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In metalworking and manufacturing, cutting wheels are commonly used tools to cut material from a workpiece.
What is a cutting wheel? A cutting wheel, or cut-off wheel, is different from a grinding wheel in both how it works and its design. Grinding wheels remove material by grinding at a shallow angle, while cutting wheels make precise, narrow cuts, usually at a 90-degree angle. Because of this, cutting wheels are thinner than grinding wheels. While they aren't strong enough for side grinding, their thinness makes them perfect for clean, accurate cuts.
Senmine offers a variety of cutting wheels for different jobs, ranging from 1mm thin wheels to larger ones for bigger cuts. This guide will explain the different types of cutting wheels and help you choose the right cutting wheels for your needs.
Cutting wheels come in several types, with common ones including type 1, type 27, type 41, and type 42. Each type is defined by its unique shape and characteristics, indicated by the different numbers.
| Type | Design | Key Feature | Best Use |
|---|---|---|---|
| Type 1 (Type 41) | Flat | Deep, precise cuts | General-purpose cutting |
| Type 27 (Type 42) | Depressed center | Extra clearance for tight spaces | Right-angle grinders and flush cuts |
A type 1 cut-off wheel, also called a type 41 cut-off wheel, has a completely flat design. It's often considered the most efficient option for general-purpose cutting. Without a depressed center, it offers more cutting surface and reduces interference with the workpiece.
The flat shape makes it ideal for creating deep 90-degree cuts. While it allows for maximum cut depth, it slightly limits visibility for the operator. Despite the reduced visibility due to its flat profile and the way it mounts close to the guard, type 1 cutting wheels are highly effective in tools like grinders, die grinders, high-speed saws, stationary saws, and chop saws.
Unlike the completely flat type 1 wheel, a type 27 cut off wheel (also known as a type 42 cut-off wheel) features a depressed center. This design provides extra clearance when the operator is working at tight or angled spaces. However, it limits the wheel's ability to make cuts around corners, profiles, or extrusions. The depressed center also allows for a raised hub, which helps keep the wheel securely in place.
The depressed-center profile offers better visibility for the operator while cutting and enables flush cutting. The raised hub lets the locking nut sit recessed, making it easier to work in tight spaces. Type 27 cutting wheels are specifically designed for use with right-angle grinders.
Cutting wheels are usually made up of several materials, including the abrasive grains that perform the cutting, the bonding agents that secure the grains, and the fiberglass that strengthens and reinforces the wheel.
The grains in a cutting wheel are the abrasive particles responsible for the cutting action.
There are various types of grains used in cutting wheels. Common ones include ceramic alumina, zirconia alumina, aluminum oxide, and silicon carbide.
• Ceramic Alumina: Ceramic alumina is highly effective on steel, stainless steel, and other tough metals like inconel, high-nickel alloys, titanium, and armored steel. It delivers excellent lifespan and cutting performance when properly maintained. Additionally, it tends to cut cooler than other grains, minimizing heat discoloration.
• Zirconia Alumina: Zirconia alumina excels at cutting steel, structural steel, iron, and other metals, making it perfect for heavy-duty tasks like rail cutting. It offers fast cutting speed, long lifespan, and excellent durability under high pressure.
• Aluminum Oxide: Aluminum oxide is one of the most commonly used abrasive grains. It provides a fast initial cut and consistent performance when cutting steel and other metals.
• Silicon Carbide: Silicon carbide is a very hard grain that offers sharp and fast cutting. However, it is more brittle compared to other grains, making it less durable.
The grit of the grain also plays a role in determining its performance. Grit refers to the size of the abrasive particles, much like sandpaper is classified by particle size. Grit sizes typically range from 16 to 60, with smaller numbers representing larger, coarser particles and larger numbers indicating smaller, finer particles.
The bond in a cutting wheel is the material that holds the abrasive grains in place.
Manufacturers often refer to the "grade" or "hardness" of the wheel, which refers to the hardness of the bond, not the abrasive grains themselves. A harder bond typically means the cutting wheel will last longer, while a softer bond tends to wear out more quickly.
However, a softer bond has some benefits. It sheds worn-out grains faster, exposing fresh, sharp grains for quicker cutting. In contrast, a harder bond holds the grains in place for longer, but it doesn't release them as quickly, which can result in slower cutting over time.
When cutting certain metals, like stainless steel and aluminum, it's crucial to avoid introducing contaminants. Always ensure that the abrasive contains less than 0.1% chlorine, iron, and sulfur to prevent contamination. Products free of contaminants will be clearly labeled.
One common bond used in cutting wheels is resinoid, which contains organic compounds. Resinoid bonds are known for their shock resistance and ability to handle high peripheral speeds, making them ideal for cut-off applications. These bonds also allow for self-sharpening by exposing fresh grains as they wear. Some specialized bonds, such as resin-over-resin, offer additional resistance to moisture and heat, creating a stronger overall bond to make the most of the abrasive grains.
Related read: Complete Guide to Diamond Bond Types
Cutting wheels are reinforced with fiberglass, which can vary in layers—single, double, or triple reinforcement. Single reinforcement uses a single layer of fiberglass, offering fast cutting speeds while reducing burrs on the workpiece. Double and triple reinforcement feature multiple fiberglass layers, providing extra support for high-vibration and heavy-duty industrial tasks.
At Senmine, all our cutting wheels for right-angle and die grinders are made with two layers of reinforcement. We also offer single-reinforced wheels in our large-diameter chop saw range and triple-reinforced wheels in our new high-speed gas and electric saw line.
| Wheel Type | Cutting Speed (m/min) | Lifespan (Linear Meters) | Suitable Material Hardness (HRC) |
| Ceramic Alumina | 12-15 | 380-450 | 45-62 |
| Zirconia Alumina | 18-22 | 280-350 | 30-50 |
| Fiberglass Reinforced | 15-18 | 400-500 | 20-45 |
Diamond Cut Off Wheel Lifespan Comparison
When using cutting wheels, the type of tool available to the operator often determines the wheel size, and selecting the right size for the job is crucial. The correct size depends on the revolutions per minute (RPM) rating — the RPM of the cutting wheel should match or exceed the RPM rating of the grinder it will be used with. Along with checking the RPM rating, it's important to ensure that the wheel fits properly on the tool without interfering with or removing the guard.
A cutting wheel's RPM rating is typically matched to its diameter and the tool it is designed for. Common wheel diameters include 2 to 4 inches for die grinders, 4 to 9 inches for angle grinders, and 12 to 20 inches for chop saws, stationary saws, or high-speed saws.
| Wheel Diameter (cut off wheel) | Tool Compatibility | Application |
|---|---|---|
| 2 cut off wheel | Die grinders | Precision cutting for small materials |
| 3 cut off wheel | Die grinders | Ideal for cutting thin metal and small pipes |
| 4 cut off wheel | Angle grinders | Cutting sheet metal, rebar, and light materials |
| 5 cut off wheel | Angle grinders | Used for cutting steel, metal pipes, and rods |
| 6 cut off wheel | Angle grinders, Stationary saws | Heavy-duty cutting, cutting sheet metal and pipes |
| 7 cut off wheel | Angle grinders, Stationary saws | Ideal for thick metal or industrial materials |
| 8 cut off wheel | Angle grinders, Stationary saws | Cutting thick metal, concrete, and masonry |
| 9 cut off wheel | Angle grinders, Stationary saws | Cutting rebar, steel pipes, and tough materials |
| 10 cut off wheel | Chop saws, Stationary saws | Heavy-duty applications, cutting metal profiles |
| 11 cut off wheel | Chop saws, Stationary saws | Large-scale metal and construction cutting |
| 12 cut off wheel | Chop saws, High-speed saws | Cutting thick pipes, structural steel, and metals |
| 13 cut off wheel | Chop saws, High-speed saws | Ideal for industrial cutting of large materials |
| 14 cut off wheel | Chop saws, High-speed saws | Cutting large pipes, heavy metal, and construction materials |
| 15 cut off wheel | Chop saws, High-speed saws | Large material cuts in metalworking and fabrication |
| 16 cut off wheel | Chop saws, High-speed saws | Ideal for thick metal and cutting through dense materials |
| 17 cut off wheel | Chop saws, High-speed saws | Used for tough materials in heavy-duty industries |
| 18 cut off wheel | Chop saws, High-speed saws | Cutting large sections of metal and construction work |
| 19 cut off wheel | Chop saws, High-speed saws | High-performance cutting for large-scale projects |
| 20 cut off wheel | Chop saws, High-speed saws | Heavy-duty cutting, ideal for industrial and construction applications |
The thickness of a cutting wheel is often determined by the level of precision and accuracy required for the cut. Thinner wheels are ideal for precise, accurate cuts as they cut more quickly, generate less heat, and remove less material with each pass. This makes them perfect for tasks like repairs or fitting parts. However, they may not last as long as thicker wheels under the same conditions. For applications where longevity is more important than precision, a thicker wheel might be a better choice.
Senmine offers ultra-thin, high-performance cutting wheels in diameters of 4, 4 1/2, 5, and 6 inches. The Senmine ultra-thin 0.8-millimeter wheel provides a fast cutting rate and long lifespan, making it ideal for cutting thin sheet metal, tubes, profiles, and small cross-section rods. We also offer cutting wheels specifically designed for stainless steel, ensuring they are free from contaminants. Request your customized cutting wheel solution today.
So far, we've covered how types 1, 27, 41, and 42 cutting wheels have unique shapes suited for different cutting tasks. We've also explored the various grains used in cutting wheels and their optimization for different metals, as well as how diameter and thickness influence wheel speed and precision. Now, let's take a closer look at some common industrial and professional applications for cutting wheels and how to select the right wheel for each job.
In general metal fabrication, 0.045-inch wheels are commonly used. For thinner materials, a 1-millimeter wheel may be a better option, offering greater precision, reduced heat generation, and fewer burrs that would need to be removed before welding. The choice of grain typically depends on the material being worked on — higher-performance grains are ideal for structural steel and tough metals, while contaminant-free wheels are recommended for stainless steel.
We recommend: stainless steel cutting wheel
In metal pipe fabrication, the size of the cutting wheel typically depends on the diameter of the pipe being cut. For pipes 3/4 inch or smaller, a 4 1/2-inch wheel is usually sufficient. For pipes up to 2 1/2 inches, a 6-inch cutting wheel works well, and for pipes up to 3 1/2 inches, a 9-inch wheel is often the best choice. It's recommended to use the thinnest wheel possible to reduce heat and friction, and a type 1 wheel is ideal for deeper cuts unless the application requires a different approach. For larger pipes, often found in pipeline work, a depressed-center cutting wheel offers extra clearance when cutting at tight angles. A 0.045-inch wheel thickness is also ideal for cutting in fabrication yards or for field repairs along pipeline right-of-ways.
When working in the tight, hard-to-reach spaces of a ship, maximizing the lifespan of a cutting wheel is often a priority. In such cases, operators typically opt for a harder, longer-lasting wheel. However, if air tools are being used, and their hoses must reach long distances to access challenging areas, the tools may not have full power. In this situation, wheels with a soft bond are a better choice, as they allow for a faster cut. In shipbuilding, the type of material being worked on also plays a role in selecting the right cutting wheel. For example, when cutting aluminum, operators should choose a cutting wheel for aluminium that won't load up or gum up during use.
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 0.8-millimeter Ultracut wheel will provide smooth cutting and exceptional control for clean, ultra-precise cuts.
Modern railways rely on tough alloy steels that are difficult to cut, requiring high-performance cutting wheels for high-speed gas saws. A self-sharpening zirconia alumina grain, which maintains consistent cutting power throughout the wheel's lifespan, ensures optimal performance. The Senmine 14- and 16-inch cutting wheels are specifically designed for high-speed gas saws, providing the high-performance solutions needed to enhance productivity and profitability.
Construction and building sites involve a wide range of metal cutting tasks. Operators often need a versatile wheel that can handle everything from cutting rebar to making long cuts on sheet metal. In many cases, an aluminum oxide wheel strikes the right balance of performance, versatility, and affordability. Senmine offers both flat and depressed-center cutting wheels in various sizes for die and right-angle grinders. It also includes larger wheels, ranging from 12 to 16 inches, for chop saws and high-speed gas and electric saws.
These larger-diameter wheels are specifically designed with the construction industry in mind. For chop saws, the line features wheels made for stud cutting and options for burr-free cutting, which include a single layer of fiberglass. For high-speed saws, there are wheels with three layers of fiberglass, providing extra support for heavy-duty cutting applications.
Experience the advantages of high-quality cutting wheels in your industrial and professional operations by choosing Senmine as your trusted partner for surface conditioning solutions. We offer a wide selection of cutting wheels in different types, grains, bonds, diameters, thicknesses, specialized features, and price ranges, allowing us to help you find the perfect wheel or small cutting disc for your specific applications.
The value we provide goes beyond just purchasing a cutting wheel. Our Value Package includes extra benefits such as safety training to ensure the safe and effective use of your cutting wheel, as well as direct field support to address your questions and help improve your facility's efficiency and productivity.
Reach out to us today to learn more.
• How can I reduce sparks when using a cutting wheel?
Excessive sparks often occur when a wheel is overloaded or the incorrect grain is chosen. To reduce sparks, ensure you're using the appropriate wheel for the material, avoid applying excessive pressure, and check that the wheel's RPM matches the tool's specifications. If sparks persist, switch to a wheel with a finer grain for smoother cutting.
• Why is my cutting wheel wearing out quickly?
A cutting wheel’s lifespan depends on its bond hardness, the material being cut, and the conditions under which it is used. If your wheel wears out quickly, it could be because of overloading, using a wheel not suited for the material, or high-speed cutting. Choosing a wheel with a harder bond or a grain suited for the task can help increase longevity.
• Can cutting wheels be used on all materials?
No, cutting wheels are designed for specific materials. While some wheels are versatile and can handle various materials, it's important to choose the right one for the material you're working with. For example, diamond cutting wheels are ideal for cutting hard materials like concrete and stone, while resin-bonded wheels are better for metals.
• How do I choose the correct cutting wheel for my application?
When choosing a cutting wheel, consider the material you need to cut, the thickness of the material, and the required cutting speed. Thinner wheels are great for precision cuts, while thicker wheels are better for durability and heavy-duty cutting. Also, ensure the wheel’s RPM rating matches the tool you're using to prevent accidents.
• What are the signs that a cutting wheel needs replacing?
Cutting wheels should be replaced if you notice cracks, chips, or visible wear. Additionally, if the wheel starts producing uneven cuts, excessive sparks, or makes a burning smell, it’s time to replace it. Regular inspection is key to maintaining safety and performance.
• What safety precautions should I take when using cutting wheels?
Always ensure that the cutting wheel is securely mounted, and use the correct protective equipment, including goggles, gloves, and hearing protection. Never use a damaged or cracked wheel, and always follow manufacturer guidelines for maximum RPM to avoid accidents. Keep the work area clean to prevent the buildup of debris that can interfere with the cutting process.
