How to Use an Angle Grinder to Cut Metal

Over the years, I’ve come across several metal cutting tools. While some of these cutting techniques are still painfully crude, there’s a decent amount of fast-cutting tools out there.

Among these top-class metal-dividing tools, an angle grinder remains a major fixture. And it’s essential to know how to use an angle grinder to cut metal.

Angle grinders come with a simple build geared towards promoting effortless handling and straightforward cutting.

And with the info you’ll get here, you’re guaranteed to cut metal better and with maximum safety assured.

How to Cut Metal with an Angle Grinder in Simple Steps

Step 1: Put on safety equipment

Fast-spinning discs, metal spatter, seriously-fast torque motor: these mean you’ve got to kit up first. Wear a face shield with durable glass, thick boots, overalls, and other safety gear. Also, get earmuffs on if you’re not OK with the grinder’s apparent noise.

Step 2: Set up grinder

Setting up a grinder isn’t tricky. You just need the guard around the disc removed and place a suitable disc onto the

Step 3: Turn machine on

The grinder has to get to its highest speed before any cutting can take place. Cut the workpiece from its back end toward your position. Cutting away from your position gives you lesser control of the machine, which may cause accidents.

Ensure you cut with your full alertness to avoid the grinder binding with your workpiece. This practice keeps your motor safe and limits kickback incidents.

Step 4: Keep a straight cut

Follow the guidelines already laid out through your workpiece. Straying from your guidelines may send the disc into an awkward position.

Step 5: Finish cut edges

After cutting through a metal piece, the next step is to finish up the edges if necessary. Get a stone grinder on your machine and gently sand both sides of your cut piece for a smoother finish.

Other Uses of an Angle Grinder

  • Sanding
  • Tile cutting
  • Blade sharpening
  • Paving slab cutting
  • Grinding
  • Polishing

Types of Angle Grinder Discs

  • 115mm – 4½ in
  • 125mm – 5 in
  • 150mm – 6 in
  • 180mm – 7 in
  • 230mm – 9 in

These discs are ideal for several cutting tasks. Also, some thicknesses determine the type of metal these grinders can cut.

Safety Tips for Angle Grinding

Wear PPE

Goggles, safety boots, overalls, gloves, have to be used when operating an angle grinder. With these personal protective wears, you’re guaranteed more protection. You’re also sure of lesser injuries if an accident takes place.

Unplug from power when switching wheels

It isn’t advisable to plug in your grinderwhile switching discs. You could get seriously hurt in the changing process.

Your angle grinder should remain unplugged to ensure your hands, face, and torso are perfectly safe.

Attach handles at all times

Removable handles come fitted with every angle grinder. A better grip is assured with this fixture.

Don’t remove this handle during operation as an imbalanced angle grinder will likely give you a bad cut.

Grip angle grinder with both hands

Both hands have to grip the grinder during operation. Ensure your hands form a tight grip, as proper handling is crucial to avoiding accidents.

Use guard

Removing a grinder’s wheel guard should never be considered. Even as a seasoned pro operator, running a grinder without its wheel guard could be deadly.

The wheel guard protectsflying discs. Without these disc guards, you’re likely to experience significant injuries, so you’ve got to keep them on.

Pre-run discs before long-term operation

The only way to discover a defective wheel is through a brief test run. Get a new set of discs run in an enclosed space for a minute or two. This practice limits accident if the discs shatter. After thoroughly running the discs, it’s safe to use along with other protective procedures.

Avoid kickback

A kickback incident could leave more than just a slight gash. That’s why you’ve got to maintain high alertness through the grinder’s operation.

Grinders tend to kickback when they’re used in cutting thicker metal plates. To avoid kickback, you’ve got to place your running discs on a straight line until you cut through the other sheet end.

When you’ve cut to the other end of your workpiece, work the machine in line with the deep cut. Using this method limits kickback and keeps you safe from injury.

Another way to avoid kickback is to place the rotating disc out of the plane with your body position. Kickback incidents are likely to send the grinder flying straight back. With this positioning, you keep your hands, face, and torso adequately protected.

Use away from flammable materials

Cutting with an angle grinder close to flammable materials may cause a fire. Metal spatter carries a lot of heat enough to initiate a reaction.

Place all flammable materials, including oils, far away from your workspace.

Secure workpiece before cutting

Your workpiece has to be clamped down or secured with other heavy stuff before you begin slicing through it. An unsecured metal piece is more likely to change positions, which may result in injury.

Sudden shifts in your workpiece may cause your grinder’s disc to break. And who knows where the ruptured discs may want to fly to at break-neck speeds.

It could be deadly to work with an unsecured metal piece, so you’ve got to consider this carefully.

Maintain balance

Cutting on uneven or slippery surfaces is potentially dangerous. Make sure where you’re stepping on is litter, water, and oil-free. Obstacles and other spillages have to be taken out of your work area to prevent accidental, potentially-fatal falls.

Store safely

Safely storing your grinder ensures no one comes to harm, even when it’s not in use. Children and inexperienced adults could get a severe cut or worse from trying to operate a grinder.

Storing it up in a locked compartment is crucial to avoiding severe accidents.

Required Tools for Proper Angle Grinding

Nearby power outlet

A power outlet is always required for an angle grinder to function. Most of these machines operate at varying voltages, so you seldom have to worry about current ratings.

Power cable

Cables that come with angle grinders are sometimes notoriously short. You’ll need a much longer power cable to get cutting jobs completed at a distance.


Angle grinders emit sounds that are mostly unfavorable for the human ear. A set of earmuffs will keep your ears healthy during extended cutting operations.


The required dimension of discs needs to be available. Having an undersized or oversized disc makes it more likely for accidents or limited cutting potential.


A clamp is essential to keep your workpiece in place throughout a cutting operation. Ensure you get a durable clamp before getting the cutting job started.


Your cutting task has to follow a marked pattern. Without a template, you’re more likely to miss your intended cut pattern.

Final Word

After checking out the essential info on how to use an angle grinder to cut metal, you’re guaranteed a lot better cutting. Make the most from cutting through metal sheets, and get those plates cut in two with greater ease.