Expert’s tips for working with diamond tools
Wear safety glasses with side shields (full face shield), respirator, ear protectors and gloves. Always wear safety shoes (use an apron if necessary). Before installing the diamond tool, check the seating surface and flanges of your equipment for chips, dents or other damage. If necessary, make sure that there is no dirt or dust on the surfaces and flanges of the diamond tool. Do a dry run with no load. minimum 30 seconds. Always make sure that there is no vibration, no radial and axial runout, and no unusual noise when idling. If any runout is detected, turn the flanges together with the diamond tool 180° around their axis (the shaft need not be turned) and repeat the rotation at idle speed. If the above deviations occur again, diagnosis of your equipment or diamond tools must be carried out. Installing a spacer between the diamond wheel and the clamping flange can facilitate the subsequent unscrewing of the clamping flange. Thin and plain paper, foil, etc. can be used as a gasket.д., no more than 0,1-0,15 mm thick. If you use an extension cord to perform your work, unwind it completely. The cable cross-section on the extension cord must be at least 2×2.5 mm, and the circuit breaker must be at least 15A. The arrow on the side surface of the diamond tool body (marked direction of rotation) must always coincide with the direction of rotation of the equipment shaft. Do not overload during operation, otherwise the cutting capacity of the blade may be reduced! Avoid deep cutting. To achieve a longer service life and stable cutting performance of the diamond cutting disc, it is recommended that the maximum cutting depth is reached in several passes. Pass the rebar by rocking the angle grinder back and forth (in cutting direction) while changing the cutting depth (pendulum cutting method). The smaller the feed pressure, the more controlled the accuracy of the cut. Make sure that the body does not rub against the material to be cut. Alternate cutting methods. straight, pendulum, shuttle.
In order to keep the diamond wheel working reliably, try not to remove it from the angle grinder until it has worn down completely. In most cases this information applies if you are cutting hard materials such as porcelain stoneware or granite. After each repositioning, the diamond wheel should be dressed (lapped) to minimize radial run-out and chipping at the kerf of the workpiece. If the cutting ability of a diamond tool decreases, it must be resharpened. Typical signs of reduced cutting performance are: heating of the cutting disc, reduced cutting speed, in some cases, deformation of the body, and increased material breakage. Cut highly abrasive material into thin strips (5 to 6 cuts) without coolant. Highly abrasive materials: masonry, cement-sand plaster, fresh concrete, abrasive sharpening or grinding wheels.
Cutting plywood with an angle grinder
To cut plywood with an angle grinder, wood discs are often used. Because of the large accumulation of dust, you must work in a well-ventilated room so as not to breathe the burning odors. It is better to saw along a pre-marked line, pay attention before the end of the process, so the wheel does not jam the sawed off part of the sheet.
Cutting OSB with an angle grinder is safer and higher quality with a properly selected disc. The ideal disc would be what is popularly called a three-toothed wood saw blade, which is designed to work at high rpm. It will be a plus if the angle grinder has a speed regulator.
What is the functionality of the consumable material
When selecting a nozzle, you may face the fact that they are either solid or segmented. Segmentation is used to improve air cooling efficiency. Crumb, which has different degrees of granularity, is used as a diamond spraying. Modern industry produces the considered tips using these methods:
- Silver soldering of diamonds. This is the simplest method, which has a big disadvantage. chipping of the crumb at the exposed high temperatures. Such wheels are used only with the additional method of water cooling
- Laser welding. this method of production makes it possible to obtain the most reliable and efficient devices. They are used for cutting concrete, granite, marble
- Electroplating method. this method of attachment of diamond crumbs allows you to use the nozzle for processing soft types of natural stone
- Thermal bonding or sintering. this method is as reliable as laser welding, and serves to cut the concrete wet or dry technology
Diamond discs differ in external diameter, which determines the ability to cut concrete products of different thicknesses. When choosing a cutting wheel of the appropriate diameter it is important to consider the power of available power tool.
Benefits of diamond discs
We observe the widespread use of discs with diamond cutting because of the large number of advantages. Here are the main ones:
With diamond wheels, you don’t need to grind and deburr the cut additionally;
the structural integrity is better maintained due to the absence of strong vibrations;
the work is performed more qualitatively and quickly;
the diamond wheel cuts the surface accurately and makes it smooth and even.
How to choose a wheel for an angle grinder
When choosing the right nozzle for the angle grinder need to pay attention to the following points:
- Choose the required disc diameter (it must not exceed the maximum allowable size of the tool of a certain model of angle grinder, which is limited by the size of the protective hood) and the area of its use. the field of use is indicated by the name of the disc: cutting, grinding, sharpening, etc. The type of blade can tell you what kind of material it works with. But often the type of material manufacturers indicate with the help of visible strips of a certain color: green. concrete; blue. metal and so on. Sometimes the disc is labeled with a clear symbol for the type of material the tool is designed to work on.
- Study the markings on the disc itself. It is made up of numbers and letters of the Latin alphabet. Initial letters indicate the type of abrasive: A. corundum; AS. electric corundum; S. silicon carbide. Then there are numbers indicating the grit size of abrasive inclusions. This index affects the thickness of the material to be removed. the coarser (coarser to the touch) grit is used for non-ferrous metals. They work on soft surfaces with good performance. With coarse grit discs, workpieces of various steel grades are cut, roughened, and ground. The letters at the end indicate the hardness of the bonding material. The hardness increases as the serial number of the letter increases. Important: The softer the bonding material, the harder the material that can be handled by the bit. Conversely, the harder the bond of the disc, the softer the workpiece material. The final part of the inscription consists of numbers indicating the maximum rotation speed. Speed per minute or m/second.
Be sure to study the labeling of the disk: here you will find all the information you need
What you need to install the disc?
Installing the disk on the angle grinder, as a rule, is a fairly simple process in which you need to follow a few rules. In order to produce it, it is necessary to equip yourself with the appropriate tool. a wrench, which will be needed to unscrew the nut. The next step after unscrewing it, will be the replacement of the disc angle grinder or its primary installation. If it happened that jammed the disc in the angle grinder, to remove it will have to crush and extract the remnants from the gap between the supporting flange and nut with a flat screwdriver or chisel.
Which way you put the cutting wheel can depend on several factors. First, if the disk is not flat, there is only one way to put it and the question disappears by itself. Secondly, if the wheel is still flat, you can be guided by the label. if the angle grinder turns away from yourself, then it is set with the label inward, if on itself, then, respectively, outward. If this principle is not followed, you can expect undesirable results. disk breakage during sawing or just its rapid wear and tear.
How to mount a cutting disc onto an angle grinder correctly
As for the direction in which the disk rotates on the angle grinder, then it is primarily a question of security. It is believed that the concrete should be cut in the direction of the blade rotation or towards yourself. Ideally, sparks should fly to the side to the left of the person working with the tool. If this is not possible, an alternative position with a shear of sparks pointing downwards can be used. In any case, you should not allow a situation where sparks are flying from the user, because if the disc jams sharply, the angle grinder will be guided in its direction.
In other words, to cut materials against the direction of rotation of the disc or away from yourself is extremely unsafe, because in the case of a wedge, there is a sharp ejection of the angle grinder in the direction of the person working. By the way, if you have additional questions concerning how to install the disk on the angle grinder, you can also view training videos, of which there are more than enough on the Internet today.
If you still have questions or need advice on changing and installing discs, it is enough to leave an application on the site or call the contact phone number and our experts will prompt you how to act correctly. See diamond discs for our complete range of diamond discs.
How to attach the cutting wheel to the angle grinder correctly?
Correct installation of the cutting wheel on the angle grinder. with the ring facing downwards (picture below). If to look at a landing washer of the angle grinder, it has notches (nicks), and a clamping nut is smooth, therefore at installation of a cutting disk with a ring upwards notches cut in, rather soft, body of a disk, thereby reduce section of a disk in a place of fastening that can lead to disk rupture. Notches on the seating washer are provided by most manufacturers of professional angle grinder to hold the disc firmly and prevent it from rotating. The aluminum ring is malleable when the notches are pressed hard, but still strong enough to prevent the disc from tearing.
And now some useful information about cutting-off wheels (discs).
The base of the cutting disc consists of glass fiber net layers with different types of abrasive material such as corundum, electrocorundum or silicon carbide on top. In the production process, the wheel is subjected to heat treatment, which makes the product more resistant to damage. To do this, the cutting disc is baked in an oven at 200 °C.
What to do if the disc is jammed on the angle grinder?
Everyone, who has experience in intensive work with angle grinder probably at least once, yes encountered with this situation.
Usually, this happens if the disc is jammed between the parts, it stops or breaks, and the angle grinder motor continues to rotate and thus tightens the nut irreversibly.
So what can you do if the disc on the angle grinder is jammed??
Every craftsman has his own secrets.Especially for you, we learned a few of them and now we will share the most common ways out.
remove the disk from the angle grinder
First, find out in which direction to unscrew the nut.
The flange should always be rolled in the direction in which the disk rotates.
For this kind of work you need either two torque wrenches or two clamps.
Here’s what you need to do: destroy the remains of the disk, one key to fix the washer, located behind the disk, the second unscrew the flange.
remove the disk from the angle grinder
This method involves using the famous VD-40 grease.
It’s probably like duct tape, is applicable in all cases of life.
You need to spray the flange, wait about 5 minutes and try to unscrew it with a wrench.
remove the disc from the angle grinder
This method is used in extreme cases.
When no other methods help, you can try to saw the flange with a tool such as a hacksaw for metal, and then buy a new one in a specialized store.