Cutting, Grinding and Finishing: 7 Tips For Success

The bottom line: The more you know about the base material, the better your results.

Tip No. 3: Match the Disc to the Tool

Correctly matching the tool and abrasive can deliver significant cost savings and productivity gains as the efficiency of the abrasive is directly affected by the tool it’s being used on. If the wrong tool is used for the job, problems will arise even with the right accessory. In grinding especially, it’s key to match the appropriate abrasive product to the highest-performing tool (based on amperage or RPM) allowed by the job. For example, using a low-amperage tool with a 14-gauge extension cord can’t turn the grinder fast enough to provide optimal performance.

Tip No. 4: Stay in Motion

With any abrasive product, it’s important to keep the wheel or disc in constant, smooth motion and avoid bearing down with heavy pressure or dwelling in one spot. Constant motion reduces the risk of gouging or material damage and helps prevent heat buildup that can cause discoloration.

Pull the initial stroke toward you rather than pushing the tool away from your body. This greatly reduces the risk of gouging, especially when you are using a new wheel.

Tip No. 5: Watch the Angle

Position the tool at a slight angle to the workpiece when grinding. Increasing the angle of the grinding wheel provides more aggressive grinding but reduces wheel life. Reducing the grinding angle lessens the pressure being applied to enhance product life, but it also minimizes cut rate.

Grinding or finishing at an angle that is too steep may cause you to work much harder than necessary since you’re not getting the full benefit the product is designed to provide.

When using cutting wheels, hold the tool at a 90° angle, perpendicular to the workpiece. This position enhances safety and helps improve wheel life and cut rate.

It’s critical to use grinding and cutting wheels as designed to enhance safety and get the best performance and efficiency.

Tip No. 6: Store Equipment Properly

Storage recommendations depend on the type of product you use. Resin-bonded abrasives should be stored at ambient temperatures, as exposing them to big temperature swings negatively affects the bonding agent. Compare this to coated abrasives (flap discs), which are less susceptible to changes in temperature.

With any abrasive product, store it in the original packaging when possible. If you remove the disc or wheel from the package and then store it in a toolbox, you may lose track of what type of product it is and what materials it should be used on. Storing the product in the original packaging helps reduce the risk of cross contamination, which is a critical issue in some applications. Any product used on carbon steel, for instance, should not be used on stainless steel or aluminum.

The risk for contamination is high when a wheel is left on a grinder. When the grinder is taken back to the toolroom, it becomes difficult to remember which material the product was used on previously.

In addition to proper storage, always inspect the abrasive product and the tool for any cracks or damage before using it.

Tip No. 7: Always Be Safe

Beyond choosing the right product, following proper safety procedures is also critical to success. The most important safety practice is to always use the tool guard.

Safe operation also involves watching the speed. The RPM rating of the accessory should meet or exceed the RPM rating of the tool. For example, a 7-inch grinding wheel that is worn down to a smaller size should not be used on a 5-inch grinder, because the wheel was not designed to be used at the much higher speed of the smaller tool. Also, if you can’t read the RPM rating on either the tool or the abrasive product, don’t use them.

It’s also unsafe to use an abrasive product on a task for which it wasn’t designed, such as using the sides of a cutoff wheel to perform grinding or deburring. Grinding with the side of a cutoff wheel—even for a few seconds—can damage the wheel and reduce the fiberglass reinforcement, causing the wheel to break apart.

Any product modifications can compromise safety and efficiency. Be sure you’re following the recommendations for proper use. You can also try using a different wheel or disc to improve performance for the application.

Previously Featured on The Fabricator.

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