How to Use an Angle Grinder to Cut Metal



Cutting metal with an angle grinder

There’re tons of cutting tools in the market. However, angle grinder can be said as the most reliable one when it comes to cutting metals. This is due to its ability to switch and handle different wheels and accessories, depending on your needs.

In this article I will give you an insight of how to properly cut metals with an angle grinder. On top of that, it will also answer a few FAQ that you might be curious about.

Cutting Metal With an Angle Grinder

1. Round up the necessary tools        

The first and most important step is to prepare the necessary tools. Without the right tools, everything else is meaningless after all. This includes safety tools to prevent you from getting hurt.

The tools are:

  • Angle grinder
  • Metal disc
  • C-clamp
  • Power outlet/source
  • Earmuff
  • Metal material you plan to use

As for the safety tools, you should prepare eye googgles, gloves and safety boots. Lastly, make sure your working area isn’t slippery and is always dry.

2. Set up the grinder    

After getting everything ready and putting on all the safety tools, proceed with setting up your angle grinder.

Ensure your grinder is unplugged from the power source. Then, insert the metal disc into the grinder. Assure that the metal disc and other attachments are fastened properly and correctly fitted.

3. Mark the area to be cut  

Next, you’re going to mark the area of metal you’re going to cut to improve accuracy.

Lay the metal on top of the workbench and clamp it securely so it doesn’t move around. Then, score the outline according to the design you want to achieve carefully.

To achieve a straight line, simply mark each end of the line and cut accordingly. Extend each cut slightly over the marked line at the corners to make sure the corners of the metals are cut accordingly.

For more complicated designs such as curves or zigzags, etch the stretch points with an awl followed by highlighting the whole pattern.

4. Turn the grinder on and start cutting

Now that preparations including outlining it completed, it’s time to get to the real business and start cutting the metals.

Plug your grinder to the closest power supply and turn it on. Ensure that you’re holding the grinder firmly before turning it on as you might get shocked due to its power and vibration, especially for beginners.

 With the disc spinning, slowly cut the marked outline.

Read also: How to Cut Steel Pipe with a Sawzall

6. Stay consistent with the direction

This basically means that you should not change directions of the grinder carelessly while cutting.

Changing direction immediately while cutting may cause several problems. For example, your cuts might end up not precise. Or worse, they might rev offline.

There might be times when you notice the grind becoming less swift. When this happens, don’t stop cutting and carry on with the procedure in one direction back and forth along the marked line.

7. Finishing the cut

After you’ve successfully cut the metal according to your need, be careful not to touch the sharp edges produced after cutting.

Turn off the power of the grinder and unplug it from the power source, then change the disc with a 40-grit flapper.

Plug and turn the grinder back on, then slowly smoothen the sharp edges by running the accessory along the sharp edges until they are smooth enough.


See how versatile the angle grinder is? Cutting and smoothing of metals can be done with affordable equipment. Now that you’ve finished reading, I hope that this article helped you in a way. Keep safe, follow the step-by-step solution and happy working!

Frequently Asked Questions

Like its name suggests, a cut off tool is used for cutting surfaces. Angle grinder on the other hand, is a much more versatile tool that can accomplish various tasks including sharpening and grinding.

Simply change the disc accordingly and the grinder can be used for different purposes.

This totally depends on you! Though most angle grinders are equipped with safety protective guards, you never know.

No worries though! Follow the safety tips mentioned above and you should be clear from dangers.

Yes it can, provided with the right disc. However, they’ll wear down more quickly due to the toughness of the steel.