Originally Posted by
scott77
i was once told that a pipe cutter makes the ends flare out a bit
fwiw
Sort of. Flaring happens when the cutting wheel displaces the metal as it cuts through, unlike a saw, which removes metal chip by chip, about the width of the saw teeth. Pipe cutters don't remove metal, simply deform it with a hard, thin, circular rolling knife-like blade. I find a file (or grinder or belt sander or deburring tool) is usually necessary to fix the sharp edge left by a pipe cutter, which is on the inside of the tubing when using a pipe cutter. Some materials will actually flare out a bit, aluminum may be more prone to this IME. I think it may have to do with the softness and the thickness of the tube wall which affects this. Steel (and copper, FWIW) tends to end up with a slightly smaller O.D. at the cut area, with perhaps a much smaller flare. In any event, a file or powered tool will take care of it.