Hi. I saw a message posted to this group by someone saying that he can cut 1 square inch of soft steel cross section in 60 seconds. That sounded pretty fast to me, and I decided to give it a try. I was able to cut about half a square inch of steel bar in about 30 minutes. This is with a regular Craftsman hacksaw with a good blade. I am using a large vise which holds the work steadily. I used a small amount of gear oil in the kerf. The saw is cutting (I can feel it bite on the cutting stroke), and filings are coming out. Actually, a1/2 inch square cut is quite a bit of filings. But this is approximately 1/60th the rate that the newsgroup post alluded to. I thought that I should be at least within a factor of 10. The steel that I am using is part of a bracket, and it cuts easily with a file (no skate).
I know that an expert computer programmer can program 60 times faster than a beginner, and get paid 10 times as much, but computer software is a strange animal. I would think that I should be able to get within a factor of 10. The blade wasn't buckling, so I think that a high-tension hacksaw would not give all that much of a boost. It may improve cutting speed by a factor of 3.
So, how does one cut a square inch of steel in 60 seconds? Inches do matter!