These high-performance cut-off wheels are capable of rapid cutting because of its design, binder, and abrasive grit. The optimal cut-off wheel for process-accompanying quality control, thanks to its precisely regulated production procedure that ensures consistently good cutting quality with little wear. The universal applicability of the cut-off wheels means they can be used with any standard cutting machine, and their superior cutting qualities mean less time is spent in the following preparation stages. These cut-off wheels have a high value-to-price ratio because of their efficient cutting and minimal wear.
HOW TO CUT WHEELS AS A GUIDE
Cutting wheels are used on a variety of instruments in the metal fabricating and manufacturing industries to remove unwanted material from the workpiece. A cutting wheel is defined as. Different in purpose and construction from grinding wheels, cutting wheels are also known as cut-off wheels. In contrast to grinding wheels, which utilise an abrasive to remove big chunks of material from a workpiece at a shallow angle, cutting wheels often create thin, precise cuts at right angles to the workpiece. So, cutting wheels are often less thick than grinding wheels; although they lack the lateral strength necessary for side grinding, their minimum thickness makes them superior for clean, precise cuts. Weiler Abrasives provides a variety of cutting wheels to meet your needs. We sell cutting wheels ranging in diameter from 1 mm to wheels suitable for making even more substantial incisions. How to pick the best cutting wheel for your needs is laid out in detail in this comprehensive tutorial.
HAWKS AND OTHER CUTTING WHEELS
There are a variety of cutting wheels to choose from. Common kinds are 1, 27, 41, and 42, with the corresponding numbers denoting the varied forms and qualities of the wheels.
CUTTING WHEEL, TYPE 1 (TYPE 41 CUTTING WHEEL)
Flatness is the defining characteristic of a type 1 cut-off wheel, also known as a type 41 cut-off wheel. It is often regarded as the most effective wheel design for general purpose cutting. It has a larger cutting surface and less material interference since its centre is not depressed. The flat profile is useful for making precise 90-degree cuts in a variety of materials. As a result, the maximum depth of a 90-degree cut may be achieved while the operator’s field of view is reduced to a negligible degree. Type 1 cutting wheels are great for grinders, die grinders, high-speed saws, stationary saws, and chop saws despite the fact that the operator’s line of sight may be obstructed due to the wheel’s straight profile and the way it mounts near to the guard.
CUTTING WHEEL OF THE TYPE 27 (TYPE 42 CUTTING WHEEL)
A type 27 cut-off wheel, sometimes called a type 42 cut-off wheel, has a sunken centre instead of being fully flat. The wheel’s restricted cutting capabilities while manoeuvring around corners, profiles, or extrusions is offset by the depressed centre, which provides more clearance when the operator is operating at a constricted angle. Because of its lowered profile, a hub that can firmly anchor the wheel in place may be elevated without interfering with its design. Because of its design, a depressed-center cutting wheel improves the operator’s vision of the cut, and its high hub allows the locking nut to be recessed, allowing for flush cutting. Those using right angle grinders should use cutting wheels of type 27.
MATERIALS FOR CUTTING WHEELS
There are a number of components found in cutting wheels, including the cutting grains themselves, the bonds that keep the grains in place, and the fibreglass that gives the wheels their structural integrity.
The cutting action of a cutting wheel is accomplished by the individual grains that make up the abrasive. Numerous variations of grains exist. Ceramic alumina, zirconia alumina, aluminium oxide, and silicon carbide are some of the most often used grains for cutting wheels.
In ceramics, alumina is used for:
When it comes to cutting hard metals like steel, stainless steel, inconel, high nickel alloy, titanium, and armoured steel, ceramic alumina shines. When used and cared for correctly, it has a longer lifetime and better cut, and it cuts cooler than other grains, minimising heat discoloration.
The combination of zirconia and alumina:
Zirconia alumina is suited for rail cutting and other heavy-duty applications because to its outstanding cutting performance on steel, structural steel, iron, and other metals. It can withstand tremendous amounts of pressure without breaking, and it cuts quickly and lasts a long time. An extremely prevalent abrasive is aluminium oxide. It has a high initial cutting speed and maintains that speed throughout the cut, making it ideal for use on steel and other metals.
Carbide of silicon:
Silicon carbide is a highly tough grain that may be used to make razor-sharp, lightning-fast blades. It’s not as sturdy as other grains, however, so it’s friable. The roughness of the grain also affects its physical and functional characteristics. The grit indicates the average particle size of the abrasive, just as the grain size of sandpaper dictates the grit size. Smaller numbers indicate bigger, coarser particles, while greater numbers indicate smaller, finer particles; grit sizes vary from 16 to 60.
The bond is what keeps the abrasive grains in place in a cutting wheel. The grade, or hardness, of a wheel is a term often used by manufacturers. The grade indicates the binding strength rather than the actual hardness of the abrasive granules themselves. With everything else being equal, a cutting wheel with a firmer bond will last longer than one with a weaker bond. The grains in a softer bond fall off more quickly, allowing for a smoother cut. It’s possible that the grains will stay there even after they’ve been worn down, if the relationship is strong enough. When the connection is loosened, the new, sharp grains are revealed more quickly, increasing the wheel’s cut rate. When cutting some metals, care must be taken to prevent the introduction of impurities. Always use an abrasive with less than 0.1% chlorine, iron, and sulphur when cutting stainless steel and aluminium to prevent contaminating the cutting surface. Products that are guaranteed to be free of contaminants will be clearly labelled as such. The resinoid bond is often utilised with abrasive grains in cutting wheels. There are organic compounds in resinoid bonds. They’re more resilient to stress than other bonds and can keep working even when subjected to high radial accelerations. These tools are great for cutting off excess material, and they can sharpen themselves by exposing fresh grains. Resin-over-resin bonding is used for certain specialty connections. To make greater use of the grains, these linkages give increased resistance to moisture and heat and a stronger overall binding.
Fiberglass is used to strengthen cutting wheels in a variety of ways. A single layer of fibreglass is used in single reinforcement, which is beneficial for providing fast cutting and minimising burrs on the workpiece. For high-vibration and heavy-duty industrial applications, double or triple reinforcement with many layers of fibreglass is used. All of the cutting wheels for right angle and die grinders sold by Weiler Abrasives are constructed with two layers of reinforcement. A few of the wheels in our new high-speed gas and electric saw wheel line are triple-reinforced, but the majority of them are single-reinforced, like the ones in our large-diameter chop saw line.
CHOOSING THE RIGHT SIZE CUTTING WHEEL
When it comes to cutting wheels, the size is often determined by the operator’s available tool, however picking the right size for the job at hand is also crucial. To determine the optimum cutting wheel size, the recommended RPM (revolutions per minute) must be compared to the recommended RPM (revolutions per minute) of the grinder being used. Making ensuring the wheel fits on the tool without removing the protection or interfering with the RPM rating are both essential.
The diameter and intended use of a tool are often reflected in the wheel’s maximum RPM rating. Die grinders typically use cutting wheels between 2 and 4 inches in diameter, angle grinders between 4 and 9 inches, and chop, stationary, and high-speed saws between 12 and 20 inches.
WHEEL THICKNESS CUTTING
Wheel thickness is often determined by the required level of accuracy and precision in the cut. A thinner wheel has the potential to provide a more accurate and precise cut. They do a better job of cutting with less heat produced. When repairing repairs or customising a product, thinner wheels are preferable since they remove less material with each cut. However, their shorter lifespan is offset by their superior handling. A thicker wheel may be appropriate for uses where precision and accuracy are less important than lifespan. Two ultra-thin high-performance cutting wheels are available from Weiler Abrasives: the Tiger® Zirc Ultracut 1 mm and the Tiger Inox Ultracut 1 mm. The diameters of any of these cutting wheels are 4 1/2 or 5 inches. If you need to cut thin sheet metal, tubes, profiles, or rods with a tiny cross section, go for the Tiger Zirc Ultracut 1 millimetre. It has an ultra-fast cutting rate and a long life. Because of its purity, the 1-millimeter Tiger Inox Ultracut is recommended for usage with stainless steel. Weiler Abrasives now offers a cutting-edge new series of stationary and high-velocity saw wheels in addition to their popular chop wheels. The thickness of the chop saw wheels is 3/32 inches, while that of the high-velocity saw wheels and the stationary saw wheels is 1/8 inches. Some of the most specialised variants of these cutting wheels are able to deliver precision rail cutting, burr-free cutting, and stud cutting for heavy-duty applications; this makes them well suited for use in the metal manufacturing, construction, and rail sectors.
UTILIZATION OF CUTTING WHEELS
Cutting wheels of kinds 1, 27, 41, and 42 have been described so far; these wheels all have somewhat different forms that are better suited to certain cutting tasks. We have looked at the several types of grains used in cutting wheels and how they are best suited for usage with various metals, as well as the impact that wheel diameter and thickness have on cutting speed and accuracy. Let’s take a look at some of the ways in which industrial and professional cutting wheels are put to use, as well as some tips for picking the correct wheels for the job.
FABRICATION IN GENERAL
Metal fabricators often use wheels with a diameter of 0.045 inches. Thinner materials may call for a finer cut using a 1-millimeter wheel, which also generates less heat and leaves fewer burrs that must be removed before welding. Workpiece material makeup will dictate the grain selection, with higher-performing grains used for structural steel and difficult-to-cut metals and contaminant-free wheels used for stainless steel.
When working with metal pipes, the diameter of the pipe usually dictates which cutting wheel is used. There is often no need for a larger than 4-and-a-half-inch diameter when working with a pipe that is 3/4 inches or less in diameter. The optimal cutting wheel diameter for a pipe up to 2 1/2 inches is 6 inches, while for a pipe up to 3 1/2 inches, 9 inches is often the best option. It is also recommended to utilise a type 1 wheel for a deeper cut and the thinnest wheel feasible to reduce heat and friction, unless the application places stricter limitations on you. Cutting operations in fabrication yards or on the right of way for field repairs benefit from wheels with a thickness of 0.045 inches, and a depressed-center cutting wheel gives more space while operating at a limited angle for the bigger pipe typically found on the pipeline.
Making a cutting wheel endure as long as feasible is frequently a top concern for an operator working in the tight, difficult-to-access regions of a ship. This is why the operator may choose a Tiger Ceramic wheel, which is both harder and perhaps more durable. However, the air tools’ efficiency may be compromised if the hoses have to be extended over lengthy lengths, making it difficult for operators to reach remote regions of the ship. Wheels with a soft bond are best for this situation since they make it simpler to keep up a quick cut. There is a close relationship between the work material and the cutting wheel choice in shipbuilding. Cutting wheels that don’t load or clog up are preferable when dealing with metal, so maybe go with Tiger Aluminum.
The cutting of metal with great precision is a standard pre-welding step. Precision is not necessary for a simple cut-off procedure, but it may save both time and money if the material’s original aesthetic features are preserved throughout the restoration process. To make clean, precise cuts, welders often use cutting wheels that are 0.045 inches (just over 1 millimetre) in diameter. A 1-millimeter UltraCut wheel will give smooth cutting and great control for clean, ultra-precise cuts on thin sheet metal, profiles, and tiny diameter rods.
High-speed gas saws need a high-performance cutting wheel because modern railroads employ alloy steels that are difficult to cut. The wheel’s superior performance is the result of a self-sharpening zirconia alumina grain that maintains its cutting edge for the duration of its use. Tiger Zirc’s 14- and 16-inch cutting wheels provide the high-performance solutions essential for boosting productivity and earnings with high-velocity gas saws.
PROJECTS SIX: BUILDINGS
Metal cutting serves several purposes on building and construction sites. Most operators are on the lookout for a wheel that can do many functions, such as slicing through rebar and making extensive cuts in sheet metal. A lot of the time, an aluminium oxide wheel will have the optimal balance of adaptability, efficiency, and cost. The Tiger AO series of die and right angle grinder accessories includes both flat and depressed-center cutting wheels. Tiger AO now offers chop saws and high-velocity gas and electric saws in greater diameters ranging from 12 inches to 16 inches. Multiple specialty wheels for use in the building trade are included in this set of big cutting wheels. The collection of chop saw wheels includes a stud-cutting wheel as well as single-layer fibreglass burr-free cutting alternatives. The high-speed saw comes with wheels made of three layers of fibreglass, making them more durable and reliable for cutting through tough materials.