Are you looking to cut metal with an angle grinder but not sure which blade to use?
With so many options available, it can be overwhelming to choose the right one for your project. But fear not, we’ve got you covered.
In this article, we’ll break down the different types of cutting discs and their recommended uses, so you can make an informed decision and achieve the best results possible.
Whether you’re a DIY enthusiast or a professional tradesperson, read on to learn more about what blade to cut metal with angle grinder.
What Blade To Cut Metal With Angle Grinder
When it comes to cutting metal with an angle grinder, the type of blade you use is crucial to achieving a clean and precise cut.
Firstly, it’s important to note that you should always use blades that are specifically rated for angle grinders. Never use metal-cutting circular saw blades instead, as they have base shoes that pull the metal towards the base while you cut, which can be dangerous when used with an angle grinder.
Cutting discs come in different thicknesses, and the type of wheel you select depends on the type, shape, and thickness of the steel that needs to be cut. For standard everyday jobs on either stainless or mild steel using an angle grinder, choose a 1mm or 1.6mm thickness in your disc.
For projects that involve thin metal such as sheet metal, choose a 1.0mm or 0.8mm thinner cutting disc. These thinner discs will cut through sheet metal faster and minimize discoloration, leaving less work in the clean-up of the surface of the metal once you’re done.
When working with aluminum, it’s recommended to apply cutting wax or another type of saw lubricant to the cutting disc to preserve the life of the blade and avoid chipping.
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, it’s important to note that 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 also worth noting that if you’re looking to cut metal lath or hardware cloth, using a diamond blade in your angle grinder can make the job easier. We recommend using a diamond blade that’s labeled as a ferrous-metal-cutting blade, but many tradespeople use a regular masonry diamond blade with good results.
Understanding The Different Types Of Cutting Discs
When it comes to cutting discs for angle grinders, there are several different types available, each with their own specific use.
The most common type of cutting disc is the standard flat disc, also known as a Type 1 or Type 41 disc. These discs are completely flat and are typically considered the most efficient type of wheel for general all-purpose cutting. Because they lack a depressed center, they provide more cutting surface and minimize interference with the workpiece. The flat profile helps create deep 90-degree cuts into a workpiece, allowing for the maximum depth of a 90-degree cut at the expense of a small amount of visibility for the operator.
Another type of cutting disc is the thin cut-off wheel. As the name suggests, these discs are thinner than standard cutting discs and are used primarily for cutting metal bars and sheets. Due to their thin design, these discs can be dangerous, so it’s important to wear proper protective gear when using them. Thinner discs will cut through sheet metal faster and minimize discoloration, leaving 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 thicker cutting disc, such as a 1.6mm or 2.5mm thickness. However, it’s important to note that 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 also worth mentioning that there are specialized cutting discs available for specific materials, such as diamond blades for cutting through metal lath or hardware cloth. These blades are labeled as ferrous-metal-cutting blades and can make the job easier. However, many tradespeople use a regular masonry diamond blade with good results.
Abrasive Discs: Best For Cutting Ferrous Metals
When it comes to cutting ferrous metals such as steel or iron, abrasive discs are not the best option. They wear down quickly, cut slowly, and shrink in diameter as you use them. Instead, we recommend using a diamond blade that’s rated to cut ferrous metal. These blades are made with a harder material and will last much longer than abrasive discs.
Diamond blades are also more efficient at cutting through thicker metals, making them the ideal choice for heavy-duty jobs. They cut quicker and cleaner than abrasive discs, leaving a smoother finish on the metal surface.
It’s important to note that when using diamond blades, you should always follow the manufacturer’s instructions and use the appropriate safety gear. The dust generated from cutting metal can be harmful if inhaled, so wearing a dust mask is essential.
Diamond Discs: Ideal For Cutting Non-Ferrous Metals
If you need to cut non-ferrous metals such as copper, brass, aluminum or even PVC plastic pipe, a diamond disc is the ideal choice. Diamond discs are made with a vacuum brazed diamond coating that is extra thick and durable. This coating ensures that the blade lasts significantly longer than traditional cut-off wheels, making it a cost-effective choice for those who frequently cut non-ferrous metals.
Diamond discs are also excellent for demolition work, as they can cut through a wide range of materials quickly and efficiently. In addition, they maintain a constant cutting depth throughout their lifespan, which means you won’t have to constantly replace them like you would with traditional abrasive discs.
When selecting a diamond disc for cutting non-ferrous metals, look for one that is labeled as a ferrous-metal-cutting blade. These blades are specifically designed to cut through harder materials like steel and iron, but they also work well on softer metals like copper and aluminum.
It’s important to note that diamond discs generate more heat than traditional abrasive discs, so it’s essential to use them with caution and follow all safety guidelines. Always wear appropriate safety gear such as gloves and eye protection when using an angle grinder with a diamond disc.
Carbide-Tipped Discs: Perfect For Cutting Thick Metal
If you’re looking to cut through thicker, denser metals with your angle grinder, carbide-tipped discs are the perfect solution. These discs are specifically designed for intense metal cutting applications on materials between 3/16″ and 1/2″ thick.
Carbide-tipped discs are made with precision ground carbide teeth, which are harder, more heat-resistant, and offer greater impact-resistance than standard bi-metal blades. This means that they are capable of cutting everything from mild steel pipe to angle iron to stainless steel plates and much more. They will drastically outlast and cut faster than traditional bi-metal blades with cobalt alloy teeth on difficult-to-cut metals.
The combination of these characteristics makes carbide-tipped discs ideal for cutting metals that would almost immediately destroy a carbon steel or traditional bi-metal blade. These discs are extremely long-lasting and are capable of straighter cuts, less vibration, and reduced operator fatigue.
When selecting a carbide-tipped disc for your angle grinder, look for a disc with a 1″ wide body and .050″ thickness for even greater impact resistance. The 8 TPI makes this blade extremely aggressive and fast cutting. Additionally, make sure to choose a disc that is the appropriate length for your job – 6″ inch blades are more rigid than longer blades resulting in a straighter cut.
Choosing The Right Size And Thickness Of Cutting Disc
Choosing the right size and thickness of cutting disc for your angle grinder is essential for achieving the desired cut. The thickness of the disc will depend on the type, shape, and thickness of the metal you are cutting. It’s important to choose a cutting disc that’s rated for angle grinders and avoid using circular saw blades, as they can be dangerous when used with an angle grinder.
For standard everyday jobs on mild or stainless steel, a 1mm or 1.6mm thickness of cutting disc is recommended. Thinner discs such as 1.0mm or 0.8mm are ideal for cutting thin sheet metals as they cut faster and leave less work in the clean-up of the surface once you’re done.
When working with aluminum, it’s recommended to use cutting wax or another type of saw lubricant to preserve the life of the blade and avoid chipping.
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, it’s important to note that 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 also worth noting that diamond blades can be used for cutting metal lath or hardware cloth. A diamond blade labeled as a ferrous-metal-cutting blade is recommended, but many tradespeople use a regular masonry diamond blade with good results.
Safety Precautions When Using An Angle Grinder To Cut Metal
Using an angle grinder to cut metal can be a dangerous task, and it’s important to take proper safety precautions. Here are some essential safety tips to keep in mind:
1. Wear appropriate personal protective equipment (PPE), including eye protection, hearing protection, a full-face mask, hand gloves, and suitable attire. Avoid wearing loose clothing and tying long hair.
2. Choose the right cutting disc for the job, and make sure it’s rated for use with an angle grinder. Never use a circular saw blade instead.
3. Ensure that the cutting disc is properly installed and secured before use. Follow the manufacturer’s instructions for correct fitting, and never use a worn or damaged disc.
4. Keep the angle grinder at a 15 to 30-degree angle to the metal being cut, and hold it firmly with both hands. Use minimal pressure to avoid the disc grabbing and causing kickback.
5. When cutting heavier steel, use a thicker cutting disc, but be aware that thicker wheels cut slower and generate more friction and heat through the cut.
6. Apply cutting wax or another type of saw lubricant when cutting aluminum to preserve the life of the blade and avoid chipping.
7. Never operate an angle grinder in proximity of flammable items, as sparks produced during operation can cause fires.
8. Take regular breaks to rest your hands and arms, and stop using the grinder immediately if you feel fatigued or uncomfortable.
By following these safety precautions, you can ensure that your angle grinder is used safely and effectively when cutting metal.