Grinders Vs Sanders: Understanding Differences And Applications

Do you have a project that requires the removal of specific materials? Perhaps you're wondering which tool is better—a sander or a grinder?

A sander or a grinder are the two primary tool types for any DIY project that involves surface preparation and finishing, whether in woodworking, metalworking, or another craft. Both are similar-looking, whirring, spinning instruments, yet they have different purposes in the workplace.

In this article, we'll discuss the differences between sanders and grinders and their applications, focusing on which is most beneficial so you can choose the right tools for the job.

SANDERS VS. GRINDERS: IMPORTANT DISTINCTIONS DESCRIBED

Sanders could be more flexible, but they are pretty specialized and good at precise tasks. Conversely, Grinders are incredibly versatile tools. With interchangeable discs, they can carry out various functions, including cutting, grinding, sharpening, polishing, and rust removal.

A SANDER: WHAT IS IT?

To smooth it out, Sanders gently removes material from a surface through an abrasion. They accomplish this by applying either a linear or circular motion to sanding belts, sandpaper sheets, or sanding discs as they move across the material's surface. Even though they remove a lot less material, they can still be powerful and cause harm to a surface if not utilized properly.

Sanding machines come in various forms, such as belts, discs, longboards, and orbital sanders. Each of these power sanding tools offers a variety of patterns and finishes for delicate surface preparation or finishing tasks.

A GRINDER: WHAT IS IT?

Imagine sparks shooting skyward or quickly piercing through metal. Grinders are robust instruments that quickly remove material with much greater aggression. They cut, grind, or polish surfaces using a hard, abrasive disc or wheel.

Various grinders are available, including bench, angle, and die grinders. Heavy-duty jobs like grinding welds, cutting metal, and sharpening tools are preferred.

USES AND APPLICATIONS

SANDERS APPLICATIONS: FOR THE PERFECT END

Imagine a polished, flawlessly smooth surface. With a sander and some effort, you can accomplish this. Although they work best on wood and plasterboard, sanders can also be used effectively on metal, plastic, and composite materials when the proper abrasive substance is used. They work great for surface smoothing, paint or varnish removal, and preparing surfaces for a fresh coat.

TYPICAL APPLICATIONS FOR SANDERS

• Leveling and smoothing metal, wood, and other material surfaces. 
• Removing previous coats, such as varnish and paint. 
• Preparing wooden surfaces for coatings such as paint or stain. 
• Forming curves and forms that are curved and smooth. 
• Sanding down the corners and jagged edges. 
• Buffing and polishing surfaces.

GRINDERS APPLICATIONS: THE HEAVY-DUTY CHALLENGER

Grinders are excellent at polishing welds, sculpting stone, and cutting through metal. They may be used on various materials, such as concrete, stone, and metal, making them more adaptable. Therefore, they are invaluable for tasks involving substantial material removal or shaping.

TYPICAL APPLICATIONS GRINDERS

• Metal, concrete, and other materials are cut and shaped. 
• Cleaning surfaces of deposits such as rust and scale. 
• Smoothing rough edges and welds. 
• Sharpening blades and gadgets. 
• Buffed and polished metal surfaces, 
• Edges are chamfered and deburred.

PRECISION AND FINISH 

Although grinders can aggressively remove material, they can leave a rough finish. Because of their kinder method, Sanders is the better choice for getting a smooth, ready-to-finish surface. Starting a project with a grinder for the heavy lifting and switching to a sander for the last touches is not unusual.

GRINDER AND SANDERS: ABRASIVE PRODUCTS

Because they provide the cutting action required to shape and smooth materials, abrasive goods are indispensable for sanding and grinding applications. They are available in several shapes and sizes, each with a distinct function, such as grinding wheels, sheets, discs, and sanding belts.

The following are some typical abrasive product kinds that are used with grinders and sanders:

TYPICAL SANDERS ABRASIVE PRODUCTS:

• SANDING DISCS: These are circular abrasive discs fastened to a backing pad on a disc sander. These coated abrasives, available in different grits and diameters, are frequently used to sand smooth surfaces and shapes. PSA, hook-and-loop, and resin fiber sanding discs are the three most popular varieties. 
• SANDING SHEETS: Hand sanders or sanding blocks with rectangular abrasive sheets connected to them. They offer fine control for intricate work and are frequently used for hand sanding. 
• POLISHING DISCS: specific abrasive discs made for surface finishing and polishing. They give various materials a smooth, glossy finish and are usually composed of fine abrasives.
• LONGBOARD SANDPAPER: These thin, long sanding strips are especially attached to longboard sanders, file boards, and straight-line air sanders. They are frequently employed in the marine industry for boat building and repair, as well as autobody and furniture manufacturing.
• SANDING BELTS: These are abrasive material loops continuously wound around a drum or fastened to a belt sander. They come in various grades and materials, making them appropriate for multiple sanding jobs on metal, wood, and other surfaces.

TYPICAL GRINDERS' ABRASIVE PRODUCTS:

• GRINDING WHEELS are abrasive wheels installed on grinders for heavy-duty grinding and cutting. They are appropriate for working on metal, concrete, and other hard materials and come in various sizes, shapes, and grit levels. 
• CUT-OFF WHEELS: These thin, reinforced abrasive wheels are made to cut through metal, plastic, and other materials. They offer quick, accurate cuts and are frequently used in angle grinders. 
• WIRE WHEELS AND BRUSHES: Abrasive instruments composed of crimped or knotted wire bristles are called wire wheels and brushes. They are suitable for cleaning, prepping, and stripping rust, paint, and coatings off metal surfaces. While cup and end brushes can focus on particular locations, wire wheels can cover more broad areas. 
• FLAP DISCS: These abrasive discs are made of several overlapping sandpaper sheet flaps. They offer a consistent finish and are incredibly adaptable, making them perfect for grinding and polishing curved surfaces. 
• SANDING BELTS: These were discussed previously in the section on sanders, but they can also be used as a grinder to quickly remove material from most surface types when used with a different type of abrasive material, such as a ceramic sanding belt on a stationary belt sander.

SANDER VS. GRINDER: WHICH IS BETTER?

A grinder or sander should be selected based on the specifications of your job. A grinder is the best option if you need to shape materials or remove a lot of material, while a sander is better for final touches and surface smoothing.

Here are some alternative project scenarios, suggestions on which tool would be better, a quick justification, and a Benchmark Abrasives product recommendation.

1. RUST ELIMINATION FROM METAL SURFACES 

• Suggested Tool:

Grinder

• Suggested Product

An angle grinder equipped with a strip disc or a wire cup brush 

• Why?

Grinders are the best tools for quickly removing rust and corrosion from metal surfaces so that they may be painted or welded due to their strong motor and abrasive capabilities. Rust may be effectively removed using wire cup brushes and strip discs without causing any harm to the underlying material. However, if you have some extra time to clear away some surface material, you can also use a grinding disc, flap disc,

2. A WOODEN DECK'S REFINISHING

• Suggested Tool:

Sander

• Suggested Product:

Gold sanding disc with medium-to-coarse grit for Orbital Sander.

• Why?

An orbital sander is a delicate yet efficient tool for smoothing out rough wood and removing old paint or stains from decks, leaving an even, clean surface ready for resealing.

3. SHARPENING TOOLS

• Recommended Tool:

Bench grinder or belt sander

• Recommended Product:

PSA Disc or Sanding Belt

• Why?

Because it offers accuracy and the capacity to work with rigid materials, a bench grinder is ideal for honing the blades of most tools, including chisels, axes, and lawnmowers. 

4. READYING PLASTERBOARD FOR PAINTING

• Recommended Tool:

Sander

• Recommended Product:

The Plasterboard Sander with fine-grit aluminum oxide sandpaper 

• Why?

Sanders gives plasterboard a smooth finish, eliminating flaws and producing an excellent surface for painting.

5. CUTTING METAL PIPES

• Recommended Tool:

Grinder

• Recommended Product:

An angle grinder with a cut-off wheel

• Why?

Grinders are necessary for plumbing jobs or metal manufacturing because they have the strength to quickly and effectively cut through metal pipes.

6. REFURBISHING FURNITURE

• Recommended Tool:

Sander 

• Recommended Product:

Fine-grit sandpaper for detail sanders

• Why?

A detail sander can work around furniture's nooks and crannies, scraping off old finish or preparing surfaces for fresh paint or stain.

7. SMOOTHING WELDED JOINTS

• Recommended Tool:

Grinder

• Recommended Product:

Angle Grinder equipped with a grinding disc

• Why?

An angle grinder is the best tool for flattening out welded connections and ensuring a clean, smooth surface on metal workpieces. 

8. FINISHING COUNTERTOPS

• Recommended Tool: 

Sander

• Recommended Product:

Random Orbital Sander with fine-grit sandpaper

• Why?

A random orbital sander may produce a flawless finish without swirl marks, whether sanding oak, laminate, or even some composite counters.

Since we obviously cannot cover every situation where a grinder or sander would be used, our abrasives experts are available by phone or email if you still have queries.

ALWAYS PUT SAFETY FIRST

Remember that authority entails accountability. When misused, sanders and grinders can both be hazardous. Your primary armor consists of dust masks, gloves, and eye protection. Make sure you're prepared before you power up—dust, flying debris, and sharp edges are no joke.

CONCLUSION: GRINDER VS. SANDER

Let's go straight to the point: which tool is best for you?

• MATERIAL MATTERS: Metal, stone, and concrete are rough materials that grinders can handle. Sanders will be a better option for softer surfaces like plasterboard, plastic, and wood. 
• VERSATILITY MATTERS: The grinder's interchangeable discs provide greater versatility for cutting, grinding, polishing, and other tasks. More sander work should be done for finishing and smoothing. 
• ACCURACY IS ESSENTIAL: A sander is your friend for precise shaping or delicate sanding. Grinders work well for more challenging applications where precision is less critical.

 We at Benchmark Abrasives know the importance of the right tools and accessories for your projects. Browse our wide range of high-quality tools and abrasives to find the ideal fit for your upcoming project. Our abrasives specialists are here to assist you with questions or guidance.