
Choosing the Right Cutting Wheel (Based on Cutting Material)
Every metal fabrication industry utilizes cutting wheels for large-scale grinding and metalworking applications. They are also frequently employed to remove large quantities of material from metal surfaces. The cutting wheel is primarily an angle grinder, or chop saw attachment.
Today, this article will explore, How to choose the right cutting wheel based on wheel types, grain quality, grinder, and cutting material.
Choosing Cutting Wheel- Based on wheel type (T1/T27)
An angle grinder uses two types of cutting wheels: Type 1 (flat wheel) and Type 27 (depressed center wheel).
Type 1 Cutting Wheels are utilized for the general cutting of metals. Type 1 cutting wheels are flat wheels that do not have a depressed center so that they can provide a large cutting surface.
Type 27 Cutting Wheel is also referred to as depressed center wheels because of its sunken center. Type 27 wheels are perfect for cutting tight curves and hard areas.
Choosing Cutting Wheel- Consider the quality of grain
When it comes to abrasive grains, aluminum oxide is the most widely utilized grain in cutting wheel production. This abrasive grain has a fast cut-rate, and extensive lifespan and produces a rapid, smooth, and easy-to-control cut. Aluminum oxide grains are perfect for grinding stainless steel, hard steel, iron, and other metals.
Choosing Cutting Wheel- Based on wheel thickness
Cutting wheels are available in different sizes (especially based on the thickness of the wheels).
Wheel thickness is the most important factor to consider while choosing the right cutting wheel.
- Select a wheel that is 1mm or 1.6mm thick for general-purpose cutting of mild steel or stainless steel.
- For cutting through hard metals, choose standard thin 0. 045 inch & ultra-thin 1 mm cutting wheels.
Although thin-cutting wheels remove less material at once and provide fast and clean cuts. The main advantage of using them is they produce less heat as well as reduce surface discoloration.
Choosing Cutting Wheel- Based on a grinder/tool
There are different power tools to cut metal depending on the shape and size of the sheet. Among them, an angle grinder is the most common and universal power tool to use with cutting wheels. Angle grinders are small in size, cost less, and cut metal efficiently. Angle grinders are available in a range of diameters to fit different abrasive cutting wheel sizes.
Choosing Cutting Wheel- Based on cutting material
Choosing the right cutting wheel based on the material can be a difficult task. Premium cutting wheels from benchmark abrasives are perfect for cutting through a variety of metals, including aluminum, stainless steel, copper, titanium, metal alloys, and other hard materials.
You can select a cutting wheel by considering the following crucial factors:
#1 Cutting Wheel For Aluminum
Aluminum is a lightweight metal. Its hardened form is made by processing it with other metals. Along with the various benefits of aluminum, there are also some difficulties while working. Aluminum has a low melting point and abrasive-resistant nature. Cutting aluminum requires a durable and efficient cutting wheel.
Type 1 premium thin cutting wheel from benchmark abrasives is the best cutting wheel to cut aluminum.
T1 Thin Cutting Wheel For Aluminum
Type 1 cutting wheels from benchmark abrasives are powerful enough to cut any hard material. This aluminum cutting wheel is designed with mixed abrasive grain composition (silicon carbide and aluminum oxide). T1 thin-cutting wheels last longer and provide an excellent cut rate.
#2 Cutting Wheel For Stainless Steel
Stainless steel is an alloy composed of chromium, iron, and carbon. This chromium provides a corrosion-resistant coating on metals. Although stainless steel resists rust and oxidation, precautions must still be taken during aluminum fabrication and processing. To avoid contamination of the metal workpiece, you need the right bonded abrasive wheel.
Type 1 4x ceramic cutting wheels are perfect for cutting stainless steel.
T1 4X Ceramic Cutting Wheel For Stainless Steel
Benchmark abrasives Type 1 4x cutting wheels are designed with high-quality ceramic, which is a stainless steel-friendly abrasive. In addition to increasing productivity, the stainless steel cutting wheel minimizes rework and eliminates all potential cross-contamination.
#3 Cutting Wheel For Hard Metals
Cutting hard metals like titanium, hardened steel, and nickel alloy requires a cutting wheel with extensive life and a high cut rate. Ceramic-based cutting wheels are capable of cutting through hard metal with more efficiency.
Why are ceramic cutting wheels best to cut through hard metals?
Ceramic cutting wheels are designed and bonded with ceramic abrasive grain. In ceramic abrasives, granules are composed of crystalline structures. This crystalline structure of grain has numerous self-sharpening cutting edges that cut faster than other abrasive grains. As a result, the material removal rate (MRR) of ceramic cutting wheels is high.
#4 Cutting Wheel For Steel
Cutting steel is quite easier than aluminum and stainless steel. As we know, Wheel thickness is the most important factor when choosing a metal cutting tool. Thin cutting wheels are a perfect choice for cutting steel. The thinnest cutting wheels are ultra-thin (1mm) or thin (0.045").
Zirconia and aluminum oxide bonded cutting wheels are best for cutting through steel.
Zirconia Cutting Wheel For Steel
Benchmark abrasives zirconia cutting wheels provide efficient cutting and a high material removal rate when cutting through structural as well as carbon steel. Zirconia alumina is a self-sharpening abrasive grain that provides a constant cutting rate throughout life.
Aluminum Oxide Cutting Wheel For Steel
Benchmark abrasives provide aluminum oxide 4 1/2 cutting wheels. These cutting wheels consist of aluminum oxide grain that is strongly bonded together to provide long life to the wheel and an effective cut rate on steel and other metals.
Essential Safety Tips
- Always wear PPE: Personal protective equipment plays a crucial role while working with cutting tools. Ensure to wear protective gear before using cutting wheels. Protective gear includes face shields, helmets, goggles, respirators, hand gloves, earplugs, and a body suit for full body protection. These gears will protect you from flying dust and debris, sparks, and noises. Without proper gear, there will be a chance of getting harmed or it poses severe health risks.
- Always work within the speed limit: Avoid using cutting wheels beyond their maximum speed limit. Exceeding speed limits can pose a danger to the operator as well as to the wheels. Check the user manual before using the cutting wheel.
- Inspect the cutting wheel: Check the cutting wheels before operating. This ensures safe and smooth work. If you discover any broken parts, replace them right away. Also examine whether the cutting wheels are properly mounted or not. Make sure to use wheel guards to shield you from flying debris.
- Awareness and Training: ensure that all the operators are aware of the uses of cutting wheels, handling them and also what risks they pose. Organize training programs, including emergency procedures in case of severe accidents. Always adhere to safety guidelines.