Quick Buying Guide - Cutting Wheels for Angle Grinders, Die Grinders, and Chop Saws
Step 1: Foundational Choices - Profile & Thickness
Wheel Profile: Type 1 (Flat) vs. Type 27 (Depressed Center)
The wheel's shape, or profile, is the first major decision. A Type 1 wheel is completely flat, offering the maximum cutting surface. A Type 27 wheel has a depressed center, allowing the grinder's flange to sit recessed, which is essential for making flush cuts.
| Feature | Type 1 (T1) - Flat | Type 27 (T27) - Depressed Center |
|---|---|---|
| Shape | Completely flat face | Center hub is pushed back |
| Best For | General purpose cutting, straight cuts | Flush cutting (e.g., bolts, rebar) |
| Advantage | Maximizes cutting depth and surface area | Prevents grinder flange from interfering with the cut |
| Disadvantage | Cannot make flush cuts | Slightly less cutting depth than a T1 wheel |
Wheel Thickness: Speed vs. Lifespan
A wheel's thickness directly impacts its performance. Thinner wheels cut faster and remove less material for a cleaner cut, while thicker wheels cut slower, but last longer and can make more aggressive cuts.
| Wheel Thickness | Cutting Speed | Lifespan | Best For |
|---|---|---|---|
| Ultra-Thin (.040") | Fastest | Shortest | Sheet metal, minimal material loss |
| Standard Thin (.045") | Fast | Standard | General purpose metal cutting, balanced performance |
| Thicker Wheels (1/16" +) | Slower | Longest | Heavy-duty cutting, pipeline work, added durability |
Step 2: Match the Wheel to Your Job
Material Compatibility
Using the correct abrasive grain for your workpiece is the key to preventing wheel loading, overheating, and poor cuts.
| Abrasive Material | Best For | Key Advantage |
|---|---|---|
| Aluminum Oxide | Steel, Iron, Ferrous Metals | Tough, durable, and cost-effective for general-purpose metal cutting. |
| Silicon Carbide Blend | Aluminum, Copper, Brass (Non-Ferrous Metals) | Prevents wheel 'loading' by staying cool on soft metals. |
Tool & Diameter Guide
Select a wheel diameter that matches your tool's specifications. Larger diameters are for stationary saws, while smaller discs are for handheld grinders.
| Wheel Diameter | Compatible Tool(s) | Typical Applications |
|---|---|---|
| 2” – 3” | Die grinders, air cut-off tools | Tight spaces and precision cuts (e.g. auto body sheet metal, exhaust trimming) |
| 4” – 4.5” | Standard angle grinders (4” or 4.5” grinder) | General metal cutting (e.g. rebar, bolts, metal tubing) |
| 5” – 6” | Angle grinders (5”/6” grinders) | Heavy-duty cutting with deeper cuts than 4.5” |
| 7” – 9” | Large angle grinders (7”/9”) | Industrial and pipeline work, cutting large metal pieces or pipe |
| 12” – 14” | Chop saws (metal cut-off saws), Gas-powered saws | Stationary or portable cutting of bar stock, rails, and structural materials |
Frequently Asked Questions (FAQ)
What Is An Abrasive Cut-Off Wheel Used For?
An abrasive cut-off wheel is used with power tools (like angle grinders, die grinders, or chop saws) to quickly cut through metal or other materials. The thin, abrasive disc spins at high speed to slice through objects such as steel bars, pipes, bolts, or sheet metal. Unlike a saw blade with teeth, a cut-off wheel grinds through the material with thousands of abrasive particles.
What's The Difference Between A Cut-Off Wheel And A Grinding Wheel?
Cutoff discs thickness range from ultra-thin 0.04” to 3/32” while the thicker grinding discs range from 1/8" to 1/4". The thickness of grinding wheels makes them much sturdier so you can grind a surface from different angles.
Can I Use a Cut-Off Wheel for Grinding?
No, you should never use a cut-off wheel for grinding. Cut-off wheels are thin and designed only for cutting at a 90-degree angle. Trying to grind with a cutoff wheel can cause it to shatter, creating a serious safety hazard. Use thicker, dedicated grinding wheels for surface grinding.
What are Cutting Wheels Made Of?
Cut-off wheels are a composite material consisting of three main components: an abrasive grain (usually Aluminum Oxide) that does the cutting, a bonding agent (typically a phenolic resin) that holds the grains together, and internal layers of fiberglass mesh that provide reinforcement and structural integrity to prevent breakage at high speeds.
When Should I Use A Type 1 Vs. Type 27 Cut-Off Wheel?
Use a Type 1 (flat) cut-off wheel for most straight cuts where you need the full depth of the wheel and aren’t cutting flush with a surface. Use a Type 27 (depressed center) wheel if you need a flush cut or more clearance. The Type 27’s recessed center lets your grinder’s locking nut sit out of the way, but it slightly limits cutting depth. In general, if you’re unsure, Type 1 wheels are the default for cut-off tasks, while Type 27 are specialty wheels for specific situations.
What are the Best Cut Off Wheels for Aluminum Cutting?
Aluminum is a soft metal with a low melting point. This means that with the wrong tools, you can damage the metal or cause extra work caused by burr formation. The best cut-off wheels for aluminum avoid load by using abrasives that remain cooler to avoid this. An aluminum cutting disc with a special formulation of aluminum oxide and silicon carbide can be used for cutting aluminum and other soft metals like brass, bronze, copper, and other non-ferrous soft metals.
What Thickness Should I Choose?
Thinner wheels (0.040"-0.045") cut faster with less material waste but are less durable. Thicker wheels (1/16"-1/8") last longer and handle aggressive cutting better.