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Cutting and Forming Copper Sheet Metal

Cutting and forming sheet metal can be done with shears, Disk Cutting tools are for cutting and forming copper Sheet Metal and are often used in jewelry and small metalwork.
Here's a breakdown of how to use some of them on copper sheet metal:

Burrlife or Beeswax for lubrication of cutting surface
Steel Block as work surface, not wood.
Heavy Brass Mallet
Disk Cutters, Bevelled end up - the cutting side of the punch is a flat smooth surface.

1. Disk Cutter (circular tool with round holes)

This is used to punch out perfect circles of metal.

Steps to use:

  1. Anneal your copper (heat it to a dull red and let it air cool or quench in water if it's safe—wear gloves).

  2. Place your copper sheet between the plates of the disk cutter.

  3. Select the punch size that fits the hole.

  4. Align the sheet so the desired area is under the hole.

  5. Insert the corresponding punch into the hole.

  6. Use a heavy brass mallet or an arbor press to strike the bevelled end of the punch. It will shear the metal and drop a disk through the bottom


    🛠️ Proper Usage Tips

    • Insert the Punch Correctly: Always insert the flat, sharp end of the punch into the corresponding hole of the disc cutter, ensuring it makes direct contact with the metal sheet.

    • Strike the Beveled End: Use a heavy mallet or hammer to strike the beveled end of the punch. This will drive the sharp end through the metal, creating a clean cut.

    • Avoid Reversing the Punch: Striking the sharp cutting end can damage both the punch and the disc cutter, leading to poor cuts and potential injury.

    Quick Reference: Using Disk Cutters on Copper

    ✅ Anneal copper before cutting (heat to dull red, then cool).

    ✅ Use a heavy mallet or arbor press for clean punches.

    ✅ Lubricate punch tips with Bur Life or beeswax.

    ✅ Always place cutter on a steel block, not wood.

    ✅ Align copper and punch carefully—no tilt.

    ✅ Check punch sharpness regularly.

    ✅ Use correct gauge copper (20–24 gauge ideal).

    ✅ Remove stuck punches gently by flipping and tapping.


    Disk Cutter Troubleshooting Guide

    Issue

    Cause

    Solution

    Cutter won't pierce copper

    Copper is too hard (work-hardened)

    Anneal the copper before cutting

    Punch doesn't go through

    Not enough force used

    Use a brass/rawhide mallet or an arbor press

    Punch gets stuck

    No lubrication / tight fit

    Lubricate punch with Bur Life or beeswax

    Ragged or uneven cuts

    Copper or punch misaligned

    Ensure copper is flat and punch is vertical

    Noisy, ineffective cut

    Cutter not on solid surface

    Place on a steel bench block or anvil

    Won't cut thicker sheet

    Gauge is too high for tool

    Use thinner copper or alternative tools

    Punch not sharp

    Edge dull or damaged

    Sharpen or replace punch

     

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