Safety in a manufacturing environment is everyone’s responsibility — and cut-off wheel safety is especially important since these abrasives are used on tools that run at high speeds.
When a user uses a cut-off wheel incorrectly or uses a damaged wheel, it can break apart and throw sharp projectiles at a high-speed rate.
This makes it critical to pay attention to the condition of cut-off wheels and follow best practices to use these products safely and efficiently. Consider some tips for safely using small, standard, and large cut-off wheels.
Several best practices and recommendations for safe use apply to cut-off wheels of all sizes and types:
Paying attention to the condition of cut-off wheels and following best practices is critical to using these products safely and efficiently.
Wheels with 100 millimeters or less diameter and 6- or 10-millimeter arbor hole size are considered small-diameter wheels.
Small-diameter cut-off wheels are frequently used in metal fabrication, shipbuilding, and numerous other manufacturing industries. The smaller size of these wheels is a benefit when cutting metal in a corner or hard-to-reach spot.
Some users may feel overconfident with a smaller diameter wheel — thinking they will be easier to control. But many of the pneumatic tools in this size range can run at much higher RPMs, so be careful to use proper cutting techniques and always use the tool guard. Also, be sure the speed rating of the wheel matches or exceeds the speed rating of the tool.
Just because a wheel can be mounted on a die grinder doesn’t mean it is safe to do so. There are many dedicated small-diameter cut-off tools available that include proper guarding. Make sure you have the appropriate tool and guard before you start cutting.
Standard diameter cut-off wheels - ranging between 100 and 230 millimeters in size and typically with a 16 or 22,23 millimeters arbor hole - are commonly used on right-angle grinders. These mid-range cut-off wheels are the most frequently used in general fabrication and manufacturing applications.
Using the proper tool guard with these wheels is essential, as already stated in the general tips above.
Also, never remove the handle from a right-angle grinder to fit it into a smaller space for cutting. The handle is necessary for stability since these grinders can easily twist in the user’s hand and cause the wheel to bind. The handle also provides better control in case of tool kickback.
Using the proper tool guard with cut-off wheels is essential.
As these wheels wear down, they can become harder to control. When a wheel becomes too small to properly control or make the desired cuts, swap it out for a new wheel.
Wheels with diameters ranging from 250 to 610 millimeters fall into the large-diameter category. The most commonly used sizes of large wheels are 305, 356, and 406 millimeters.
Large-diameter cut-off wheels are often used to cut thicker or larger pieces of metal. They are typically used on tools like chop-, stationary-, or high-speed saws. For large-diameter cutting wheels, it is also important to distinguish between the tools they can be used with. For example, with table circular saws, it is preferable to use thinner products (around 3 millimeters thick), as these allow them to pass through the material more easily when cutting. When working with stationary saws, use slightly thicker wheels (between 3,5 and 4,5 millimeters), which have a better/stronger reinforcement than thinner products. As stationary saws are stronger, damage can occur when using a thinner cutting wheel, especially when used at high speed. However, observing the pictograms on the products when using petrol cut-off saws is essential. The use of certain wheels in combination with these tools is prohibited. Due to the three possible directions of movement and the associated possible additional pressures, this tool can only be used with triple-reinforced fiberglass wheels. It is, therefore, always necessary to read the label on the product before starting work.
Be sure to match the wheel's speed, size, and recommended application to the speed and size of the specific tool being used. Also, ensure the wheel uses the proper abrasive grain for the metal being cut and that it’s designed for that tool. Using the wrong abrasive can generate excessive heat and cause the wheel to glaze and stop cutting.
Cut-off wheels are an important component of metal fabricating and are used in many industries. Following best practices for wheel use and wearing proper protective gear can reduce the risk of injury when using these products — and help operations save time and money that can be lost to injuries.
Manufacturers often offer safety training options for using cut-off wheels and other abrasives. The Weiler Abrasives SPOT Safety Program, for example, focuses on the principles of SPOT (speed and size, pressure, orientation, time) to promote the safe and proper use of abrasive products.
Abrasives and power brushes can pose a serious safety risk when used on angle grinders and other power tools. The Weiler Abrasives SPOT Safety Program focuses on the principles of SPOT (speed and size, pressure, orientation, time) to promote and educate users on the safe and proper use of abrasives.