As an enthusiastic DIYer, there are times you ponder, ‘how to use an angle grinder to cut metal.’ This is especially true if you’re looking to get the job done fast. Likewise, you may also have asked, can you even cut metal with a grinder? The answer is yes! This is because the design and build of angle grinders, which are powerful electric tools, make this possible.
Firstly, it’s important to bear in mind that there are lots of cutting tools available in the market today, which include; circular saw, miter saw, and sawzall and lots not forget bench grinders which unlike angle grinders, are mounted to a workbench or stand. Nevertheless, a lot of attention is shifting to the use of angle grinders, given the popular demand for quick, straightforward and mobile solutions. Most people are also after a versatile tool that can be used for cutting hard and inflexible metal.
To understand how you can use this machine, you need to first learn about its key features.
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How to Use an Angle Grinder to Cut Metal – Key Features
An angle grinder has a spindle washer and a spindle nut that can be connected in different alignments. These allow them to accommodate a variety of thinner and thicker wheels that are interchangeable.
Angle grinders are built to support a various range of tasks. All you have to do is change the discs, and they can perform specific tasks.
Finding the right angle grinders and accessories
- Go for a 4 by 4.5 grinder
- If you want an angle grinder that will come handy for most projects, then go for a 4 by 4.5-inch grinder. Not only is this a standard size, but it is not too large to inconvenience you for DIY projects.
- Pick a grinder with a motor that pulls 5 to 9 amps.
- The power of the motor in an angle grinder is significant as it dictates its strength. To be on the safe side, go for one that supports between 5 and 9 amps for a little extra power.
Verify the RPM on the grinder before buying accessories
One of the details you should always know about your grinder is its maximum rotations per second (RPM). This will guide you when buying accessories as the last thing you need is an accessory that exceeds this rate. If the RPM of an accessory is greater than that of the grinder, it can easily break apart and cause harm to you.
Focus on the safety features of the grinder
You need to be safe when using a grinder, and this means having a model with excellent safety features. Some of the features to consider are:
- Soft handles that reduce vibrations
- Grinding discs with noise reduction
- Wheel brake technology that allows you to stop the grinder in less than 2 seconds.
How to Cut Metal with an Angle Grinder
Angle grinders can be used for many purposes such as cutting out mortar, scoring, stripping rust & paint, debarring, and cutting out tiles, stone & concrete. All this depends on the accessory you settle for, and this should be the first step you take when you want to cut metal.
The go-for accessory for this job is a cutting wheel or metal cutoff disc, which has similar functions to a saw. You will need to attach the cutting wheel into the grinder and fasten the spindle nut. It would be best if you did this while the grinder is unplugged for your safety. As a rule, always ensure the spindle nut is securely tightened to avoid the risks of it coming off while in use.
After preparing your grinder:
- Draw the outline for the cut.
- Use a permanent marker to draw where you want to cut off.
- Suppose you want to make a straight cut mark the two ends on the metal piece. On the other hand, if you want a pattern or a zigzag cut then outline the different curves after sketching out the straight points using an awl.
Before you rush into using a grinder, it is essential to take into account the following safety precautions:
- Always put on protective gear. You are going to cut metal using a powerful electric tool with a spinning disk, which means there will be a lot of flying debris. To protect yourself ensure you have full-face protection, gloves, and a long-sleeved coat. You will also need to protect your ears using earplugs or noise-cancelling earmuffs.
- Remember to support the grinder with both hands. Regardless of how strong you might be, a standard operating rule is to hold the grinder with both hands. One hand should be on the handle and the other on the deadman’s switch. If the grinder does not have a deadman’s switch, use the other hand to hold the weight of the tool.
- Allow the grinder to get to full speed before using it on a surface. Once you hit the power button, do not be in a rush to use the grinder. Instead, let it come to full speed before using it.
- Apply light pressure when cutting metal. Do not use your force to cut metal; instead, let the grinder work for you. All you need to do is hold the grinder on the object, and it will perform its duties.
- Hold the wheel perpendicularly whole cutting metal. You should know how to use the correct angles of the grinder while using it for different functions. While cutting remember to hold the wheel perpendicularly.
- Have the disc guard on at all times. There are moments when it seems like the guard gets in the way but never be tempted to take it off. Have in mind that the guard is there to protect your arms from taking a hit.
- Only put the grinder down after it has stopped spinning.
- When you are not using the grinder, unplug it from your power source.
How Thick of Steel Can An Angle Grinder Cut?
The thickness of steel that a grinder can cut is dependent on the type of disc you are using and its cutting capacity. If you are using a 4 by 4.5 inch grinder that has a flat diamond cutoff blade you will need a:
- 1mm or 1.6mm iron-free disc for cutting stainless steel or mild steel
- 1mm or 0.8mm cutting disc for cutting a thin sheet of metal
- 1.6m or 2.5 mm cutting disc for cutting angle iron or structural steel
Note: If you are cutting aluminum you will require a type saw lubricant to eliminate the risks of chipping. This will also enhance the lifespan of the cutting disc.
Conclusion
You can always rely on a grinder to cut metals. But, you must remember to be careful when using this device and carefully choosing the right cutting wheel/disc. You will also need a little practice to master how to use this tool efficiently.
Finally, if you’re also into woodworking and looking to build out your collection of tools, you may want to check out our guide on: How To Take Apart a Pallet Without Breaking the Boards.