Abrasive vs Diamond Cut Off Wheels - PowerPak Civil

*Disclaimer*
The information contained on this page is for promotional and informational purposes only. All equipment should be used by trained professional tradesmen who have been trained how to use the equipment described on this page, and understand the risks of their work. PowerPak assumes no responsibility for errors or omissions in the use or misuse of any product purchased. In no event shall PowerPak be liable for any direct, special, indirect, consequential, or incidental damages or any damages whatsoever, whether in an action of contract, negligence or other torts, arising out of or in connection with the use of this information or the contents of this page. PowerPak reserves the right to make additions, deletions, or modifications to the contents on this page at any time without prior notice.

If you are looking for more details, kindly visit our website.

It’s finally here, the topic you’ve been waiting for us to cover. After thousands of request letters and calls, we are finally going to give you the scoop on abrasive and diamond cut-off wheels.

Okay, okay, you caught us, there was no influx of requests for this topic. But even though you didn’t ask for it, we know you’ve been wondering which is better. Unfortunately, the answer isn’t cut and dry. Diamond and abrasive cut-off wheels are two very different options with their own set of pros and cons.

Traditionally, workers start off using abrasive cut-off wheels, and many only use abrasive wheels for their entire careers. Others go back and forth between abrasive and diamond as needed. Both paths are good, as long as it cuts clean.

Let's get into what makes these two options so different and when it makes sense to pick up one over the other.

Cut-off Wheels

Before we get into the specifics of these two options, let’s get everyone on the same page. You can get cut-off wheels in a bunch of different sizes, but for this article, we are primarily talking about 4.5” and 7” wheels used in angle grinders. But, a lot of what we are covering here will apply to cut-off wheels of any size.

We are also explicitly talking about cut-off wheels, also known as cutting wheels. Not to be confused with grinding wheels, cup wheels, flap discs, wire wheels, or any other wheel options for angle grinders. To include all of those other wheel options would make this a much bigger discussion, so for today, we are just sticking to the tried and true, cut-off wheels.

Abrasive Cut-Off Wheel

Dare I say, there is a lost abrasive wheel hiding under a cabinet in every garage, shed, and workshop across America.

For decades, if you needed to make a clean 90-degree cut through a metal pipe, rod, or sheet, you would pick up a pack of abrasive cut-off wheels, load one into your angle grinder, and get to cutting. They are a great option because they cut fast and they are cheap, so you can buy a bunch of them.

Abrasive cut-off wheels often referred to as bonded wheels or bonded abrasive wheels, are exactly as the name implies. They are comprised of abrasive fibers all bonded together into a wheel. As the wheel cuts, it sheds the used dull abrasive fibers making way for the next row of fresh abrasive fibers. This constant shedding is the main reason these wheels can cut so quickly. It's also why the wheels wear away into nothing, just as quickly.

You can get these wheels with different grain materials, and each material performs differently, so you want to pick your grain based on what you are cutting.

Zirconia cut-off wheels are a popular option because they offer excellent cutting capabilities for the cost. These durable wheels cut fast and work well on steel, iron, and other metals.

Aluminum Oxide is another commonly found option and is probably the most popular. Workers like the consistently low cost of these wheels, and how fast they cut.

Ceramic wheels are a good option when you need to mitigate heat while cutting. These wheels tend to be a bit cooler while cutting, making them a good choice for stainless steel, steel, and metals that are difficult or slow to cut through.

There are other grain options, but those are the three you will come across most frequently. These cut-off wheels come in two "types" as well.

Type 1 wheels are flat all the way across. These wheels are great for deep straight cuts, but the limited visibility while using the wheels requires some expertise while operating. These are sometimes called Type 41 wheels.

Type 27 wheels have a depressed center where the wheels mount. This little bit of offset gives workers much better visibility and the option of flush cutting, with the tradeoff of not being able to cut as deeply as a type 1. These are sometimes called Type 42 wheels.

And finally, these wheels often have a level of reinforcement. You’ll see a wheel labeled as single, double, or tripled reinforced. That indicates how many layers of fiberglass reinforcement are in the wheel. This is a significant feature because weak abrasive wheels are known to crack and shatter mid-cut, sending shards of shrapnel flying in all directions.

A combination of fiberglass reinforcement and stronger bonding agent have made modern abrasive wheels much less likely to crack, but beware, some low-cost options are still known to crack and break.

Diamond Cut-Off Wheel

There is a lot less to break down with diamond cut-off wheels. These are metal wheels with diamond-coated edges. They don't shed away like abrasive wheels; they operate similarly to any other diamond cutting blades you would use in a saw. You can cut with it until it dulls, and with a diamond coated edge, it will take a long time to dull.

One factor to consider when buying a diamond cut-off wheel or any diamond coated blade is weighing the cost-benefit between cheap and expensive wheels. Not all diamond wheels are made with the same quality standards, and you can buy more affordable options that won’t last as long or may chip or break easier.

Surprisingly, buying the best, most expensive wheel isn’t always the right move. If it’s your first time cutting, or you only cut occasionally, and you don't have the skill set down pat, you can quickly damage or ruin a $25+ diamond wheel. In those situations, starting with a lower-cost option would make more sense to save some money in the long run.

If you have the experience and need a wheel that doesn't need to be swapped out as frequently or have a project requiring a wheel that doesn't change size every cut, then splurging for the higher-end diamond wheel might be the best option for you.

For more information, please visit PTATOOLS.

Comparing Diamond and Abrasive Cut-Off Wheels

There at a lot of differences between these two options. These two wheels are constructed differently, and the differences don't stop there.

Cut Speed

Many factors affect the cut speed of a wheel, but regardless, abrasive wheels cut faster. That's not just in the best-case scenario but in almost all scenarios. Abrasive wheels are just faster at cutting across the board. It's hard to say how much faster, but with the right material, it's a significant margin.

Mess/Dust

It’s no surprise that diamond wheels produce significantly less dust than abrasive wheels. When an abrasive wheel cuts, it sheds layers of its grain and produces metal dust from the item being cut. Diamond wheels don’t shed.

This is a factor in work conditions where dust levels are being managed or if you are trying to reduce cleanup time.

Heat

In most cases, diamond wheels will create more heat while cutting, mainly because they cut slower, and the longer you are cutting, the more heat is going to be produced. Producing too much heat while cutting can cause a lot of problems. It can warp, discolor, or burn the material you are cutting.

There are many methods and best practices for cutting to help mitigate the heat.

Cost

This is the topic where we hear the most arguing. Some workers believe diamond wheels are a rip-off because you can buy an abrasive wheel for a fraction of the cost. A 4.5” FORTEM Abrasive wheel costs around $2, and a 4.5” FORTEM Diamond blade costs closer to $16. That’s a big jump.

The counterargument is that Diamond wheels last longer. That's why they cost more.

Worker’s counter back with the fact that you can buy eight abrasive wheels for the cost of one diamond wheel. Does a diamond wheel last longer than eight abrasive wheels?

Well, most diamond wheels claim they will last up to 30 times longer than an abrasive wheel. We all know that claims like these often boast "best-case conditions." In real-world conditions, I think you'd find that a diamond wheel and a pack of abrasive wheels of the same cost will last for about the same amount of time.

If you are planning on doing a lot of cutting, either option will be fine. If you only need to make a few cuts, you can save money with an abrasive wheel.

Safety

When used correctly, all wheels are safe, and when misused, all wheels are a hazard. It's generally recognized that abrasive wheels can be the less safe option. We previously mentioned that cheap wheels have a tendency to shatter mid-cut, but many workers go for years without ever seeing a low-cost wheel break.

The safety factor everyone should consider is the sparks. Abrasive wheels produce more sparks than diamond wheels. If you work in a shop with oily rags or on a jobsite with dry conditions, keeping sparks at a minimum could be a requirement.

Stop Arguing

That’s it. In most cases, choosing one wheel over the other won't make too much of a difference, but as always, it’s important to know the differences in case you never need one over the other. So, end the debate; no need to argue anymore.

PowerPak carries a selection of cut-off wheel options in a variety of sizes and brands, including our own in-house brand FORTEM as well as other top brands like Z Speed. Shop our website to get quick delivery and follow us on social, so you don’t miss out on any promotions.

Angle grinders are versatile tools that find applications in various industries and DIY projects. One of the key components of an angle grinder is the cutoff wheel, which plays a critical role in cutting through different materials such as metal, concrete, and tiles. When it comes to cutoff wheels, there’s an ongoing debate about whether a thin or thick wheel lasts longer. In this article, we will explore the factors that influence the longevity of cutoff wheels, the advantages and disadvantages of both thin and thick wheels, and help you make an informed decision based on your specific needs.

Understanding Cutoff Wheels

Before delving into the discussion of thin vs. thick cutoff wheels, it’s essential to understand what these wheels are and how they work. Cutoff wheels, also known as abrasive wheels or discs, are composed of abrasive grains bonded together with a matrix material. The abrasive grains are responsible for cutting through the material, while the matrix holds them together and provides structural integrity to the wheel.

Cutoff wheels come in various sizes, diameters, and thicknesses. The thickness of the wheel is a crucial factor that affects its performance and longevity. Thin and thick cutoff wheels serve different purposes and are designed for specific tasks.

Thin Cutoff Wheels

Thin cutoff wheels are characterized by their slim profile. They typically have a thickness ranging from 0.045 inches to 0.125 inches (1.1 mm to 3.2 mm). These wheels are commonly used for precision cutting tasks and are ideal for making clean, narrow cuts in metal, steel, and stainless steel. Thin wheels are known for their ability to produce minimal material wastage, making them suitable for applications where precision and efficiency are essential.

Advantages of Thin Cutoff Wheels:

1. Precision Cutting: Thin wheels excel at making precise cuts, which is crucial in applications such as metal fabrication, plumbing, and electrical work.
2. Minimal Material Wastage:Due to their narrow profile, thin wheels create less material wastage during cutting, which can be cost-effective.
3. Reduced Heat Generation:Thin wheels generate less heat during cutting, which helps prevent overheating and material distortion.
4. Faster Cutting Speed: The slim design of thin wheels allows for faster cutting, improving overall efficiency.

Disadvantages of Thin Cutoff Wheels:

1. Fragility:Thin wheels are more prone to breaking or shattering, especially when used incorrectly or on hard materials.
2. Limited Depth of Cut: Thin wheels may not be suitable for applications that require cutting through thick materials.

Thick Cutoff Wheels

Thick cutoff wheels, on the other hand, have a greater thickness, typically ranging from 0.125 inches to 0.250 inches (3.2 mm to 6.4 mm) or even more. These wheels are designed for heavy-duty cutting tasks, such as cutting through thick steel, concrete, masonry, and other hard materials. Thick wheels provide stability and durability in demanding applications.

Advantages of Thick Cutoff Wheels:

Durability: Thick wheels are more robust and less prone to breaking, making them suitable for heavy-duty applications.

1. Versatility:Thick wheels can handle a wider range of materials and are effective for cutting through thick sections.
2. Longer Lifespan:Due to their durability, thick wheels tend to have a longer lifespan, reducing the frequency of wheel changes.
3. Enhanced Safety: Thicker wheels provide a greater margin of safety and stability during cutting.

Disadvantages of Thick Cutoff Wheels:

1. Slower Cutting Speed: Thick wheels tend to cut more slowly compared to thin wheels, which can affect productivity.
2. Increased Material Wastage: The wider kerf created by thick wheels results in more material wastage.

Factors Affecting Cutoff Wheel Longevity

The longevity of a cutoff wheel depends on several factors, regardless of whether it’s thin or thick. Understanding these factors will help you make an informed decision:

1. Material Type:The type of material you’re cutting plays a significant role. Thin wheels are better for soft materials like aluminum, while thick wheels are suitable for hard materials like steel and concrete.
2. Wheel Quality:The quality of the cutoff wheel, including the abrasive material and bonding agent, influences its longevity. High-quality wheels tend to last longer.
3. Operating Speed: Running the grinder at the correct speed for the wheel and material is crucial. Excessive speed can wear out the wheel quickly.
4. Proper Technique: Using the right technique, including maintaining a consistent cutting pressure and angle, can extend the life of the cutoff wheel.
5. Wheel Size: The size of cuttingwheel should match the grinder’s capacity and the job at hand. Using an appropriately sized wheel can improve longevity.
6. Cooling: Cooling mechanisms, such as water or air cooling, can help dissipate heat and extend the life of the wheel.
7. Wheel Dressing: Regularly dressing or truing the wheel helps maintain its sharpness and cutting efficiency.

Making the Right Choice

Choosing between thin and thick cutoff wheels depends on the specific tasks you need to perform. Here are some guidelines to help you make the right choice:

If you are looking for more details, kindly visit Cut-Off Wheels Manufacturer.

1. Thin Cutoff Wheels:

• Use thin wheels for precision cutting in tasks that require clean, narrow cuts.
• Opt for thin wheels when working with soft metals like aluminum and copper.
• Consider thin wheels for tasks where minimal material wastage and heat generation are crucial.

2. Thick Cutoff Wheels:

• Choose thick wheels for heavy-duty cutting in thick steel, concrete, and masonry.
• Use thick wheels when stability and durability are paramount, especially in demanding applications.
• Consider thick wheels for tasks where a longer lifespan offsets the slower cutting speed.

Conclusion