Metal cutting saw blades for tools that use circular blades do not typically resemble traditional cutting blades with teeth around the outside edge. Instead, a solid abrasive disc is used to make the cuts. The disks are made from an abrasive mix of grit and adhesive, formed into a circle, with a fiber webbing running through it.
Most typical electric angle grinders use a 4 1/2-inch diameter abrasive disc. The disc is supported on an axle bolt with a cupped washer underneath fastened in place with a nut. The disc spins on a horizontal plane with the front edge protruding from the front end of the tool. Cuts are made with one hand on a handle above and behind the disc. The other hand operates a trigger at the back end of the tool. The discs vary in thickness and abrasiveness depending on the type of cut needed. A metal cutting disk for hardened steel is also available, made from steel with a diamond-coated edge.
Metal cutting discs for circular saws of standard size are 7 1/4 inches in diameter. They are made similarly to discs for angle grinders but without the cupped center washer. A diamond-shaped plate with a round hole in the center is used for mounting. Circular saws are best for light cutoff on a few pieces, or cutting sheet metal and metal paneling. Metal discs can also be used with a diamond-coated edge, with vent notches at regular intervals.
A cutoff saw wheel is larger than either an angle grinder or circular saw disc. It is typically 10 or 12 inches in diameter. The saw's cutoff motion drops the disc down through the material for a clean cut at a straight 90 degrees. Metal discs for cutoff saws may require lubrication from saw wax to prevent overheating. Cutoff saws are used for cutting pipe, metal studs, metal strap and square metal stock.
Smaller cuts for projects such as body work and machining are often made with rotary tools. Rotary tools can be fitted with a wide variety of grinding, cutting and sanding accessories. The cutting discs are small, ranging from 1 to 2 inches in diameter. They are very thin, made with metal with a diamond-coated edge. Abrasive wheels are also available. Rotary tools are used for cuts in sheet metal and other lightweight materials.
The abrasive and grain structure which is the roughness of the wheel. Hardness grade is also another thing which you need to take into consideration; if you want a harder material then choose the later letters in the alphabet. Any variation, even minimal with the above said features will have great effect on the overall performance of the tool.
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