"Machining" steel ends

[GrahamRounce]

Hi again - I've found that a bench belt sander with a 40-grit belt is quite good for cleaning and squaring the ends of steel bars up to say 10x10mm, but it's sometimes not easy keeping the bar perpendicular, even by using a hole in some aluminium block to hold it.
What I'd like is a metal file like a sanding disc, that's faster and more durable, and more easily controllable.
Any suggestions, thanks!

 

[Agent_zed]

If you want a diy solution you could use a windscreen wiper motor to make a reciprocal file. I've seen it done a lot to make powered hacksaws so not much difference to make it hold a file. With a perpendicular L shaped bed to hold the steel it should be able to file it square.

 

[ChaiLatte]

Make a platform/table that is perpendicular to the belt. Make a fence that fixes to that platform.

There is a difference between a belt sander and a belt grinder. for serious stock removal on metal, the latter tool will perform better. The quality of the abrasive used will make a big difference. Standard aluminium oxide abrastve can be improved upon by zirconium abrasive and that can be improved upon by ceramic abrasive. The trendy new kid on the block is called Cubitron.

There must be a hundred 2 x 72 belt grinder videos on YouTube. Watch some of them and take note of what fixtures, tables, fences etc. people use to present the work to the belt.

Imagine you wish to reduce the length of a 10 x 10 bar by 50mm. The only way you would remove material faster than the proper belt running at the proper speed is to cut 2" off the end of the stock with an angle grinder.

 

[Sideways]

A large portable bandsaw like the milwaukee corded one will cut 100x100mm I'd say. It's a good cut but you will need to dress it to get it just right.
Depending on the refinement needed, a disc in an angle grinder would be my choice, not a file.
If you want any degree of precision, the best way must surely be to use a milling machine.