipe material.

Abrasive Disc Cutting

• Abrasive sawing is a basic, manual method of cutting-to-length product to the customer's specification in any alloy. An abrasive saw operates with a circular abrasive blade or resin-composition wheel—either wet or dry—that grinds through the product.
• Cut size capabilities depend on the machine. Some abrasive cutting machines can handle a solid round up to 4 in. outside diameter (OD). This general-purpose method is useful for hand-loading applications and small product runs that do not require critical end conditions.
• While an abrasive saw is easy to use and requires little or no setup time, it cannot provide a square cut or tight tolerances. Because the process uses a cutting or burning action, it is not efficient for thick-walled material. It also might leave a heat-affected zone (HAZ) that can affect secondary processing.
• While abrasive sawing is inexpensive and quick, it produces significant kerf and a heavy burr that might have to be removed by deburring.

Band Saw Cutting

• Band saw cutting is a fully automatic process and the most common method for cutting rod, bar, pipe, and tubing. This process is excellent for large-volume cutting. Some band saws can handle large product bundles.
• The blade is a continuous band of metal, available in various tooth configurations, that rotates on two wheels. Depending on the model's design, the blade's approach to the metal may be horizontal or vertical. Each configuration has advantages for particular products or applications.
• Band saw cutting is a viable method for cutting a variety of shapes, such as squares, rectangles, channels, I beams, and extrusions. A band saw's capabilities vary depending on the model. Most are automated, and some feature CNCs. Shuttles make it possible to cut any material length. While shuttles typically are 20 to 24 in. in length, longer ones are available.
• Despite the many advantages of band saw cutting, it is not an efficient process for cutting thin-walled products. Moreover, band saw cutting produces a burr and does not achieve tight tolerances.

Cold Sawing

• High-precision cold sawing is suitable for cutting smaller-diameter or thin-walled material that requires tight tolerances. A circular cold saw uses a wheel blade and cutting fluid, which usually is applied with a mist lubricator. While some cold saw units can handle round tube up to 180mm and round solid up to 100 mm they are most effective at cutting product with a maximum OD of 80mm.
• A cold saw's steel blade is fixed and does not walk or wander. Cold sawing produces square or perpendicular cuts and minimal or no burrs. This automated cutting method can bundle-cut material with a length tolerance of ±0.1mm and squareness tolerance of 0.05mm.
• Because it is a cold cutting process, cold sawing does not produce a HAZ, which can be a benefit for product that requires subsequent finishing.