In metal cutting, a common rule of thumb is that half the success of a job depends on selecting the right saw blade. Choosing a blade essentially comes down to two things: tooth pitch and tooth form.
Let's start with tooth pitch.
The basic principle is to maintain between six and twelve teeth in the cut at any given time. That's the sweet spot. For thin-walled tubes or sheets, you need a finer pitch-typically 8 to 14 teeth per inch. For solid bars or heavy plates, go with a coarse pitch, around 2 to 4 teeth per inch. Too fine a pitch will clog; too coarse will struggle to pull the cut.
Now tooth form.
For general structural steel, a standard regular-tooth blade works just fine. But for stainless steel or alloy steels, which tend to vibrate, always use a variable-tooth blade. It helps break up resonance and delivers a much smoother cut. For soft non-ferrous metals like aluminum or copper, use a hook tooth blade-the one with a large positive rake angle. It cuts fast and resists gumming.
In short: fine pitch for thin sections, coarse pitch for thick sections, variable pitch for hard materials, and hook teeth for soft ones. Get the selection right, and you've already done half the work.
