How to cut with an angle grinder without sparks

Dangerous mistakes when working with an angle grinder, which is better not to commit

What you need to know first and foremost to work with an angle grinder:

  • The tool is not allowed to be used without a protective cover;
  • When using an angle grinder, you should always wear goggles to protect yourself from metal dross, which can easily fly into the eye;
  • Sparks from the angle grinder should fly back, although many remake angle grinder, so that the sparks fly forward, not under the feet. But in this case, it is much more difficult to hold the tool in your hands;
  • While working on the angle grinder should not pour water. Some craftsmen, for example, pour water on the angle grinder disc when cutting concrete to reduce the amount of dust, but this can lead to electrocution;
  • It is imperative that before you cut metal with an angle grinder, you must think about where the sparks will fly and whether anything will catch fire as a result.

In addition, you should not put on the angle grinder disk larger diameter than you can. Some clever people, in the absence of a disk, remove the protection and put a disk with a larger diameter, which is not designed by the manufacturer of the tool. As a result, not only the level of vibration increases, but also the risks associated with damage to the wheel, which inevitably leads to serious injury in the absence of a protective cover.

Also, you can not use when working with an angle grinder, circles that have any obvious defects. Very often the disc “walks” from side to side, which indicates a violation of its internal reinforcement. All this can cause disk failure when cutting materials.

What not to do when working with an angle grinder?

Before you work with an angle grinder, you must always make sure that the workpiece is firmly clamped in a vice. Very often, pressing a corner or a sheet of metal with your foot to the ground and cutting it, the angle grinder disc touches rocks and other objects that literally fly away at high speed. Therefore, keep a small clearance from the ground and place something under the material to be grinded.

The worst thing when working with an angle grinder is a backfire, when the disc jams or the tool is not held tightly in your hands. The angle grinder may only be held with two hands and very firmly. In doing so, the body position must be such that the angle grinder is between the feet of the person working and the body is not in line with the cut.

In this case, even if the angle grinder and vomits out of hand, the drive will go to the side and will not cause much harm.

Loading an oversized disc

For each device is suitable for a certain size of grinding disc, which is indicated in the certificate of the angle grinder. If the line “cutting disc” has a value of 125 mm, it means that 125 mm is the maximum diameter of the grinding disc that can be put on the device. It is not uncommon that the operator puts a larger disc on the angle grinder to cut thicker metal or a more dimensional structure. How is that dangerous??

angle, grinder, sparks

First, if you want to use a larger blade, you have to remove the blade guard because the blade might not fit. The operator loses protection and, if the blade is damaged, could be injured by broken shards.

Secondly, the possibility of damage to the cutting disc due to incompatible speeds increases. Note that for each disc size there are their allowable rpm for the angle grinder, at which they will work: for grinding wheels up to 125 mm diameter 11000. 12000 rpm, for grinding wheels up to 180 mm diameter 8000. 8500 rpm, for grinding wheels up to 230 mm diameter 6700 rpm. That is, you can cut with big discs at lower speeds, and with small discs at higher speeds. It is worth to mention that the linear speed of the edge of the disk should not be more than 80m/sec, so when you increase the diameter you need to decrease the rpm. At high speed, a large disc would break into pieces, and it would be dangerous for the operator.

Conclusion: never exceed the maximum size of the cutting disc. If you need to cut thick metal, it is better to buy a device for large discs, for example, Zubr angle grinder-P230-2100 PV.

How to cut with an angle grinder, sparks from yourself or on yourself?

In this issue I would like to discuss with you one question, how to work properly with the angle grinder and what is not recommended to do when working with this tool.

Many people argue about how the disc on the angle grinder should rotate, away from you or toward you?

Just the other day I saw a cutting disk in small pieces, and it was not the quality of the disk, but a gross violation of the cutting rules.

The man was cutting a sheet of material about 1 mm thick., The rotation of the disk was from itself.

And the mistake was in the fact that cutting in this position was necessary to pull the angle grinder to yourself, not away from you.

As a result, the disk hit a sharp edge and it broke into small pieces.

The most important thing is that no one was hurt, very lucky. It would seem to be an understandable thing, but not everyone knows about it. Perhaps this would not have happened if the metal was much thicker.

A little about protection and safety when working with an angle grinder.

I don’t know why, some people remove the protection from the tool, I never do this.

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I have it set like this:

Even if your hand accidentally slips, you can’t reach the abrasive wheel:

So, I work with the angle grinder only sparks toward me, along the body of the angle grinder, it’s much more comfortable and logical to me.

How to cut with an angle grinder without sparks

In the last post we dealt with the correct side of the cutting wheel. Now I want to talk a little bit about the direction in which the wheel should rotate when cutting, and how to hold the angle grinder correctly?

Since I already had the manual for the Metabo angle grinder in my hands, I decided to look at how this issue is described there:

angle, grinder, sparks


That means that regardless of the material to be cut, because it is not mentioned, it is necessary to cut in the opposite direction. In doing so, I want to note from myself that you should cut with an angle grinder what is designed for cutting with an angle grinder. If you suddenly want to use an angle grinder clearly not on purpose, and cut, for example, profiled sheet metal or other similarly thin materials, which are usually cut with scissors, then here already in the opposite direction it will be difficult to saw, and dangerous. So once again I want to clarify. the manual describes only the cases of intended use of the tool.

If you look at the figure close up, you can see that this is the top view, and the work is done with a small angle grinder, although this is a common figure for all grinders:

Notice how the body of the angle grinder is tilted. the angle grinder is not pushed forward, but pulled toward you. This makes it much easier to hold in your hands.

So, the direction of the cut should be toward the rotation of the wheel, because otherwise the wheel can jump out of the kerf, and the angle grinder should be led toward you. If the wheel pops out of the kerf, the angle grinder can roll on it on the surface of the workpiece toward you, will tumble in weak hands, turn the cutting wheel toward you, and cut you in half. If the wheel is jammed and it will also pop out destroyed, in addition to the above, the inertia of rotation scatters its splinters to the sides. If the wheel is jammed during counter cutting and leading into itself, on the contrary, it digs into the cut and stops quickly, and most of the splinters remain under the workpiece, and the rest. in the cover.

Often when such counter cutting, sparks fly to the person working and also block the cutting direction. And if the wheel breaks, the splinters will also fly in the direction of the sparks. How do you do that??

I think safety is more important than the ability to accurately control the cut. When you cut sheets, you can use a guide made out of angle bars. When cutting parts, their cross-sectional size does not require constant monitoring of the cutting direction. When it comes to sparks and possible wheel splinters, it’s important to learn how to hold the angle grinder correctly. In a workshop environment this is not difficult. right hand on the additional handle, perpendicular to the body of the angle grinder, an angle of 100-110 degrees, that is, the right elbow is even further from the front edge of the wheel. The left one on the body with the button, parallel to the angle grinder. angle grinder parallel to your body. The sparks should fly past to your left. The cut is controlled from above and slightly to the right, above the auxiliary handle. You should not be in the plane of rotation of the wheel at all.

In the conditions of a real object, for example, when dismantling metal structures, it is impossible to hold an angle grinder all the time as described. You have to rely on the hood, the mask, the overalls and the intellect. However, you should always keep in mind the recommendations of the direction of rotation of the wheel and the guidance of the angle grinder. With each cut you should understand in what direction the angle grinder will tear during jamming, where the fragments of the wheel will fly, where the angle grinder itself, how it will tumble in this case, and immediately change your position if you are not satisfied with the result.

In the economy very often have to cut off pieces of long pipes, fittings, etc.п., that are lying on the ground. Raising them to the level of the vice is often not possible. You have to saw on the ground, and even with a large angle grinder. How to protect yourself as much as possible in this case?

I have been working with a large angle grinder with 230 mm circles from time to time for several years now. Naturally, I will always have little experience with this kind of work, so I would like to determine the safest techniques for myself.

The safest handstand with a heavy angle grinder seems to me to be. Right hand, as usual, on the additional handle, left hand on the handle with the button. Let’s assume that my right foot is holding the pipe against a wooden bar and pressing it down from above, or I’m just standing on the ground if the pipe is fixed. Bending down and resting my right shoulder on my right knee. In this position I am in a similar position to the workshop, but the weight of the angle grinder is not on the right arm and back muscles, but on the knee support. The left leg is set back and the foot is turned perpendicularly, adding stability, but it is not in the plane of rotation of the wheel.

This is not always a good support, e.g. if you have to make a deep cut in a wide pipe that cannot be rotated. Then I just stand up so that the sparks fly back between my legs. Control of sawing in this case is carried out either from the left, from the side of the circle, or from the right (then the right shoulder again rests on the right knee). In case of splintering, all the hope in the above case is on the shield only. But it’s important not to give the wheel lateral forces, or it will be torn from the shaft, ripping out its middle, which will remain under the nut, and it will come off the angle grinder, continuing to rotate at breakneck speed. Since you are in the plane of its rotation, it can cut you in half, ricocheting off the part or the ground. I had the circle torn off, when I was sawing rusty bolts from the plane, on which I lightly pressed the plane of the circle. Luckily, the wheel came off neatly and just went sideways.

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The shield on the angle grinder is mandatory. Small angle grinders with grinding or even cut-off wheels without shields are often used for repairs on vehicles so it is easy to get under. Suicides, yo.

Goggles (specifically safety goggles that cover your eyes from all sides) are mandatory. When you cut or grind a lot of abrasive and metal is flying in different directions, ricocheting off everything you can. For dismantling steel structures on the site a mask is preferable, but only closed, so that sparks that ricochet under it do not fly, and reinforced, to keep the flying fragments of the disk in case of its destruction. The downside to the mask is it fogs up. But if you wear a respirator, which is important in daily work, fogging is practically nonexistent The grass-cutting mask cannot be used. It is open at the bottom and does not protect against ricochets of sparks, but on the contrary, catches them and makes them ricochet again to the face. And yes, when you work with angle grinder daily it is necessary to use earphones or earplugs, otherwise you will get fast hearing loss.

Sparks on themselves

When cutting metal with an angle grinder sparks on themselves, the risk of injury is much less, because if you do not hold the tool in your hands, it will fly in the opposite direction from you.

But it is important that there is nobody in front of you on the cutting line. The disadvantage of this method is that sparks are flying in the operator’s direction and can burn your clothes.

Of course, it is better than getting hurt, but it is still unpleasant. Today in practice both of these methods are used, and in conclusion we want to give general recommendations, where which method of cutting with an angle grinder is better to use.

Instructions for use of the angle grinder

Knowing the peculiarities of the angle grinder device, as well as the differences in the methods of grip allows you to avoid gross errors during work.

Step 1. cleaning the work area

Before you begin work, it is necessary to free the work area. Remove all unnecessary things from the access area: trash, unnecessary tools, film, cloth.

Leave only those things that may be needed directly during the work. It is important that there are no objects or cables underfoot that you could trip or get caught in.

angle, grinder, sparks

Important! No pets or small children should be in the work area while the angle grinder is in use.

Step 2. preparation of the product

Before cutting with the angle grinder, the workpiece is properly secured in a vise, clamping or other fixture. It is not allowed to clamp the parts with your hands, feet or use an assistant.

Step 3. preparing the tool

Preparing the tool is the selection of the nozzle. They vary, depending on the type of material and manufacturer. The disk must be intact, without chips, cracks or other defects.

Set-up the wheel with the machine switched off. Switch on after the disc is clamped.

Step 4. starting and setting up

Starting and setting up the instrument begins when the disk or nozzle is installed.

How to cut without dust

  • The instrument is taken so that the sparks are directed toward yourself (cutting method from yourself). The plane of the wheel is parallel to the worker’s body.
  • Your right hand is firmly grasping the auxiliary handle of the angle grinder. Left. controls switching on of the tool and adjustment of disk rotation speed.
  • The grinder is to the left of the operator’s body. No contact of the tool with human body is allowed.

When the operator takes the starting position, turn on the device and let it idle to warm up the unit and spin the disc to operating speed.

Step 5. cutting or grinding

When cutting, the tool is held and guided without pressure. Work is performed with the edge of the wheel. It is important to control depth of penetration of the nozzle. The less it enters, the less it wears.

When grinding, grinding wheels are used as a scraping wheel. Personal protective equipment is used when grinding surfaces with bristle circles.

An expert’s point of view: what to cut profiled sheeting?

Even if you have ordered the required length of profiled sheeting, it may be necessary to trim the sheet during installation. Sometimes profiled sheeting must be shortened or “fit”: for example, in places where the roofing material adjoins the chimney. If you are installing a roof or fence complex shape may require trimming corners profiled sheeting.

The question arises: how to choose the right tool for cutting? Let’s formulate the general requirements for it. A tool for cutting profiled sheeting must:

  • Cut profiled sheeting without metal overheating, not to burn out the polymer and zinc coating. Trapezoidal sheet is a “pie” of several layers: the steel base coated on both sides with zinc, primer and a polymer layer (on the front side) or a protective coating (on the underside). Each layer has a specific function: to protect the steel base of corrosion, provides trapezoidal sheet aesthetic appearance, etc. If one or more layers burned, it affects not only the aesthetic characteristics of corrugated board, but also on the functional. the steel base will be exposed to corrosion;
  • do not create sparks when cutting. Sparks from the abrasive disk can damage polymer and zinc coatings. The consequences of such damage we pointed out in the previous paragraph;
  • Leave a clean line to trim the cut, do not deform the edges of the profiled sheet. Otherwise formed “burrs” should be bent, and flattened edges. to straighten. This will require a significant investment of time;
  • Not to melt edges of profiled sheet. Otherwise it will lead to damage of protective and polymer layers along the edges of the sheet and, as a consequence, to the occurrence of edge corrosion.

Let’s consider what electric and hand tools are optimal for trimming profiled sheet, and what is forbidden to use.

Note: do not forget to treat cut areas with repair enamel.

Is it possible to cut profiled sheeting with angle grinder?

Profiled sheet it is strictly forbidden to cut with this tool for three reasons:

  • Spectacular sparks that fly out from under the disc while working, damaging the decorative and protective layer. They get on the polymer coating, burn through it and the zinc. In places where sparks hit, corrosion can occur.
  • Abrasive disk saw profiled sheeting due to friction. As a result, the metal is heated, under the influence of high temperatures the polymer and zinc coating along the edges are burned out, which leads to edge corrosion.
  • Abrasive disk leaves “jagged” edges.
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So: “angle grinder” can quickly cut profiled sheeting, but it will become unusable. Therefore, the answer to the question “how to cut the profiled sheeting “angle grinder” is simple: no way.

Is it acceptable to cut corrugated sheeting with a circular saw?

angle, grinder, sparks

Cut profiled sheeting with a circular saw, even if you use a diamond disk with fine teeth. not the best option. This tool cuts the metal due to the heat; disk melts the edges, and with them. the zinc and polymer coating. Thus, the edge of the sheet is again unprotected from corrosion.

No sparks during cutting, which can cause burns in polymer and zinc coating. But because of aggressive impact on the edges of the sheet we do not recommend this tool.

Can you use an electric jigsaw to cut corrugated sheet metal?

Yes, it is one of the most popular choices, especially the jigsaw with laser pointer. with this tool you can quickly cut a sheet without losing the marking.

When to use?

When you want to get a curved or straight cut on one or more sheets of corrugated board up to 21 mm in height. To cut a stack of sheets, this tool is not used. the jigsaw may fail.

Electric jigsaw is often used for cutting profiled sheet because:

  • Almost everyone has it, it does not need to purchase additionally.
  • They are easy to work with, it does not require any special skills.
  • With the jigsaw, you can saw profiled sheeting at any angle.

This tool is only suitable for profiled sheet up to 21 mm in height (not higher than C-21). If you have chosen a material with higher corrugations, it is better not to use an electric jigsaw: it will tear the metal. Also, it does not have enough blade length for cutting corrugated board with high waves. On functionality of the tool work with such material too will not affect in the best way. it can break.

There is a possibility of metal overheating when working with an electric jigsaw. To avoid this, follow our tips:

  • Control the power of the jigsaw. Do not turn on the tool at full power, otherwise you risk overheating the metal and scorching the polymer and zinc coating.
  • Drip oil on the blade periodically (any oil will do). It will help to reduce the friction and therefore the metal will be less hot.

Attention: While cutting profiled sheet with jigsaw creates fine metal chips. It should be promptly removed with a soft cloth (do not use an abrasive brush for this! you can damage the polymer coating). Otherwise, bits of metal left on the surface can begin to rust and spread corrosion around.

Is it permitted to use the cricket bit in a drill?

This is also quite a popular tool. Almost everyone has a drill, you just need to buy an inexpensive attachment for it, with which the drill will work like electric scissors. Also, do not forget to purchase a set of replacement blades.

Drill with a nozzle “cricket” accurately cuts the metal without deforming the edges of profiled sheeting. Edges do not bend, they do not need to straighten afterwards, the edges are obtained flat, without “burrs.

What to use when?

For longitudinal or cross cutting of profiled sheets, for shape cutting, for cutting hard to reach areas. The thickness of metal should not exceed 0.8 mm.

Attention: When cutting, the core drill bit must be positioned absolutely perpendicular to the surface of the profiled sheet. In this position the tool will work properly.

Do you use a cutter for cutting corrugated sheet??

Yes, use. They have three main advantages:

  • They cut metal faster than an electric jigsaw, and are comparable in speed to an angle grinder.
  • They can be used to start cutting not from the edge, but from the middle of the sheet (the tool cuts a hole in the right place of the sheet).
  • Do not deform edges of corrugated sheet. The line for the trimmer trimmer cuts evenly.
  • Cut profiled sheet of any height and any thickness of steel.

Safety rules when cutting metal with an angle grinder

Cutting metal products requires compliance with safety rules. even with safety devices and sophisticated design, the tool can lead to accidents, including injuries from pieces of metal that break off, fire from sparks, etc. п.

Photo 1: Personal protective equipment: goggles, ear muffs, gloves, helmet

  • Wear personal protective equipment (PPE): canvas gloves, respirator, goggles.
  • Do not grind using the side of the wheel.
  • Do not use bent or severely deformed consumables.
  • Make sure that the metal cutting disk does not cross with electric cable, lubricants and other foreign objects.
  • Do not plunge too deeply into the workpiece as this could damage the wheel and tool.
  • Before you start up the machine with a newly mounted disc, check that it is idling.
  • Clamp the part to be grinded in a vice. If you hold the angle grinder in your hands, the cutting tool could injure your hand.
  • Wait until the machine is completely stopped before removing and replacing the disc.

Course of the experiment

Set up the angle grinder by leaning it on the base plate. The blade itself is between the jaws of the bench vice.

Additionally, the author ties safety ropes to the angle grinder. so it does not fly off in an unknown direction when the disc jams.

The author wraps the body of the angle grinder with painter’s tape. it will simulate holding the angle grinder in your hands.

After the preparatory work is complete, the experiment itself can begin.

There is no sense to describe the whole process, you can see everything on the video. But let’s just say that if you cut metal with sparks on itself, the angle grinder tends to pull forward when the disc jams.

And, on the contrary, if you cut metal with sparks from yourself, the angle grinder, having escaped from the hands, flies back. in the direction of the cutter, and it can be very dangerous.

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