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Do-it-yourself welding corner. Do-it-yourself magnetic square for welding

Hello. Today I want to talk about a magnetic welding square that I recently made. I have to make some gates and entrance gates soon, so I decided to make some magnetic squares this winter. They will save me a lot of time and effort when welding rectangular structures from profile pipes.

Here's what I needed for this:

1. An old speaker from a car stereo.
2. "Magnetic" sheet metal(steel) 1 mm thick
3. Thin aluminum strip.
4. Blind rivets.

As you know, the speakers have quite powerful ferrite magnets.

Using a hammer and chisel, I separated the "magnetic part" of the speaker. (It is attached with four rivets).

After that, it remains to remove the magnet. It is located between two steel plates and secured with glue. It was necessary to lower it for some time into acetone, or into the 646th solvent ... But I just took a knife, which I don’t mind, inserted between the plate and the magnet, and, with light blows of the hammer, separated the plates.

I used to get it "clean", but this time the ferrite magnet chipped a little ... Oh well ... I'll grind on a diamond cup.

Next, I started making plates. I cut them out of an old window tide. (I myself am surprised, but it was made of "black" non-galvanized iron, 1 mm thick!). The metal was very well magnetized, which was what I needed in the first place.

Using a locksmith's square, attaching it and the resulting magnet to the workpiece, I determined the dimensions of my future product, drew it and cut it out with a grinder:

Next, I marked and cut out the corners. Corners need to be cut for several reasons:
First, when cutting profile pipe(and especially, with a thick circle on, burrs remain on the edge. When welding, they will easily melt and will not interfere. But the square will rest against them. (But even half a millimeter will greatly change the angle in this case). Therefore, after the pipes are cut to size, you have to clean up these burrs, and waste time on this.

Secondly, if there is not a large gap in the corner, you can accidentally weld the square itself to the workpiece !!!

So I cut them like this:

I did not mark the second plate. I just attached the first one to it (already with cutouts) and, according to this template, marked it and also cut it out:

Next, I went into fine tuning. Indeed, it is not possible to cut very accurately with a grinder, and accuracy is needed to a fraction of a millimeter. Therefore, I had to finish it manually. I took a piece of a wide profile pipe, spread a strip of emery cloth on it, and manually, on it, grinded the sides of my metal triangles, periodically putting them into a locksmith square and checking "for clearance"

After that, evenly folding the blanks and squeezing them in a vise, I drilled holes in them for rivets. (I forgot to take a picture of this process). And after that, just in case, pulling them through the holes with M5 screws, I “finished” them again on sandpaper, already two together.

Next, I want to focus on a common mistake when making homemade squares. Many do-it-yourselfers make them "open". That is, they do not cover the butt with anything! It is unacceptable. Because when working with metal, there is a lot of sawdust, frozen spatter of scale, small scraps and other magnetic debris. Since all this debris is very light, it adheres to the magnet abundantly. Here, for example, is a photo of a weak (!!!) magnet, with which I deliberately "poked" on the workbench after I cut and finished my workpieces:

See how much he got?!!! The magnet itself is not even visible behind the garbage!!! This is how garbage and a magnetic square will collect. And even stronger, because its magnetic properties are more powerful!!!

That is why its shape should be such that it can be easily cleaned!!! That is, its ends should represent smooth planes. I made them from a thin aluminum plate. Some kind of edging from the shelf of an old refrigerator fell under my arm.

From it I cut out a strip with a width equal to the thickness of the magnet:

And from it he bent a frame around the perimeter of the plates. It will be nested between them, and tightly clamped with rivets. The ends of the square will be tightly closed, magnetic dirt will not get inside, and it will be easy to remove it from the surface of the plates.

By the way, pay attention: I had to cut the magnet at the bottom a little. This is my mistake - when estimating the dimensions of the plates, I did not take a correction for the thickness of the aluminum plate, and then the magnet did not fit in it ....

So, let me focus on one more thing. A ferrite magnet is quite easy to cut with a grinder. But, unlike metal cutting, it is not worth trying to use an abrasive wheel at the same time !!! It will slip and you will just overheat the magnet. (By the way, if anyone does not know, permanent magnets lose their properties from overheating.). You need to cut with a diamond wheel. The diamond wheel for wet cutting, popularly called the "tiled" wheel, is best suited. It has a solid cutting surface and does not chip the cut:

And when cutting, the magnet needs to be cooled with water.
Next, I want to explain why I made the ends of aluminum, and at the same time focus on another common mistake. As you know, any magnet has two poles, conventionally called "north" and "south". Both poles are equally well attracted to the metal. For magnets of this shape, the poles are on planes. That is, when we apply metal plates to the planes, then these plates are already the poles of the magnet. And it is with them that our square will "stick", and not at all with a plane between them.

But, most importantly, the poles of the magnet cannot be "short-circuited" with magnetic material! This reduces its properties, and, in addition, contributes to the fact that the magnet, albeit slowly, but demagnetizes! And another mistake is that many people connect the plates with steel (!!!) screws. This, of course, is already a trifle, but if possible, then it is better to exclude it. And here's how I did it...

I decided to connect the plates with rivets.

Magnetic square designed for fixing metal parts during welding, soldering, assembly of structures. It is used to work with round pipes, rectangular pipes, strips, angles, profiles, sheet, solid and other types of metal. square quickly and reliably connects parts, reduces work time, facilitates installation and replaces bulky clamps and clamps. Angles: 45°, 90°, 135°.

There are many types and designs welding elbows from different manufacturers. For various kinds works magnetic squares are available in various sizes, different forces, even with a continuously variable working angle.

Naturally everything welding corners different in price. But if the brand is not very important to you and appearance, then magnetic square can easily be done with your own hands. A home-made device is quite enough for welding and installation work in a garage or a subsidiary farm, and most importantly homemade device nicer and cheaper.

Anyway welding square will find its application.

Let's start manufacturing. Store sample was taken as a basis magnetic square. Its dimensions have been changed to fit magnet, from the speaker, from the old TV. It turned out such a drawing.

Steel grade can be any, in my case it is steel 3. Plates welding elbow you can cut it manually, you can use a grinder, the main thing is to be accurate corners. In my case, the plates were cut from metal using laser cutting. We got such blanks.

Now you need to make a spacer between 2 plates magnetic square she needs to protect magnet from sticking of metal filings and to give rigidity to our structure. The simplest thing that turned out to be at hand is plywood, we cut out a blank with a hole under magnet and reduce the contour of the part by a couple of mm. This is done so that the spacer does not interfere with fixation. magnetic square such as a water pipe.

Now that we have all the necessary details, we collect magnetic square using aluminum rivets, having previously smeared the parts with glue, for greater reliability. The plates must be assembled strictly in parallel.

When the glue dries, it remains only to paint homemade magnetic square, first with a primer, and then with paint, in the color you like.

As a result, we get welding square similar in its characteristics to store samples. The main thing to remember is that during operation it is undesirable to allow strong heat magnetic square, since temperature can lead to loss magnetic properties.

Small metal objects are difficult to hold in one position during the welding process. Fixation is carried out with improvised means so that the products do not move. A magnetic corner is suitable as an auxiliary tool.

It is also called a welding square. It will come in handy and home master, and a professional welder. This mechanism improves the quality of the weld and the part as a whole. Consider how to make a magnetic corner for welding with your own hands.

Types of magnetic holders for welding

The magnetic square is a mechanism for clamping one piece or joining two of its parts, providing support in a given position when welding. It is suitable for single procedure and batch production. Devices differ in design and features of operation. There are such welding magnets:

standard square with non-switchable magnet and stationary corners;

clamp - a flexible device with the ability to adjust angles, appropriate for products of varying complexity;

holders with different power - used to hold workpieces with different characteristics: for small ones - low power, for large ones - high power;

disconnected models - after disconnection, the holders disconnect themselves, the element is released without effort;

universal squares - equipped with several angles with commonly used parameters for complex and simple work;

three-coordinate and quadrangular fixtures - appropriate for welding in difficult high-temperature conditions, they use ferrite magnets that can withstand temperature changes and cylinders.

For home use you can assemble a magnetic corner for welding with your own hands. Handicraft tool withstands mechanical stress. It can fix large-sized parts, permanently hold and join parts of products to obtain high-quality seams.

Angle: permanent action

Corner models are two plates with a magnet placed between them. These are multi-position devices with adjustable clamping angle within 30⁰-135⁰. They are appropriate for quick fixation of the elements to be welded. Plates allow you to hold in the subject in one of 6 positions. Such mechanisms are acquired when, during the welding process, the workpiece needs to be rotated in several angles.

Important! Fixed angle tools should be selected in situations where welding is carried out in frequently used positions.

Disabled

Switchable models - devices with a magnetic field, which is turned off by a special rotary lever. They make it easier to clamp and release the workpiece to be welded. Such devices are easily cleaned of metal chips and small items.

Main selection criteria

For professional works you should choose a high quality tool. Devices are exposed to high temperatures, which reduce the magnetization coefficient of low-quality copies. The fixture must be free of chips, recesses and other defects at the points of contact with the clamped product. Irregularities do not allow you to firmly fix objects at a given angle.

Important! The advantage of switchable corners include the ability to turn off the magnetic field both on the entire device and on its individual faces. These devices are appropriate for craftsmen who often weld parts of complex configuration.

Chinese squares stand out for their budget price, but they do not withstand temperature extremes, so they break quickly. For welding products at different angles, it is recommended to choose a customizable mechanism or purchase a kit containing several types of tools for clamping at certain angles.

Homemade magnetic corner

Home craftsmen will be able to assemble a magnetic corner for welding with their own hands. For its manufacture does not require highly specialized knowledge. You must first prepare:

magnet - thickness less than 15 mm;

steel sheet 2-3 mm thick;

bolts M6 with a set of nuts or rivets;

heat resistant adhesive.

Important! The configuration of the magnet does not matter. Practice shows that it is better to choose its round shape. Suitable option from a powerful speaker

The sheet of steel is marked in the shape of a triangle for subsequent cutting of the elements of the magnetic corner for welding with your own hands, it is better to take ready-made drawings. Bulgarian cut out the first element according to the markup. The second part can be marked on the first by attaching it to the steel sheet. With the help of a file, the cut surfaces are cleaned to a perfectly even state. Finished elements must be the same, errors are not allowed.

Triangles are applied to each other and clamped so that the edges coincide completely. They are fixed in a vice. Holes of the same diameter are drilled in the corners as bolts or rivets that will fasten the elements.

A magnet is placed between the triangular plates. Its size should not exceed the parameters of the triangles. The surface is pre-coated with glue. Parts of the holder are fastened with bolts or rivets. Coloring with heat-resistant enamel is carried out after the glue has hardened.

Important! Your DIY neodymium magnet tool is capable of holding workpieces weighing over 3kg. The condition of non-heat-resistant analogues is recommended to be periodically monitored, therefore it is advisable to fasten their parts with bolts

When making a magnetic corner for do-it-yourself welding, you should take into account the features of the upcoming work. For welding at high temperatures, heat-resistant ferrite magnets must be provided. They don't need state control.

Overheating of a mechanism not intended for heating leads to a decrease in its magnetic effect and irreversible failure. In non-separable structures, it cannot be replaced.

In order to carry out high-quality and safe welding work, in addition to a specialized working tool, protection of hands and face, additional equipment is also recommended - successfully used professional specialists and by occasional welders, a magnetic welding square will make the job easier, more precise and more accurate.

What are the benefits of using magnetic squares?

Any additional devices that facilitate the work of the master have positive aspects of use. A magnetic corner for welding is an indispensable attribute even with a one-time need, not to mention the in-line work performed by professionals:

due to the fact that the metal parts intended for welding are securely fixed, the welder gets more freedom of action and, therefore, convenience in work;
due to the fact that the assembly of the elements to be welded is carried out before direct welding, one person is enough to complete it - magnetic corners minimize labor costs;
when using a magnetic welding corner, the installation of parts is carried out clearly, and therefore the seam will be accurate: when welding structures of increased accuracy, the corners are not a recommendation, but a necessity;
in the production of a large amount of welding work, such corners are simply irreplaceable - they will significantly reduce the time spent by a specialist on welding;
for parts of non-standard configuration it is also convenient to use welding magnetic corners;
parts to be welded can be securely fixed not only on a horizontal, but also on a vertical surface;
in addition to welding, soldering and other types of work connecting individual elements, magnetic corners will be convenient, for example, when marking or cutting steel - a strong fixation will keep individual parts of the structure from falling.

As a rule, elbows of well-known manufacturers have a configuration that allows one such magnetic lock to set different welding angles: 45°, 60°, 90°, 135°. A self-made magnetic corner makes it possible to work with almost any angle of the tool profile set.

What are magnetic welding angles?

Magnetic corners can be different both in configuration, which allows you to set different angles for welding, and according to the principle of operation:

a magnetic square for welding of the most common design allows you to set fixed angles determined by the profile of the tool;
a magnetic clamp with adjustable angles is a flexible tool with which you can perform work of any degree of complexity and accuracy, setting almost any angle;
the magnetic latch can have a permanent or switchable magnet - turning off the magnets after welding allows you to remove the fixation without any physical effort;
most modern models of squares have several standard angles - this design makes this tool versatile, allowing you to perform welding work of varying degrees of complexity;
squares also differ in power: powerful magnets are needed to fix heavy elements of global structures, but tools with low power are recommended for welding compact parts of low weight and are usually used for domestic work.

The price for each tool is formed based on several indicators: the design and the ability to build several angles, the possibility of adjustment, magnetic power, the popularity of the manufacturer, etc. The cost of magnetic holders varies widely: from 300-400 rubles for a household copy and 800-900 rubles for a set of standard fixing angles up to 3000-5000 rubles for a professional tool.

How to choose a magnetic square for welding?

For simple amateur work, inexpensive standard designs of magnetic holders are quite suitable, but for complex professional work and production conditions, three-coordinate (when using cylinders) and tetrahedral squares are designed - made using ferritic heat-resistant magnets, they will give required power for secure fixation of elements of the welded structure of various weights and configurations.

In any case, a high-quality magnetic welding square must be designed for serious loads, have high tensile strength and be resistant to strong mechanical influences from the outside. A square with a certain power must firmly fix the structural elements corresponding to this power in terms of weight and size - only in this case the work of the welder will be comfortable and safe.

To facilitate the dismantling of the magnetic fixing device, it is recommended to choose elbows with switchable welding magnets - in this case, even one master can easily and quickly cope with hard work, using a special switch (one or two to enable / disable each face). Shut-off corners are usually made from durable chrome-plated sheet, and thanks to the working edges, they are successfully used in working with various profiles.

Thus, it is recommended to choose a magnetic holder for welding work based on the expected angles of the connection of parts, the weight of the tool, its size and power.

Do-it-yourself magnetic square for welding

If, for some reason, the assortment of magnetic squares presented in stores, designed to work with pipes of various sections, corners, strips, profile parts, elements from sheet, solid and other metal, does not suit, then it is easy to make such a device with your own hands. Such an easy-to-use and inexpensive tool will faithfully serve in household welding and installation work at home and in the household. There can be several design methods, the most common and cost-effective is as follows:

As a metal base, from a suitable steel grade, manually, with a grinder or with the help of laser cutting, plates are cut with the exact angles of the working planes.
To protect the magnet from sticking metal shavings, sawdust and other things, as well as for additional rigidity of the structure, a spacer is used (for example, from plywood). This part along the perimeter will be slightly smaller (by 3-4 mm) than the plates from item 1, a through hole is made under the magnet.
A magnet of arbitrary (most often round) shape is inserted inside - it is only important that it does not protrude beyond the contours of the outer plates and has a central hole for the possibility of its rigid fixation.
The assembly process consists in strictly parallel folding of all parts, for greater reliability, processing them with glue and fixing them with aluminum rivets.

When using both store-bought samples and those made independently, you should remember about the operating thermal conditions recommended for magnetic devices: heat and strong heating of the magnetic retainer can lead to the loss of its magnetic properties.