Working with an angle grinder. How to cut aluminum with a grinder safely and quickly

Why is it dangerous to cut aluminum with a grinder?

Cutting aluminum is not only difficult, but also unsafe! Especially when using a high power grinder. Due to the viscosity of aluminum, the disc will get stuck and the tool will try to pull out of your hands.

And this will not happen immediately, but only when the cut reaches a certain depth. And this may come as a surprise to an inexperienced user of the tool. And in general, with a disk stuck in the metal, cutting will not be easy.

A short story about how I had to cut an aluminum tank. And what came of it

One of my friends once had a job delivered to him and needed to saw an aluminum tank with a grinder. “It’s a piece of cake,” he thought—cutting aluminum, there’s nothing easier!

But his joy quickly disappeared when he got down to business.

The disk constantly got stuck, stuck in this metal. The Bulgarian woman tried to jump out of her hands. Sawing was a pain; it went very slowly. Various abusive thoughts did not leave my head. )))

So what to do? I got to work - I need to do it! So several hours of hard work passed. An old man passing by came to the rescue.

Seeing the torment, he began to try to give advice, but advice is sometimes difficult to accept, especially when his nerves are already at their limit. After all, the work, which seemed simple at first, was already pretty exhausting. Therefore, the first reaction to advice is the desire to send him to hell.

Nevertheless, the advice was given and in the end, as the friend said, he followed it. Imagine his surprise when after that things went much more fun.

Choosing the required grinder

Choosing the right grinding machine is an important factor that will influence the further quality of work. The safety of the worker also depends on the right choice. When choosing an angle grinder, you need to focus on the following characteristics: Power of the angle machine.
Abrasive wheel diameter.
Grinder weight.
Machine size.

The light weight of the device simplifies work, and the required size parameters allow you to work in hard-to-reach areas.

When purchasing, many people are afraid to purchase powerful devices, because, in their opinion, they are much more difficult to do the job with. But this is far from true. In construction tools that have low power, the disk may jam. The device cannot withstand heavy loads. As soon as the load becomes less, the machine will be pulled out of your hands, the disc and grinder may be damaged, and there is a possibility that you will suffer serious injury.

For those people who just want to start working with a grinding device, you need to buy an angle grinder, which should fit a 125 mm disc. The power of this construction tool should be approximately 1000 watts, and the spindle should make 10 thousand revolutions per minute. These indicators are excellent for cutting materials such as iron.

The main thing is that the device should be easy to use. The handle of this construction tool should preferably be made of rubber or other material. The material of the handle should be such that you do not feel vibration when working.

There should be special recesses on the handle that are intended for fingers. Grinders that have low power do not have such a handle.

If you feel discomfort while working, you should look for a device of a different model.

What was the tip that helped you cut an aluminum tank easily?

And the advice was as follows. The cut area needs to be lubricated. For example, used automobile oil is quite suitable for this purpose. A little practice, and the work began to boil. The disc did not get stuck, aluminum was cut with a bang. So, a simple trick from an experienced person helped save both nerves and strength. And perhaps health, since the grinder stopped getting stuck in the aluminum and trying to escape from my hands. You understand the dangers of such a situation when working with this tool. Don't believe me? Talk to surgeons, they will tell you.

Source

Selecting a grinding wheel

On the construction market you can see a wide variety of special wheels for various types of grinding and polishing with an angle grinder. Such nozzles are distinguished primarily by the type of coating:

from sandpaper;
from a sponge;
fabric;
with felt.

In addition to the abrasive coating on the wheel, various pastes with abrasive inclusions are used for grinding metal surfaces. Their use depends on how smooth the surface is planned to be. In order to perform rough sanding of aluminum, craftsmen use sanding attachments with large grains. The structure of the grinding wheel should not be dense (with a small number of grains per unit volume of the attachment). Such work results in a rather rough surface that requires cleaner grinding and polishing.

For fine and precise sanding, sponge wheels are suitable and can be used together with fine-grained pastes. After them, you can polish using replaceable felt or fabric covers, which are attached to a special attachment for an angle grinder. In this case, a paste with minimal grain sizes is used. When choosing a nozzle, the manufacturer's brand is also important. Products, the quality of which there is no doubt, are produced mainly by well-known companies, such as:

Bosch;
Berner;
Kronenflex;
DeWalt.

Methods for cutting aluminum profiles

Conventionally, all methods are divided into two groups:

cutting with compact manual or electric equipment;
cutting with special devices (portable or stationary).

Cutting aluminum on a machine The first group includes the following tools:

hacksaws for metal;
metal scissors;
jigsaws;
Bulgarians.

The second category includes:

plasma, laser, milling installations;
various saws.

Now it’s worth studying the features of each method, advantages and disadvantages, and then draw a conclusion about the best method for cutting aluminum profiles.

Is it possible to use an aluminum disc to dust wood?

What is important to know about metal saws ( aluminum and steel)

Many problems can be found without the problem of sawing wood (this is the most popular material for sawing). But, for example, for sawing metals (non-ferrous metals and steel), unfortunately, there is not much information. We decided not only to inform you about the main points when choosing or using aluminum saw blades, but also to test them. compare them with each other.

For starters, saws do not have strict standards like other consumables. Tool makers control the ball here, and the sizes and types of pollen from them dance first. Yes, metal saws can work on both hand-held circular saws, cut-off machines, and stationary or portable saws. since cutting metals for the most part. Many professional users, in accordance with other requirements for the size and quality of the saw. It is in the category of aluminum dusts that European and world brands, as well as a limited list of Russian brands, have won the highest demand and the best reputation. Here is their list.

READ 45 Degree Sawing Tool

In the sawmill and its features we published an article in one of the previous magazines, it is important to note that the production is practically located either in Europe or in China. The quality of poles of the same type is almost the same according to the standard, but it is quite easy to distinguish them, first of all, from the quality of the quarrel between the carbide inserts and the body of the disk itself. It is not visible to the naked eye, but this does not affect the quality of communication, this can be seen in our tests.

blade is best suited . For example, TM ProfOsnastka indicates that the largest saw blades can be used with the smallest number of teeth, and vice versa, the largest number of saw blades is best suited for sawing hollow and thin-walled workpieces. The quality of the saw will depend on this.

Number of teeth. This is an important point, which differs from simple standard logic: the larger the teeth, the higher the quality of cutting, and the higher the cost of the saw blade, since the cost of the saw blade is formed mainly from carbide plates. They differ in cost depending on the manufacturer and their size. According to standard logic. the thicker the plate, the more cuts there will be on it, provided that the saw itself is designed for the appropriate resource. Many grinding saws. It is important that this can only be done efficiently on appropriate machines, but usually sharpening costs almost the cost of a new saw (with the exception of large diameter wheels for industrial sawing).

The result of sawing depends on simple factors, tooth shape, angles, number of teeth. Other options are available, depending on a combination of three factors. we get the results as output. The tilt angle can be negative N(-), positive P and zero, no tilt. Blades with a negative angle will give the sharpest cutting quality when combined with the maximum number of teeth, and conversely, a positive angle will give the maximum cutting speed when cutting, but with the fewest number of teeth the cut quality will be much worse.

Hacksaw for metal

It is not always possible to use electrical equipment like miter saws, so you have to be content with the simplest tools. The first of them is hacksaws for metal. They can cut sheet material, as well as profiles of small thickness. Cutting starts from the edge, continues on the back and ends on the sides. Advantages:

the hacksaw weighs little, so your hands don’t get tired;
ease of operation;
cheapness of the tool;
Works as efficiently as a jigsaw.

takes a lot of time;
possible profile deformation;
the need to hold the profile, which does not guarantee accuracy of work.

Markings of circles for cutting metal

The content of markings applied to the surface of metal cutting wheels is regulated by GOST R 52588-2011 and GOST R 57978-2017. The first determines safety-related labeling data (including operating limits) and information about the manufacturer, and the second determines the physical and technical characteristics of the product. Both GOSTs were developed on the basis of specialized international ISO standards, so the markings of foreign manufacturers are practically no different from GOSTs.

The photo above shows a metal cutting disc from the Luga Abrasive Plant, marked in accordance with state standards. The following fields are indicated by numbers:

Construction type (ISO 41, flat).
Geometric characteristics (diameter, thickness, mounting hole). Below, under the red stripe, they are indicated in inches.
Physical characteristics: type of abrasive (A – electrocorundum); grain size; degree of hardness (Latin T - very hard); bond type (BF – reinforced bakelite).
Maximum rotation speed.
Maximum permissible peripheral speed.
What material is it intended for?
Safety pictograms.
Link to regulatory documents.
Manufacturer's logo.

In addition, GOST P 52588-2011 and international standards oblige manufacturers to apply color markings to their products in the form of a continuous horizontal stripe with a width of 5 to 20 mm, indicating the maximum peripheral speed. For metal cutting discs, this is usually a red stripe corresponding to 80 m/sec (see photo above). Some manufacturers additionally mark their products with color fields in accordance with the group of materials (metals, stone, ceramics, etc.) for which a particular type of wheel is intended for cutting. Such markings in the ANSI and ISO systems only partially coincide, so it is better to focus on signs in the form of inscriptions and pictograms.

How to cut (sharpen) tiles at a 45 degree angle?

Everyone calls this action differently: washed away, pointed, trimmed, burrs, Kremlin corner. There is only one meaning.

To properly cut the end portion of a tile at a 45 degree angle, you will need an electric tile cutter (tile cutting machine) or, as a last resort, a grinder (tips) with a disc on the tile.

The easiest way. This is a mill

It is more difficult to achieve a high-quality result with a crusher, but, in principle, this is also possible. This is the easiest way to sharpen a 45 degree tile corner yourself at home.

The process of grinding and grinding porcelain in the video below.

First of all, you must have a good diamond tile disc.

Place the tile along the edge (perpendicular to the workpiece) and sand its back (clay) at a 45 degree angle.

If it turns out to be a little uneven, you can go through the large uneven burrs of the disc again, and to get a cleaner, smoother edge, you can use this (pictured below) sanding attachment with sandpaper or a turtle .

The Velcro sanding wheels are erasable. New ones are removed and attached. The base itself with Velcro is wound onto the thread of the coffee grinder. Diamond nozzles have a much longer lifespan, but they are also many times more expensive. If you are constantly laying tiles, it makes sense to get them with diamond turtles . If you are doing the first and last renovation in your life, it is quite possible to do it with the help of sanding wheels.

When working with something like this you need a variable speed sander (at least speed!) otherwise the edge of the tile will melt and burn rather than pop.

You can buy wonderful “shells” here!

Electric tile cutter

Electric tile cutter, or, as it is also called, tile. Wet cutter. It has a water-cooled disk, and this same water extinguishes all possible dust. The tile cutter cuts along one clear, fixed path and minimizes human error such as shaking hands and so on.

The tile cutter has two working positions. Flat cut and 45° cut (actually you can set any angle from 0 to 45°, but this often doesn't make sense).

Selecting a grinding wheel

from sandpaper;
from a sponge;
fabric;
with felt.

Bosch;
Berner;
Kronenflex;
DeWalt.

Metal scissors

An even simpler tool that is easier to work with. The principle of operation is elementary - the profile is marked and then cut along the line. Advantages:

cutting occurs faster than with a hacksaw;
cheap scissors;
A good result is possible if you have high-quality tools and experience.

VIEW Metal shears on AliExpress → Disadvantages:

when crossing the profile ribs, it is possible to leave the marking line, damage the workpiece or bend it;
you will have to practice and ruin several “rough” blanks before you can work perfectly accurately.

How to cut tiles at 45 degrees?

To make a corner of two tiles look beautiful , when cutting the tiles you need to be a little short of the glaze (0.5-1mm). That is, only the clay is cut off. If you walk on the glaze (the face of the tile), it will be "ragged" and chipped. It's immediately obvious, it's not pretty.

READ The Better Way to Cut Plywood

We encountered this problem regarding cutting corrugated tiles. But more on that later.

Perhaps many of you have seen this “art”, but most often everyone thinks that it should be like this. And a tiler with twenty years of experience assures us that it cannot be otherwise.

Even if there is a need to cut the corner of the tile not from the “factory” edge and you need to reduce the icing, but there is a way to make it look beautiful.

Safety precautions

Safety precautions when cutting with a grinder are a way to protect yourself from injury and injury. Do not neglect the rules, the effectiveness of which has been proven in practice. Mandatory elements when working with an angle grinder are:

safety glasses (pulling scale out of your eyes is not very pleasant, and no one wants to lose their sight);
ear protection;
gloves;
Tight clothing that covers all parts of the body.

Never cut metal without a protective cover. A ruptured disc can fly anywhere. In this case, neither glasses nor a mask will save you. Tests have shown that a ruptured disc can penetrate a motorcycle helmet. History remembers many tragic incidents, do not forget about them.
Position your body so that it is not in line with the disc. Even if it breaks, it will fly past you.
If you are cutting a metal product that is on the ground, then place the grinder between your widely spaced legs. Example in the photo.

Electric jigsaw

Before work, it is important to make sure that the tool is equipped with a file specifically for metal. Of course, a wood blade will also cut aluminum, but the quality of the cut will leave much to be desired. The cutting of the profile begins from the back part, then the side edges are sawed in turn. Advantages:

electrical equipment makes the user's work easier;
quality close to ideal (the product will not have burrs, bevels, or other defects);
speed of work;
reusability (with the right choice of file);
A jigsaw is cheaper than similar devices for cutting aluminum profiles.

the workpiece must be securely fixed so that it does not “lead” when using the jigsaw.

Features of aluminum processing

Cutting soft metals raises many questions among ordinary people. In particular - aluminum. To process such material, there is a wide variety of sawing attachments that have different diameters. They also produce wheels for grinding aluminum. The description of cutting wheels for an angle grinder must begin with their sizes. Thus, the outer diameter of such products varies from 125 mm to 230 mm. The thickness of the cutting attachments ranges from 1 to 3.2 mm. As a rule, a larger disc diameter corresponds to a larger width. As for circles of small diameter, their thickness can be any, depending on the purpose.

If we talk about aluminum, then for its processing we use circles with a thickness of about 1 mm. This choice is explained by the fusibility of this metal. When working with a thick nozzle, aluminum becomes viscous from friction and begins to clog the abrasive wheel with its particles. In such a situation, the disc simply stops cutting.

As for the configuration and coating of the cutting part, most often wheels for aluminum have a fine diamond coating and a cutting edge in the form of several sectors. Essentially, this is a saw blade for concrete. It is convenient for them to carry out work on cutting aluminum structures. For example, cutting a profile. The diameter of such a disk has a minimum value, that is, 12.5 cm.

Circles with a maximum diameter of 23 cm are most often multifunctional and cut not only metals, but also concrete, plastic pipes and even wood with nails.

Angle grinder

The grinder is a universal assistant that works great on aluminum. It is only important not to confuse a cutting wheel with a grinding wheel, choose thin equipment to minimize material loss and protect your hands and face from sparks. Advantages:

speed of work;
decent cutting quality;
relative cheapness of equipment;
minimum user movements;
durability of the equipment, which allows you to repeatedly saw metal profiles.

Angle grinder Sparky

possibility of metal burning in the cut area;
without working skills, it is unlikely that you will be able to cut smoothly;
To increase the accuracy of the work, the grinder should be clamped into a stand, which is not supplied with the tool and is rarely found in stores (the problem is solved if you have a vice).

Now it’s worth studying special devices for working on aluminum.

How to choose the right cutting disc

When purchasing a cutting wheel for metal work, you first need to pay attention to its diameter, since it must exactly match the type of grinder on which it will be used.
In addition, you should choose the correct diameter of the mounting hole (22 or 22.2 mm). There is no need to worry about maximum revolutions and peripheral speed, since they are standard for each size. On all cutting discs for angle grinders, in addition to sizes and speeds, it is always indicated in the most visible place (in text or pictogram) what material this sample is intended for cutting. When it comes to metals, there are usually four types: steel, stainless steel, cast iron and non-ferrous metals. In addition, discs are produced for both combined use (usually steel + stainless steel) and for cutting individual non-ferrous metals, in particular aluminum. You definitely need to pay attention to the expiration date (it is stamped on the rim of the sleeve), since bakelite resins are used as a binder in such products, which dry out over time and lose their elasticity. You also need to understand that metal cutting discs of the same type, but from different manufacturers, behave differently during operation. Therefore, in order to avoid surprises, in addition to analyzing standard data, you must definitely look for additional information in customer reviews, on specialized forums, etc. The video below explains how several almost identical disks from different brands differ.

Plasma and laser machines

The best method in terms of quality and speed, but not suitable for home use. Plasma cutters and laser machines are considered professional equipment and are found in metallurgical enterprises. If there is an installation nearby and cutting an aluminum profile on it is possible, it’s worth taking advantage of. Advantages:

cutting the profile takes a couple of minutes;
the user only configures the equipment, the rest is done by the machine;
the quality of the cut is the best of all methods.

the cost of equipment amounts to millions of rubles;
inability to use at home or in the garage;
noise during operation.

VIEW Plasma cutting machines for aluminum on AliExpress →

Features of aluminum processing

Circles with a maximum diameter of 23 cm are most often multifunctional and cut not only metals, but also concrete, plastic pipes and even wood with nails.

Video: How to Cut Aluminum Sheet

If you have any experience on how to bend a solid aluminum sheet without breaking it, please share it in the comments section.

Detailed information about hand tools and equipment used for cutting aluminum profiles is described in this material.

Thin aluminum sheet is easy to cut because almost any tool can do it. What about, for example, a size angle or an awkward channel? This material describes in more detail the hand tools and equipment used to cut aluminum profiles. The work is complicated by a number of factors, but you can still divide the workpiece evenly.

READ What does it mean to cut across the grain?

A circular saw

Similar to a hand saw, but more powerful. Has the following capabilities:

performs longitudinal, transverse, oblique cuts;
can cut from any place on the workpiece (not just from the end);
modern devices prevent overheating by turning off in a timely manner or sending a signal to the operator;
The user can select the operating speed based on the thickness of the workpiece.

How to calculate the consumption of a cutting disc

There are no modern centralized regulatory documents regulating the consumption of cutting wheels for metal.
Therefore, to solve this problem, you can go in two ways. The first is to use the developments of Soviet times, for example, the departmental standards of the USSR Ministry of Installation and Special Construction VSN 434. In this document, in section 5 “Method for calculating consumption rates of reinforced abrasive wheels”, you can find tables that provide standards for the number of cuts with one wheel and their consumption per shift for each standard sizes of rolled ferrous metals and pipes. The main disadvantage of this method is the problem of non-repeatability of the parameters of cutting wheels of the same type purchased by users on the modern Russian market. Therefore, it is best to adopt your own standard for each batch of purchased disks by carrying out test cutting with several of them on certain types of metal workpieces (sheet, pipe, fittings, etc.). In this way, over time, you can accumulate a sufficient database, analyze patterns and develop your own standards with correction factors.

There is often a statement that stone cutting wheels can be used to cut non-ferrous metals without any problems. What do you think about this? Please share your opinion in the comments.