How To Use An Angle Grinder To Cut Metal?

Angle grinders can be used for a variety of tasks. However, it must be done precisely. I’ve been able to cut metal with my angle grinder a lot of times. You will learn how to use an angle grinder to cut metal in this article. You’ll also learn how to use an angle grinder to cut metal and the difference between different kinds of metal.

Cutting metal doesn’t require you to be an expert. It is possible for you to learn how to use your angle grinder correctly.

In the current century, power tools such as angle grinders aren’t yet very common, so if you’re still stuck in the 20th century, use a hacksaw instead. DIY projects like cutting metal stock can be done with hacksaws, and with enough power, you can cut something thicker if you huff and puff.

As long as you’re using the correct grinding wheels or discs for the grinder (model) you have, grinding and cutting metal materials will be a breeze.

Hence, here is my convincing argument why an angle grinder is the best tool for cutting metals like rebar, angle iron, sheet metal, and even plastic.

How To Use An Angle Grinder To Cut Metal Step-By-Step

The angle grinder concept in metalworking has now been established, so let’s examine exactly how to chop metal with an angle grinder. However, various angle grinder models might not operate the same way. Still, the precautions that you need to take are pretty similar when attempting to cut metal or steel.

1. Gather the required tools 

Required Tools

It is important to prepare the required tools before beginning. Everything else is meaningless if you don’t have the right tools. You will also find safety tools to prevent injury.

Tools include:

  1. Metal disc
  2. C-clamp
  3. Angle grinder
  4. Power outlet/source
  5. Earmuff
  6. Metal material you plan to use

Safety gear includes eye-goggles, gloves, and safety boots. Also, keep your working area dry and free of slick surfaces.

2. Before Using An Angle Grinder To Cut Metal Set up the grinder

When you have everything set up and the safety equipment on, you can start setting up the angle grinder.

You need to unplug the grinder from the power source. After that, insert the metal disc into the grinder. Ensure that the metal disc is correctly installed and fastened as well.

3. Mark the area to be cut

The next step is to mark the metal area you’ll be cutting to improve accuracy. Ensure the metal is clamped securely to the workbench so it doesn’t move. Once the outline is complete, carefully score it according to your design goal.

If you want a straight line, simply mark the ends of the line and cut accordingly. Make sure the corners of the metals are cut by extending each cut slightly over the marked line.

If your design is complicated, such as a curve or zigzag, use an awl to etch the stretch points, then highlight the entire pattern.

4. Turn the grinder on and start cutting

Having completed the preparations, including outlining it, it’s time to get to the business and begin cutting the metals.

Turn on the grinder by connecting it to the closest power supply. When using a grinder for the first time, make sure you hold it firmly so as not to get shocked by its power and vibration.

Slowly cut the marked outline as the disc spins.

6. Stay consistent with the direction

When using the grinder, don’t change directions impatiently. It is possible to cause several problems if you immediately change directions while cutting. You might not be able to get precise cuts, for example. It could even lead to them being taken offline.

You might notice the grind slowing down from time to time. Keep cutting in one direction on both sides of the marks and do not stop.

7. Finishing the cut

As you cut the metal to your needs, keep your hands away from the sharp edges produced by your cutting.


Related Post: How to Rip Plywood with Table Saw?


How thick can steel be cut with an angle grinder?

How thick can steel be cut with an angle grinder

Angle grinders have varying cutting capacities, depending on the size/type of disc you’re using as well as the angle grinder itself. Furthermore, steel thickness plays an important role in determining the cutting depth. You’ll also need to select the correct size disc since cutting discs come in different thicknesses.

However, let’s suppose you’re using a 4-1/2-inch grinder (the widest most people use) with a flat diamond cutoff blade for either mild steel or stainless steel. A stainless steel cutting disc with an iron-free thickness of 1 mm or 1.6 mm is best.

You should use a 1.0 mm or 0.8 mm cutting disc when cutting thin metal materials like sheet metal. Due to the reduction in blade thickness, these discs will exhibit a cleaner look and minimize potential discoloration.

Using a type saw lubricant when cutting or buffing metal or aluminum will extend disc life and reduce the risk of chipping. Alternatively, you can use a thicker, thicker cutting disk between 1.6 mm and 2.5 mm if you are chopping thicker material like rebar or structural steel. There are some drawbacks to using thinner blades to chop through dense steel, such as 2.5 mm cutting discs.

Due to the slower blade speed of the larger disc, the finish cut of your steel work-piece may show signs of discoloration in some cases. Why is that so? Basically, friction increases. You can always consider another power tool for cutting metal depending on how dense the material is and how clean you want the cut to be. Circular saws or chop saws are the tools of choice when precision and finesse are priorities when cutting thick dense steel.

By all means, break out the faithful grinder if your only concern is making quick cuts where accuracy and appearance are afterthoughts. Use only the recommended discs when necessary.


Angle grinders have been used to cut steel, but can they also cut metal? The answer is definitely yes. When used correctly and safely, angle grinders can be a highly effective and extremely safe way to cut metal.

The art of slicing and dicing materials with a grinder takes little practice if you have never operated one before. You can achieve this only if you use this powerful hand-held tool with the appropriate disc. 

Angle grinders are designed to cut through metals, bricks, and concrete, so durability will not be an issue. The grinder will become an essential possession rather than a luxury in time.

Normally, the average Dyer doesn’t have to work with dense steel on a daily basis, but simply having a grinder on hand when cutting metal is certainly a good idea.

Lastly, always use the correct protective safety glasses when operating the grinder and be sure you are in full control. So all that is left now is to choose the right cutting disc and your material of choice, and get cutting metal with ease.


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