The Right Abrasive Cut-Off Wheels For Your Application

A cut-off wheel is a highly useful and often used abrasive product because it is made with abrasive grain for cutting, notching, and grinding. When cutting metal, steel, or stainless steel is necessary for your application, metal cut-off wheels are a great option.

Cut Off Wheels: What is it?

Cutting wheels, also known as cut-off wheels, are structurally and operationally different from grinding wheels. Grinding wheels use abrasive wheels to remove large amounts of material from a workpiece at shallow angles, while cutting wheels produce precise, thin cuts at 90-degree angles. This is why cutting wheels are often thinner than grinding ones; their thinness enables more accurate and clean cuts even when they don't have the lateral strength required for side grinding.

Cutting Wheels: Types

Cutting wheels are available in several varieties. Typical types include types 1, 27, 41, and 42, where the different numbers denote the wheels' different characteristics and forms.

• Type 1 Cutting Wheel (Type 41)

A cut-off wheel of type 1, sometimes called a type 41 cut-off wheel, is entirely flat. In general, it is the most effective wheel for all-purpose cutting. It has less interference with the workpiece and a larger cutting surface because it doesn't have a hollow center.

The flat profile allows for deep 90-degree cuts into a workpiece. At its deepest point, it can cut up to a 90-degree angle, although its operator's field of vision is relatively limited. Type 1 cutting wheels are beneficial in grinders, die grinders, high-speed saws, stationary saws, and chop saws, even though their straight profile and method of mounting near the guard can reduce operator visibility.

• Type 27 Cutting Wheel (Type 42)

A cut-off wheel classified as type 27 (also known as type 42) is not perfectly flat in the center; instead, it features a depressed area. The hollow center of the wheel permits the operator to work at a limited angle, even though it reduces its cutting capacity when navigating around profiles, extrusions, and corners. 

Because of the depressed design, an elevated hub can also be employed to secure the wheel firmly in place.

The recessed locking nut on a depressed-center cutting wheel facilitates flush cutting and improves the operator's perspective of the cut. Type 27 cutting wheels are designed for use with right-angle grinders.

Most Well-Liked Metal Cut-Off Wheel

For many years, metal fabricators and manufacturers have relied on Benchmark Abrasives' high-quality, quickly reinforced wheels, which are manufactured in the United States. The Type 27 Depressed Center 4-½" Wheel is the most often used cut-off wheel that we offer.

This disc features zirconia grain, which reduces vibrations and facilitates smoother operation and faster cutting action. It is designed to last longer in a machine. This is a thin reinforced wheel that cuts stainless steel quite effectively. It cuts more quickly and lasts longer than any other cut-off wheel available.

Cutting Wheel Usage

Thus far, we have explored how the cutting wheels of types 1, 27, 41, and 42 provide unique forms for various cutting tasks. We've looked at the numerous typical grains used in cutting wheels, how they're tailored to work on different metals, and how wheel thickness and diameter impact precision and speed. Let's now examine several uses/'

 for professional and industrial cutting wheels, as well as to select the best wheels for these applications.

All-Purposes Fabrication

In the realm of metal manufacture, wheel diameters of 0.045 inches are frequently selected. Generally, for thinner materials, a 1-millimeter wheel may be a better choice because it provides greater precision, generates less heat, and requires fewer burr removal steps before welding. The materials in the workpiece will likely determine the type of grain to be used; better-performing grains will be used for structural steel and other difficult-to-cut metals, while contaminant-free wheels will be used for stainless steel.

Fabrication of Pipes

In manufacturing metal pipes, the diameter of the pipe to be cut often influences the selection of the cutting wheel. In most cases, a 4 1/2-inch diameter will work for pipes that are 3/4-inch or less. A 6-inch cutting wheel works well for pipes up to 2 1/2 inches in diameter, while a 9-inch cutting wheel works best for pipes up to 3 1/2 inches in diameter. Furthermore, it is advised to use a type 1 wheel for a deeper cut and to choose the thinnest wheel available to minimize heat and friction unless the application specifies otherwise.

When operating at a constrained angle, a depressed-center cutting wheel provides more room for longer tubing, which is commonly seen on pipelines. A wheel thickness of 0.045 inches is ideal for cutting tasks in fabrication yards or on the right-of-way for field repairs.

Welding Prep

Precise metal cutting is typically necessary before beginning to weld. Simple cut-off operations don't require precision, but they can save time and money for more complex work or restorations where the material's original aesthetic qualities must be preserved. It's usual practice in welding to use a cutting wheel that's 0.045 inches thick, or slightly thicker than a millimeter, to enable clean, precise cuts. 

Railways

High-speed gas saws require high-performance cutting wheels, as the alloy steels used in elevated railways are difficult to cut. A self-sharpening zirconia alumina grain provides excellent performance and maintains a strong cutting performance across the wheel's lifespan.

Construction

Many different uses for metal cutting can be found on building and construction sites. When cutting off rebar and performing lengthy cuts on sheet metal, operators frequently search for a wheel that can do it all. An aluminum oxide wheel often offers the best balance of affordability, performance, and adaptability.