Guide to Cutting Wheels - Weiler Abrasives

In metal fabrication and manufacturing operations, various tools use cutting wheels to cut material from a workpiece.

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What is a cutting wheel? Cutting wheels, or cut-off wheels, differ from grinding wheels in their function and structure. Where grinding wheels use an abrasive to grind large pieces of material off a workpiece from a shallow angle, cutting wheels typically make narrow, precise cuts at 90-degree angles. Consequently, cutting wheels are often thinner than grinding wheels — though they do not have the lateral strength required for side grinding, their minimal thickness makes them better for clean, accurate cuts.

Weiler Abrasives offers several cutting wheels for different applications. We provide everything from 1-millimeter cutting wheels to extended-diameter wheels for larger cuts. This guide to cutting wheels covers the differences between various types of cutting wheels and explains how to choose the right wheel for a given application.

TYPES OF CUTTING WHEELS

Cutting wheels come in a few different types. Some common types are type 1, type 27, type 41, and type 42, where the various numbers signify the wheels' different shapes and properties.

TYPE 1 CUTTING WHEEL (TYPE 41 CUTTING WHEEL)

A type 1 cut-off wheel, also known as a type 41 cut-off wheel, is completely flat. It is typically considered the most efficient type of wheel for general all-purpose cutting. Because it lacks a depressed center, it provides more cutting surface and minimizes interference with the workpiece.

The flat profile helps create deep 90-degree cuts into a workpiece. It allows for the maximum depth of a 90-degree cut at the expense of a small amount of visibility for the operator. Though their straight profile and the way they mount close to the guard can diminish visibility for the operator, type 1 cutting wheels are exceptionally useful in grinders, die grinders, high-speed saws, stationary saws, and chop saws.

TYPE 27 CUTTING WHEEL (TYPE 42 CUTTING WHEEL)

Instead of being completely flat, a type 27 cut-off wheel, also known as a type 42 cut-off wheel, has a depressed center. The depressed center allows for added clearance when the operator is working at a constrained angle, though it gives the wheel limited cutting ability when working around corners, profiles, or extrusions. The depressed shape allows for a raised hub as well to hold the wheel securely in place.

The profile of a depressed-center cutting wheel gives the operator a better view of the cut, and it provides the ability to flush-cut because the raised hub means the locking nut can be recessed. Type 27 cutting wheels are designed for right angle grinders.

CUTTING WHEEL MATERIALS

Cutting wheels typically contain a few different materials — primarily the grains that do the cutting, the bonds that hold the grains in place, and the fiberglass that reinforces the wheels.

GRAIN

The grains within the abrasive of a cutting wheel are the particles that perform the cutting.

Grains may come in several types. Common types of grains for cutting wheels include ceramic alumina, zirconia alumina, aluminum oxide, and silicon carbide.

• Ceramic alumina: Ceramic alumina performs exceptionally well on steel, stainless steel, and other hard-to-cut metals, including inconel, high nickel alloy, titanium and armored steel. When used and maintained properly, it offers a superior lifespan and cut, and it tends to cut cooler than other grains, so it reduces heat discoloration.
• Zirconia alumina: Zirconia alumina provides superior cutting for steel, structural steel, iron, and other metals, and it is ideal for rail cutting and other heavy-duty applications. It offers a fast cut and a long life and holds up under extreme pressure.
• Aluminum oxide: Aluminum oxide is one of the most common abrasive grains. It provides a fast initial cut rate and consistent performance for steel and other metal.
• Silicon carbide: Silicon carbide is an extremely hard grain that produces very sharp and fast cutting. However, it is also friable, meaning it is not as tough as other grains.

The grain's grit helps determine its physical and performance properties as well. The grit refers to the size of the individual abrasive particles, in the same way sandpaper grains receive classification by their size. Grit sizes range from 16 to 60, with smaller numbers indicating larger, coarser particles and larger numbers indicating smaller, finer particles.

BOND

The bond of a cutting wheel is the substance that holds the abrasive grains in place.

Manufacturers often refer to the grade, or hardness, of a wheel. The grade signifies not the hardness of the abrasive grains themselves but the hardness of the bond holding them in place. Generally, under identical conditions, a harder bond means the cutting wheel will have a longer lifespan, whereas a softer bond means the cutting wheel will have a shorter lifespan.

A softer bond does provide certain advantages — it sheds its grains more rapidly to provide a faster cut. With a stronger bond, the bond may hold the grains in place after they have become worn. A softer bond releases them faster to reveal fresh, sharp grains more often and increase the wheel's cut rate.

With certain metals, it is important not to introduce contaminants into the metal when cutting. When cutting stainless steel and aluminum, always make sure the abrasive contains less than 0.1% of chlorine, iron, and sulfur, ensuring it is contaminant-free. Contaminant-free products will have identifying labels.

One of the bonds commonly used with abrasive grains for cutting wheels is resinoid. Resinoid bonds contain organic compounds. They tend to have better shock resistance than other types of bonds and can withstand operation at elevated peripheral speeds. They are ideal for cut-off applications, and they allow for self-sharpening by exposing new grains. Some specialized bonds are resin-over-resin bonded. These bonds provide additional moisture and heat resistance, as well as a stronger overall bond to make better use of the grains.

FIBERGLASS

Cutting wheels contain fiberglass that may provide single, double, or triple reinforcement. Single reinforcement relies on a single layer of fiberglass and is useful for delivering exceptional cutting speed while reducing burrs on the workpiece. Double and triple reinforcement use multiple layers of fiberglass to provide added support for high-vibration and heavy-duty industrial applications. 

At Weiler Abrasives, all our cutting wheels for right angle and die grinders have two layers of reinforcement. We do offer some single-reinforcement wheels in our large-diameter chop saw line and some triple-reinforced wheels in our new high-speed gas and electric saw wheel line.

SELECTING CUTTING WHEEL SIZE

With cutting wheels, the tool the operator has access to will often determine the wheel size, and selecting the correct size for the given application is also essential. Choosing the correct size involves calculating the right rate of revolutions per minute (RPMs) — the RPM rating of the cutting wheel should match or exceed the RPM rating on the grinder that will use it. In addition to verifying the RPM rating, it is also important to ensure that the wheel fits on the tool without interfering with or removing the guard.

CUTTING WHEEL DIAMETER

A wheel's RPM rating tends to correspond with its diameter and the tool it is designed for. Common cutting wheel diameters range from 2 to 4 inches for die grinders, 4 to 9 inches for angle grinders, and 12 to 20 inches for chop, stationary, or high-speed saws.

CUTTING WHEEL THICKNESS

The right wheel thickness often depends on the precision and accuracy necessary for the cut. For a highly precise cut, a thinner wheel can perform with greater accuracy and precision. They cut more quickly and generate less heat. Thinner wheels also remove less material with each cut, which is ideal when making repairs or fitting up parts. The tradeoff is that they tend not to last as long as thicker wheels under identical conditions. In applications where precision and accuracy are not as critical but longevity is, a thicker wheel may be suitable.

Weiler Abrasives offers two ultra-thin high-performance cutting wheels — the Tiger® Zirc Ultracut 1-millimeter and the Tiger Inox Ultracut 1-millimeter. Both of these cutting wheels come in 4 1/2- or 5-inch diameters. The Tiger Zirc Ultracut 1-millimeter offers an ultra-fast cutting rate and long life, and it is ideal for cutting thin sheet metal, tubes, profiles, and small cross-section rods. The Tiger Inox Ultracut 1-millimeter is ideal for stainless steel because it is contaminant-free.

Weiler Abrasives has an exciting new line of chop, stationary, and high-speed saw wheels as well. The chop saw wheels have a 3/32-inch thickness, and the high-speed saw wheels and stationary saw wheels have a 1/8-inch thickness. These cutting wheels are ideal for cutting applications in the metal fabrication, construction, and rail industries, and some of the specialized models can provide precise rail cutting, burr-free cutting, and stud cutting for heavy-duty applications.

CUTTING WHEEL APPLICATIONS

So far, we've discussed how types 1, 27, 41, and 42 cutting wheels offer distinctive shapes for different cutting applications. We've delved into the various common grains used in cutting wheels and how they are optimized for use on different metals, and we've explored the way diameter and thickness affect wheel speed and precision. Now let's look into a few applications for industrial and professional cutting wheels and how to choose the right wheels for these uses.

1. GENERAL FABRICATION

In general metal fabrication, 0.045-inch wheel diameters are common choices. With thinner materials, an operator may want to choose a 1-millimeter wheel instead for greater precision, less heat generation, and fewer burrs that will require removal before welding. The choice of grain will likely depend on the material composition of the workpiece — higher-performing grains for structural steel and difficult-to-cut metals, contaminant-free wheels for stainless steel.

2. PIPE FABRICATION

In metal pipe fabrication, the choice of cutting wheel often depends on the diameter of the pipe to be cut. For a 3/4-inch or smaller pipe, a 4 1/2-inch diameter will usually be sufficient. For a pipe of up to 2 1/2 inches, a 6-inch cutting wheel is effective, and for a pipe of up to 3 1/2 inches, a 9-inch cutting wheel is often most suitable. It's also advisable to choose the thinnest wheel possible to minimize heat and friction and to use a type 1 wheel for a deeper cut unless the application imposes a particular constraint. For larger pipe often found on the pipeline, a depressed-center cutting wheel provides added clearance when working at a constrained angle, and 0.045-inch wheel thickness is ideal for cutting applications in fabrication yards or on the right of way for field repairs.

3. SHIPBUILDING

When an operator is working on the confined, hard-to-access spaces of a ship, making a cutting wheel last as long as possible is often a priority. For this reason, the operator will often want to choose a harder, potentially longer-lasting wheel like Tiger Ceramic. However, when operators must use air tools whose hoses have stretched over long distances to access difficult areas of the ship, the tools may be underpowered. In this case, wheels with a soft bond will be ideal because they make it easier to maintain a fast cut. In shipbuilding, the work material often influences the cutting wheel selection. When working with aluminum, an operator may want to select a cutting wheel that will not load or gum up, like Tiger Aluminum.

4. WELDING PREPARATION

Preparing for welding typically involves exact metal cutting. With a basic cut-off operation, precision is not critical, but with complex work or repairs that need to preserve the initial aesthetic qualities of the material, precision can save time and money. Using a 0.045-inch cutting wheel — a little more than a millimeter thick — is common in welding to allow for precise and accurate cuts. For precise cuts on thin sheet metal, profiles, and small diameter rods, a 1-millimeter UltraCut wheel will provide smooth cutting and exceptional control for clean, ultra-precise cuts.

5. RAILWAYS 

Modern railways use hard-to-cut alloy steels, so a high-performance cutting wheel is necessary for high-speed gas saws. A self-sharpening zirconia alumina grain that retains a high cutting performance throughout the life of the wheel offers excellent performance. The Tiger Zirc 14- and 16-inch cutting wheels are designed specifically for high-speed gas saws and deliver the high-performance solutions needed to increase productivity and profitability.

6. CONSTRUCTION

Building and construction sites feature a wide variety of metal cutting applications. Operators often look for a wheel that can do it all, from cutting off rebar to making long cuts on sheet metal. Many times, an aluminum oxide wheel provides the right mix of versatility, performance, and price. The Tiger AO line offers both flat and depressed-center cutting wheels in various sizes for die and right angle grinders. The Tiger AO line also expands into larger sizes from 12 to 16 inches for chop saws and high-speed gas and electric saws.

These large-diameter cutting wheels have several signature wheels designed with the construction industry in mind. For chop saws, the line includes a wheel designed for stud cutting and options for burr-free cutting that feature a single layer of fiberglass. The high-speed saw offering includes wheels with three layers of fiberglass for added support in heavy-duty cutting applications.

PARTNER WITH WEILER ABRASIVES FOR QUALITY CUTTING WHEELS

To see the benefits of superior cutting wheels in your industrial and professional operations, make Weiler Abrasives your trusted source for surface conditioning solutions. Our cutting wheels come in various types, grains, bonds, diameters, thicknesses, specialized features, and price points, so we can help you find the wheels or small cutting discs that are right for your applications.

The value you'll receive extends far beyond the purchase of a cutting wheel. Our Value Package offers additional advantages such as safety training to facilitate the safe and effective use of your cutting wheel and direct field support to answer your questions and help you make your facility more efficient and productive.

Are your cutting projects taking too long, costing too much, or leaving you with subpar results? The right cutting disc allows you to slice through the toughest materials with ease and precision. In this blog, we explore how to choose the right cutting disc for your needs.

Let's break down the top 10 factors to consider:

10 Factors to Consider When Choosing the Right Cutting Discs

1. Disc Type

The type of cutting disc you use lays the groundwork for your project's success. Each type excels in specific tasks and materials. Understanding these distinctions guarantees a safe and successful project with the best-cut quality.

These are three common metal-cutting disc types:

Abrasive Discs:

Aluminium oxide and silicon carbide are the materials that make these discs the workhorse of cutting. They expertly tackle steel, stainless steel, cast iron, and more. Although reliable, they generate heat that may cause minor warping or hardening.

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Diamond Discs:

Diamond discs are studded with industrial diamonds set in a metal or resin base. These powerhouses effortlessly slice through hard, abrasive materials like ceramic, tile, and stone.

It is also possible to use them for thinner metals, such as aluminium and copper, as long as you are cautious. Diamonds produce a lot of heat.

Carbide-Tipped Discs:

Carbide-tipped discs combine super-strength carbide tips with a steel or aluminium base. It's the perfect tool for cutting thick or hardened steel.

While pricier than abrasive or diamond discs, they reward you with durability and precise cuts.

2. Material Compatibility

Great cuts require discs with the right grit and bond. It ensures smooth operation, less risk of accidents, and a flawless finish.

Here are some disc options tailored to specific metals:

Steel:

In most steel-cutting jobs, abrasive discs with tough aluminium oxide or silicon carbide grains are suitable. For heavy-duty work, carbide-tipped discs are your best bet.

Stainless Steel:

Discs with a harder bond and finer grit protect stainless steel's finish and prevent corrosion. In some cases, diamond discs are the right choice.

Aluminium:

Thinner discs with aluminium oxide or silicon carbide abrasives paired with a suitable bond are the way to go with aluminium. While diamond discs work, keep those speeds lower to avoid overheating the metal.

Cast Iron:

Consider strong, coarse-grit abrasive discs for handling cast iron. Choose carbide-tipped discs for heavy-duty cutting.

3. Disc Size

Size matters when cutting discs. The disc diameter is crucial to performance, safety, and efficiency.

Make sure your disc fits your tool and is suitable for the size and thickness of the material. It guarantees the cutting depth and keeps your equipment in top shape.

Metal cutting discs typically range from 4 to 14 inches in diameter. Make sure the disc size is right for your cutting tool.

For example, Angle Grinders handle discs from 4 to 12 inches. The cutoff saw is efficient for large projects and requires 12 to 14-inch circular saw blades.

4. Thickness

Cutting disc thickness is all about stability, wear resistance, and cutting speed.

Thicker discs are effective and last longer but might sacrifice speed, while thinner discs cut fast but wear out more quickly.

Thick Discs are known for power and durability. In jobs requiring tough materials or extended cutting, thicker discs provide more stability. They resist bending and handle the heat of a hard day's work.

Thin Discs are known for precision and speed. Thinner discs are better for fine cuts or when speed is critical. Their smaller profile dissipates heat quickly and leaves cleaner edges, ideal for careful craftsmanship.

Remember, thickness is a trade-off. Thinner discs may save you money, but they wear out faster. Thicker discs last longer, saving replacement costs over time.

5. Speed Rating

Every cutting disc has a maximum safe RPM (revolutions per minute) rating. It is not a suggestion – it's vital for your safety.

Using a disc at speed higher than its rating can lead to catastrophic failure – the disc could shatter, causing severe injuries.

Always check the maximum RPM of your cutting tool and the disc's speed rating. Never exceed the disc's rated speed. Matching tool and disc speeds ensure:

Every cutting tool has an RPM limit, and you should know yours. Inspect your disc and look for the speed rating printed on it. Never use a disc rated below your tool's RPMs.

Once you know the numbers, pick a disc rated the same as or slightly higher than your tool's limits. That gives you a safety buffer.

6. Quality and Brand

Regarding cutting discs, quality, and brand reputation are more than buzzwords. They impact safety, performance, and disc longevity.

Investing in trusted brands means you get the following:

• Rigorous Testing: A reputable brand puts its discs through multiple layers of testing, so you know they are reliable.
• Precision Manufacturing: Quality brands mean superior materials and construction, leading to clean cuts and longer disc life.
• Support and Warranties: It will be helpful to have someone by your side if anything goes awry and you need assistance.

7. Application

Cutting discs are specialised tools for a specific purpose. The type of work you're doing will determine the right disc size, material, thickness, and more.

Is it steel, aluminium, wood, or even plastic? Different discs are designed to handle specific materials. An unsuitable disc can shorten its life and cause poor cut quality.

You can choose particular discs for specific applications. For example, cutting discs for woodworking demands specific features like tooth design, kerf width, and those that prevent kickback.

If you are cutting plastic, you should choose discs designed specifically to prevent heat build-up and melt.

When cutting aluminium, use thinner discs with aluminium oxide or silicon carbide abrasives.

8. Safety Features

Cutting discs are powerful tools, and safety is non-negotiable. Here's what to look for:

Look for discs with extra reinforcement, especially for demanding tasks. These are more resistant to breakage under stress.

Some discs come with coatings that reduce heat buildup and sparks. Such safety features can prevent injuries and accidents.

9. Cost

Cost is always a factor, especially when dealing with project budgets. It's tempting to grab the cheapest cutting discs. But remember, you usually get what you pay for.

Higher-quality discs might have an upfront price tag, but they often last longer, cut better, and are safer. Long term, this can save you money.

The price of cheap discs may seem attractive. Still, you may have to buy replacements sooner, waste more material with sloppy cuts, or risk injuries.

Finding the right balance is crucial. Consider your project carefully and determine how much you should invest in your discs.

10. Safety Precautions

Cutting discs are powerful tools with the potential for serious harm. Never skip on safety. Here's your checklist:

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