How to Use a Bi-Metal Hole Saw on Stainless Steel

By Quality Industrial Abrasives and Tools | Benchmark Abrasives | Published: 2026-10-24

Category: How-to Guides

Learn how to cut stainless steel with a bi-metal hole saw. Step-by-step guide covers speed, feed, lubrication, pilot bit use, and common mistakes to avoid.

Quick answer

Use a bi-metal hole saw at low speed (200-500 RPM), apply steady pressure, and lubricate continuously to prevent overheating and extend blade life.

Why bi-metal works for stainless steel

Stainless steel is hard and work-hardens quickly if you let the cutting edge rub instead of cut. A bi-metal hole saw’s high-speed steel teeth resist dulling, while its spring-steel body flexes without cracking under the vibration common in handheld drilling. The 4/6 TPI (teeth per inch) and positive rake angle found on Benchmark Abrasives bi-metal hole saws are designed to shear through tough metal rather than scrape it.

Common mistakes that ruin a hole saw on stainless

Running the drill at full speed creates enough heat to harden the stainless surface, which then blunts the teeth. Pushing too hard without a pilot bit lets the saw skate across the work. Using no lubricant causes metal chips to weld onto the teeth. All three mistakes shorten tool life and produce rough, oversized holes.

How to cut stainless steel with a bi-metal hole saw

Step 1: Mark and center-punch the hole location: Use a center punch to create a small dimple exactly where the pilot bit will seat. Without this, the pilot bit can wander on the smooth stainless surface. Skipping the punch is the most common cause of a crooked start hole.
Step 2: Install the pilot bit and hole saw in the arbor: Make sure the pilot bit extends at least 1/4" past the hole saw teeth. A short or dull pilot bit cannot guide the saw through the initial breakthrough, especially on stainless. If the pilot bit is worn, replace it before starting the cut.
Step 3: Apply cutting lubricant to the teeth and work area: Use a heavy cutting oil or a wax-based stick. Reapply every 15-20 seconds of cutting time. On stainless, lubrication is not optional; it prevents heat buildup that hardens the metal. Cutting dry will overheat the saw and the workpiece almost immediately.
Step 4: Set drill speed between 200 and 500 RPM: For a 1" hole saw, start near 500 RPM. For larger sizes like 2-9/16", drop to 200-300 RPM. Faster speeds generate friction heat that ruins the cut. If you see smoke or the work turns brown, you are running too fast.
Step 5: Drill with steady, moderate pressure and let the saw cut: Apply enough forward pressure to keep the teeth engaged. Do not force or wobble the drill. Ease pressure as the saw breaks through the back side to avoid grabbing. A sudden drop in resistance means breakthrough is near; reduce pressure to avoid tearing the hole edge.
Step 6: Clear chips and remove the plug: After the cut, run the drill in reverse briefly to help clear chips from the side cut-outs. Then remove the hole saw and push the plug out from the opposite side. Do not pry the plug out from the front; it can bend the saw teeth.

Products referenced in this guide

2-9/16" Bi-Metal Holesaw: 2-9/16" (65MM) bi-metal hole saw made in USA with 4/6 TPI and positive rake angle. The tooth geometry cuts aggressively without needing excessive feed pressure, reducing the risk of work-hardening stainless steel.
2-9/16" Bi-Metal Holesaw