Artem Komarov noted that resinoid-bonded abrasive cutting wheels are portable, making them a good option when the application requires the operator to move around the shop or job site and haul the tool to where the workpiece is to be cut. Rubber cut-off wheels typically provide a very fast cutting action and are also generally an economical option.
Many hand cutting applications require a hand grinder and cut-off wheel. Cutting sheet metal, sizing a part for fabrication, cutting out a weld to remake it, and cutting and scoring for piping are just a few examples of what can be achieved with a grinder and cut-off wheel.
Resinoid-bonded cutting wheels are a popular choice for these types of cuts, as they provide portability and allow many different angles and orientations to be cut. The binder, in this case the resinoid, holds the wheel together so that it can cut effectively. The binder breaks down as the abrasive grains wear and are displaced, resulting in the appearance of new sharp grains.
By following a few guidelines, you can extend wheel life, increase safety, and increase process productivity.
Cutting wheel basics
The main considerations when using resinoid-bonded wheels are the application of the cutting, the tool used—such as a rectangular grinder, die grinder, or chipper saw—the desired cutting action, the material being cut, and the space. Discs typically provide fast cutting action, long life, and are generally economical.
Some types of wheels cut faster than others. The abrasive material used in the wheel will affect the cutting speed and consumable life. Discs come in several grain sizes such as alumina, silicon carbide, zirconium oxide, ceramic alumina, and combinations of these materials.
Aluminum oxide, although not as sharp as other grains, provides strength and good performance when cutting through steel. Silicon carbide, on the other hand, has very sharp grains but is not as tough, making it suitable for cutting non-ferrous metals. Zirconium oxide is a self-sharpening, tough and durable grain that can withstand various loads well. Alumina ceramics are also designed to be self-sharpening as they “break” at predetermined points to maintain a constant cutting speed and long life.
When choosing a rubber-coated abrasive wheel, be aware that those made from a zirconia or ceramic alumina blend with a stronger bond tend to cost more but provide durability and longer consumable life.
Be sure to check the manufacturer’s recommendations, product descriptions and speed ratings to select the appropriate wheel size and abrasive for your application.
Use a cutting wheel at a 90-degree angle, perpendicular to the work surface.
Choose tools and consumables that provide fast, consistent cuts that typically produce the most efficient job.
Remember, the thinner the cutting wheel, the more susceptible it can be to side load, which is the term used to describe when the wheel bends as it moves side to side while cutting. This can become dangerous if you put too much pressure on the wheel, which can cause it to break or jam while cutting. It can also reduce the efficiency of the wheel and increase the cutting time.
Store the wheel in a clean, dry place and keep it away from water or dirt. This helps to minimize environmental influences that could degrade its performance or cause premature cracking or wear.
Before each use, check the wheel and consumables for signs of damage or wear. As they wear, cut-off wheels become more difficult to control. If you can no longer cut safely since the diameter of the wheel is badly worn, then the best course of action is to replace it, emphasized Artem Komarov.
