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Steel cutting discs are found in various types, as highlighted below. These variegations cut it based on the intended use, the structure, and the materials incorporated in manufacturing.
Fiber Discs
They are ideal for heavy-duty tasks and require aggressive grinding. Fiber discs are made using durable plastic bases and have ceramic or aluminum oxide grit. This cutting disc is usually attached to a backing pad and used with angle grinders. It is perfect for shaping edges, removing material, and finishing surfaces.
Diamond Discs
They are the most durable cutting disc and ideal for cutting harder materials. These discs have a steel or resin base with synthetic diamond grit embedded on the surface. These steel cutting blades are ideal for cutting concrete, ceramic tiles, and masonry because of their durability. They can be used on angle grinders or tile saws and offer precision in their cuts.
Reinforced Cutting Discs
The steel cutting blades have a reinforced steel mesh in their structure. That helps to make their use also in heavy metal cutting applications. They can be used on angle grinders to cut metal sheets, pipes, and other heavy materials. Their practicality makes them popular because it cuts materials while minimizing wear.
Abrasive Cutting Discs
Abrasive cutting discs are made from aluminum oxide or silicon carbide. A combination of these materials leads to versatile cutting discs for metal and masonry. They are often used on angle grinders and provide good cuts for steel, brass, and copper. They are even suitable for cutting through concrete and stone. These discs wear down over time and need to be replaced for efficient cuts, but they are economical.
Cut-off Wheels
Cut-off wheels are thin cutting discs designed for precise cuts. These wheels are often used in Dremel tools and bench grinders and are favorable for cutting bolts, screws, and small metal pieces. Their thin design makes them ideal to use in tight spaces where a big wheel would be impractical.
Steel cutting discs are used in various industries to perform different operations, as highlighted below.
Manufacturing Industry
Steel cutting discs are widely used in the manufacturing industry to cut metals, including steel, aluminum, and other alloys. These discs are used to create precise cuts and shape the materials into desired forms for production. They are used to make cutting discs for metalworking and automotive parts manufacturing.
Construction Industry
In the construction industry, steel cutting discs are used for cutting metal rebar, structural steel, and other metal components used in construction projects. These discs are mounted on angle grinders or gas-cutting machines to provide quick and precise cuts while working on installation, renovation, and demolition projects.
Automotive Industry
Within the automotive industry, steel cutting discs are used in bodywork and frame applications. These discs are used in angle grinders and cutting machines to cut metal sheets, panels, and exhaust systems. These cuts offer the precision needed for repairs and modifications, as well as the implementation of new parts.
Metal Fabrication Shops
Steel cutting discs are indispensable tools for metal fabrication shops. Due to their versatility and precision, these discs are used when cutting metal pieces to construct brackets, frames, and customized components. This makes them ideal for welding and assembling projects. That is why they are widely used in the production of welding and automotive parts.
Shipbuilding Industry
In the shipbuilding industry, steel cutting discs are used to cut large metal sheets and plates. These discs are mounted on cutting machines and used to create complex shapes required for hulls, decks, and other structures within ships. The heavy-duty cutting discs can handle thick materials, offering smooth and clean cuts for welding.
Aerospace Industry
Within the aerospace industry, steel cutting discs cut alloy metals and other materials used in aircraft constructions. These cuts are which precision is required to make cutting discs for critical components such as wings, engines, and landing gear. Because of the cutting discs’ quality and accuracy, they are one of the preferred choices for thin and tough materials.
Scrap Recycling Centers
At recycling centers and steel cutting discs, metal scraps are cut and prepared for collection. These discs are used with angle grinders to remove non-metal parts such as wood and plastic from metal scraps. This prepares the scrap for processing, as only metal is collected and processed in recycling centers.
There are certain product specifications and features that are inherent to steel cutting discs. Those are discussed in the section below.
Material Quality
The ideal steel cutting blades are equipped with premium-quality, long-lasting materials. This means that the discs contain either aluminum oxide, silicon carbide, or diamond segments. The two mentioned materials are ideal for cutting metals, while diamond is ideal for abrasive materials. The durability of the material ensures there is minimal wear and maximum cutting edge.
Bonding System
In bonding the cutting disc components, the reinforced resin bonds hold the grains in place even under extreme conditions. The resin is placed to ensure it withstands high temperatures, intense friction, and pressure during cutting. This ensures the cutting edges remain sharp and the cutting surface elongates.
Usage
Steel cutting discs are efficient at cutting metals. Besides their efficiency, their versatility makes them ideal for both professionals and industries for heavy-duty use. They are used on angle grinders, cut-off saws, and bench/hand-held for the best results.
Size and Thickness
Industrial cutting discs are available in various sizes and thicknesses. The most common size range is 4.5 to 16 inches in diameter, while thickness varies from 1 to 3 millimeters. The right size and thickness in these discs ensure they are installed on various power tools and provide decent stability and flexibility for metal cutting.
Safety Features
Steel cutting discs have certain safety features to improve users' safety. The discs have a reinforced central part to ensure even distribution of the kinetic energy that comes with high rotation speed. There is also a protective cover that protects the user from metal shards or sparks that can be dangerous when cutting or grinding.
The cutting steel discs can be chosen by considering some of the factors below. So, enjoying the benefits of steel cutting blades requires knowledge of the following.
Material of the Disc
Steel cutting discs are made of several materials, each with certain advantages. There are aluminum oxide discs that are ideal for general-purpose cutting of steel and other metals, while silicon carbide is ideal for cutting hard and brittle materials like cast iron. Diamond blades are preferred for their durability and precision cutting of hard materials like concrete and stone. Understanding the materials will help one get ideal cuts.
Disc Size
Choosing the right-sized steel cutting disc depends on the cutting tools in use, which range from angle grinders to power saws. The size of the disc will vary depending on the tool being used to guarantee optimal performance. Industrial cutting discs are commonly 4.5 to 14 inches in diameter. Larger diameter discs provide deeper cuts, while smaller diameter discs offer greater control.
Coarseness
Cutting disc coarseness is one of the factors that will affect the cut finish. Fine discs have a smooth finish and provide accurate cuts, while extra coarse discs are ideal for heavy stock removal and fast cuts. The grit size will help one achieve the desired cut finish.
Bond Type
The bond type is simply the material that holds the abrasive grains together on the cutting disc. Resin bonds are usually found on metal cutting discs because of their heat resistance during intense cutting. Vitrified bonds are ideal for heavy-duty applications and provide long-lasting sharpness. Understanding one’s ideal bond will maintain the cut’s efficiency.
Reinforced
Reinforcement steel cutting discs are known for additional strength and safety, especially under extreme pressures. Look for discs with fiberglass or steel reinforcement to reduce the risk of breaking and ensure a safe cut. This will also allow room for heavy-duty cutting tasks.
Steel cutting discs can only be used on specific tools. In terms of compatibility, angle grinders, cut-off saws, and metal saws should be used with the discs to ensure optimum performance.
The ideal storage for cutting discs is cool and dry places where they won’t be exposed to direct sunlight or extreme temperatures. Some of the protective cases incorporate foam or padded lining to reduce the impact on the discs. Avoid storing them in damp areas, as this will create a chance for rust and corrosion.
A safe cutting disc will bear a manufacturer’s certification mark. There are also quality standards like ISO and ANSI that will signify the safety and performance of the discs. Also, look for the discs with certain safety features, such as reinforced designs and guards.
It is ideal to replace cutting discs after noticeable wear, such as chipped edges, cracks, or reduced cutting speed. One should also ensure the average cutting time per day will determine how frequent the replacement will be.
The durability of a cutting disc depends on the material and bond used. Although thicker discs are more durable, they are heavier and harder to control.
