Are you looking to tackle a metalworking project with your trusty angle grinder?
Before you get started, it’s important to know which type of disc is best suited for the job at hand. With so many options available, it can be overwhelming to choose the right one.
That’s why we’ve put together this guide to help you determine which angle grinder disc is best for cutting, grinding, and buffing metal.
From flap discs to cut-off wheels, we’ll cover everything you need to know to get the job done safely and efficiently.
So, let’s dive in and explore the world of angle grinder discs for metal!
What Angle Grinder Disc For Metal
When it comes to working with metal, an angle grinder is a versatile tool that can help you cut, grind, and buff your way to a finished product. However, choosing the right disc for the job is crucial to achieving the desired results.
One popular option for metalworking is the flap disc. These discs are like fine sandpaper and are ideal for rougher metals. They can be used to remove metal burrs, sharp corners, and provide enhanced precision. Some flap discs can even be used for buffing out scratches, making them perfect for renovating metal.
Another commonly used disc for angle grinders is the cut-off disc. As the name suggests, these discs are designed for cutting metal bars and sheets. They are thinner than grinding wheels, which allows for more accurate cuts. However, this also makes them more dangerous to work with. If the angle grinder is suddenly moved or bent during use, the disc can shatter and send small parts flying, which can result in serious injury.
When selecting a cut-off disc, it’s important to consider the thickness of the disc and the type of steel you’ll be cutting. For standard everyday jobs on stainless or mild steel, a 1mm or 1.6mm thickness is recommended. For thin metal such as sheet metal, a 1.0mm or 0.8mm thinner cutting disc is ideal as it will sheet metal faster and leave less work in the clean-up of the surface of the metal once you’re done.
For heavier steel cutting jobs where you need to cut through a significant thickness of metal, select a 1.6mm or 2.5mm thickness of cutting disc. However, thicker wheels cut slower and generate more friction and heat through the cut — often discolouring the workpiece and requiring additional steps to finish.
It’s important to note that when working with Aluminium, it’s recommended to apply cutting wax or other type of saw lubricant to the cutting disc to preserve the life of the blade and avoid chipping.
Understanding The Different Types Of Angle Grinder Discs For Metal
When it comes to working with metal using an angle grinder, there are several different types of discs available, each with its own unique purpose.
One popular option is the grinding disc, which comes in different sizes and types depending on the task at hand. The hardness and smoothness of a grinding disc is measured by grit, with lower grit numbers meaning a coarser disc that removes material faster but produces more sparks and a rougher finish. Higher grit numbers produce a smoother finish but remove material more slowly.
For cutting through harder materials like concrete, tiles, and stones, a diamond cutting disc is the way to go. These discs have diamond grits embedded into the edges of a steel disc and are capable of cutting through even the toughest materials with efficiency and precision. While diamond discs may be more expensive initially, they tend to last longer than other types of discs, making them a cost-effective option in the long run.
Another commonly used disc for metalworking is the flap disc, which is like fine sandpaper and is ideal for rougher metals. Flap discs can be used to remove metal burrs, sharp corners, and provide enhanced precision. They can also be used for buffing out scratches, making them perfect for renovating metal.
Cut-off discs are another popular option for metalworking with an angle grinder. These thin discs are designed for cutting metal bars and sheets with accuracy. However, they can be dangerous to work with as they can shatter if the angle grinder is suddenly moved or bent during use. When selecting a cut-off disc, it’s important to consider the thickness of the disc and the type of steel you’ll be cutting.
Lastly, wire wheels are useful for removing rust and paint from metal surfaces. Ceramic sanding discs are also available for smoothing rough surfaces without overheating them.
Choosing The Right Disc For Cutting Metal
When it comes to cutting metal with an angle grinder, selecting the right disc is essential. The two most common discs used for cutting metal are flap discs and cut-off discs.
Flap discs are ideal for rougher metals and can be used to remove sharp corners, metal burrs and provide enhanced precision. They can also be used for buffing out scratches, making them perfect for renovating metal.
Cut-off discs, on the other hand, are designed specifically for cutting metal bars and sheets. They are thinner than grinding wheels, which allows for more accurate cuts. However, they can be dangerous to work with as they shatter easily if the angle grinder is moved or bent during use. This can result in hazardous flying small parts that can cause serious damage.
When selecting a cut-off disc, it’s important to consider the thickness of the disc and the type of steel you’ll be cutting. For standard everyday jobs on stainless or mild steel, a 1mm or 1.6mm thickness is recommended. For thin metal such as sheet metal, a 1.0mm or 0.8mm thinner cutting disc is ideal as it will sheet metal faster and leave less work in the clean-up of the surface of the metal once you’re done.
For heavier steel cutting jobs where you need to cut through a significant thickness of metal, select a 1.6mm or 2.5mm thickness of cutting disc. However, thicker wheels cut slower and generate more friction and heat through the cut — often discolouring the workpiece and requiring additional steps to finish.
It’s important to note that when working with Aluminium, it’s recommended to apply cutting wax or other type of saw lubricant to the cutting disc to preserve the life of the blade and avoid chipping.
Grinding Metal With An Angle Grinder: Which Disc To Use?
Grinding metal with an angle grinder requires a different type of disc than cutting. The most commonly used disc for grinding metal is the grinding wheel or grit disc. These discs are easily recognizable and come in varying sizes and thicknesses. They are perfect for removing excess material from the surface of a project, preparing metal for welding, cleaning up cuts, and several other uses.
When choosing a grinding wheel or grit disc, it’s important to consider the grit level. Lower grit numbers are more coarse, while higher numbered grits are less coarse. If you want a smoother finish, go with a high grit grinding wheel. However, if you’re looking to remove a lot of material quickly, low-grit grinding wheels are perfect for rough, quick work.
Another option for grinding metal is the flap disc. These discs are like fine sandpaper and are ideal for rougher metals. They can remove metal burrs, chamfer edges, and take off sharp corners with enhanced precision. Some flap discs can even buff out scratches that occur during the cutting and fabrication process.
For masonry or stone work, a regular grit disc or cut-off disc won’t cut it. Instead, you’ll need a diamond cutting disc. As the name implies, diamonds grits are embedded into the edges of a steel disc. Diamonds rate a 10 on the Mohs hardness scale, making them efficient for cutting concrete, tiles, stones, etc. They offer superb durability and can work more quickly and easily on harder metals. Though diamond discs may cost more initially, they should outlast other discs in the long run, making them more cost-effective.
Buffing And Polishing Metal: What Discs Are Best?
Once you’ve cut and ground your metal, you may want to buff and polish it to achieve a smooth, shiny finish. For this, felt polishing discs and wheels are the way to go. These discs are made from tightly compressed, high-quality Australian wool and come in a variety of sizes and shapes.
Felt polishing discs are versatile and can be used with any polishing compound for both cutting and polishing. They retain their edge and are excellent for angles and corners. Black Hawk Abrasives Polish Plus felt discs have been specially designed to offer flexibility to polish on contoured surfaces while providing a cooler working action to prevent burning or discoloration on the workpiece.
For angle grinders, polishing flap discs work great. They are available in different sizes, including 4.5″ x ¾” Flap Disc, 4.5″ x ¾” Flat Disc, 2″ Quick Change, and 3″ Quick Change. The quick change polishing discs are also versatile and can be used in die grinders, drills, and air grinders with the backing pad.
When using an angle grinder for buffing or polishing, it’s important to use experienced hands due to the tool’s power. Angle grinders can run up to 13,000 RPM, so it’s advisable to use a variable speed grinder for buffing and polishing jobs. Buffing pads for angle grinders are made from high-quality wool that is wear-resistant.
Another option for buffing metal is the polishing wheel. Attached to the power of the angle grinder, these wheels are effective for metal, glass, ceramic, and wood polishing.
Safety Tips For Using Angle Grinder Discs On Metal
While angle grinders are a great tool for working with metal, it’s important to remember that they can be dangerous if not used properly. Here are some safety tips to keep in mind when using angle grinder discs on metal:
1. Always wear the proper personal protective equipment (PPE). This includes hearing protection, eye protection, gloves, and flame-retardant or resistant clothing. Avoid wearing loose clothing that could get caught in the grinding disc.
2. Make sure the work area is clear of debris and flammable materials before starting to work. Sparks generated during metalworking can easily ignite nearby materials.
3. Check the recommended RPMs of the abrasive disc before use. Never use a disc with a lower recommended RPM than your angle grinder is capable of spinning at, as this can cause the disc to break and send shrapnel flying.
4. Keep the angle grinder at a safe distance from flammable materials and always be aware of where sparks are landing.
5. Use a safety guard on the angle grinder to prevent contact with the wheel while in operation. This can lead to serious cuts and even amputations.
6. Be alert and focused while using the angle grinder. Kickback can occur when the disc is thrust away from the object it is grinding, resulting in severe cuts to hands, arms, head, torso, and legs.
7. Discs can shatter or explode, sending pieces flying across the work area. Always inspect discs for damage before use and replace them if any cracks or chips are present.
By following these safety tips, you can ensure that your experience working with angle grinder discs on metal is both productive and safe. Remember to always prioritize safety when using any power tools.
Maintaining Your Angle Grinder Discs For Longevity And Performance.
To ensure the longevity and performance of your angle grinder discs, it’s important to take proper care of them. Here are some tips to help you maintain your discs:
1. Store your discs properly: Make sure to keep your discs in a dry and clean place. Avoid exposing them to moisture or extreme temperatures as this can cause damage to the abrasive material.
2. Clean your discs regularly: After every use, make sure to clean your discs thoroughly using a wire brush or compressed air. This will help remove any debris that may have accumulated on the disc during use.
3. Use the right disc for the job: Using the wrong disc for a particular job can cause damage to both the disc and the material you’re working on. Always make sure to select the appropriate disc for the task at hand.
4. Keep your angle grinder in good condition: Regular maintenance of your angle grinder can help prevent premature wear and tear of your discs. Make sure to follow the manufacturer’s instructions for maintaining your tool.
5. Replace worn-out discs: Discs that have become worn out or damaged should be replaced immediately. Using a damaged disc can cause injury or damage to your workpiece.
By following these simple tips, you can prolong the life of your angle grinder discs and ensure optimal performance every time you use them.