5 Angle Grinder Discs & Attachments you Should Absolutely Get. Air grinder attachments
Angle grinder attachments for surface preparation
An angle grinder is a versatile tool that can be used for a variety of projects. The different angle grinder attachments allow the tool to be used for different tasks. The most common type of attachment for an angle grinder is a grinding disc. These discs come in a variety of sizes and can be used to grind down metal, concrete, or even stone.
Other common attachments for an angle grinder include abrasive discs, wire brushes, and polishing pads. However, there is a surprising amount of attachment that you can use to transform your angle grinder and transform it into the exact tool you need.
- I. Wire brushes
- 1. Knotted wire wheel brush
- 2. Knotted wire cup brush
- 3. Crimped wire cup brush
- 1. Aluminum oxide sanding discs
- 2. Zirconia sanding discs
- 3. Ceramic sanding discs
- 4. Flap sanding discs
- 1. Fabric polishing and buffing pads
- 2. Fiber buffing wheels
- 3. Felt polishing wheels
- 1. Non-woven abrasive wheels
- 2. Poly stripping discs
Wire brushes
Wire brushes for angle grinders are versatile angle grinder attachments that can be used for a variety of applications. They are commonly used to remove rust, paint, and debris from metal surfaces. You can thus use them for preparing surfaces for welding, painting, and more.
Knotted wire wheel brush
A knotted wire wheel is composed of loops of steel wires. If you’re working on a particularly stubborn patch of rust or old paint, this kind of wire brush is your best bet. It’s also suitable for cleaning up narrow surfaces, making it one of the best choices for cleaning up pipes and preparing them for welding and painting.
Knotted wire cup brush
Like the knotted wire wheel brush, the knotted wire cup brush is best used for removing material from surfaces. However, this wire brush is more suited for larger metal surfaces. You can also choose from a range of wire thicknesses depending on what you need the brush for. Thicker wires provide a coarse finish, while thinner wires provide a smoother finish.
Crimped wire cup brush
If you’re not dealing with thick or stubborn rust or paint, a crimped wire brush will probably serve you well. It’s best for light-duty to medium-duty surface preparation jobs. Thus, if you have to remove years’ worth of rust or paint, this attachment isn’t the one you should use. However, for thinner layers of material, this type of wire brushes for angle grinders is more suitable.
Sanding discs
If you’re looking for a quick and easy way to sand down wood, metal, or plastic, then you need a good angle grinder and some quality sanding discs. Sanding discs come in a variety of sizes, grits, and materials, so you’ll have a variety of options to choose from. Just make sure to choose the right size angle grinder sanding disc for your angle grinder, as well as the right kind of disc for the job at hand.
Aluminum oxide sanding discs
There is a variety of sanding discs on the market, each designed for a specific purpose. Aluminum oxide sanding discs are versatile and reliable, which means that they’re widely used for a variety of projects. They’re suitable for use on wood and metal, and they’re made with a durable and long-lasting abrasive material.
You can use them for removing finishes, shaping wood, and preparing surfaces for staining or painting. Aluminum oxide sanding discs come in a variety of sizes and grits, so you can find the perfect one for your project.
Zirconia sanding discs
Zirconia sanding discs have a long lifespan and can be used on a variety of materials, making them a great choice for your next project. Additionally, zirconia is harder than aluminum oxide, making it ideal for tougher sanding jobs.
Another thing that works in a zirconia sanding disc’s favor is that it’s more heat-resistant. Because of this, it’s a good choice for use with power tools. You can set your angle grinder to higher speeds without having to worry as much about overheating. Thus, if you’re looking for an abrasive that can stand up to even the most challenging applications, a zirconia angle grinder sanding disc is a great choice.
Ceramic sanding discs
When it comes to sanding discs, there are many different options to choose from. Ceramic sanding discs are one option that can offer a lot of advantages. These discs are typically made from a strong and durable ceramic material, and they’re best suited for tougher jobs.
In addition, ceramic sanding discs can be less likely to clog than other types of discs. This can make them a good option for those who are working on projects that require a lot of sanding. They can work harder and faster than other kinds of sanding discs, and they can also last longer.
Flap sanding discs
While other sanding discs are used for removing material from surfaces, flap sanding discs can take you one step further. Not only are they used for surface preparation and cleaning, but they can also be used to shape metal.
These discs are composed of multiple overlapping abrasive flaps that allow you to make a metal surface conform to a shape you want. They’ll also leave a smooth finish, so you won’t have to spend much more time or effort on polishing or smoothening the surface.
Buffing and polishing attachments
Buffing and polishing angle grinder attachments are important accessories in the world of auto detailing and various other fields. In general, buffing pads are used to apply a polishing compound to the paint surface, while polishing wheels are used to remove excess materials and create a high-gloss finish.
There are a few different types of buffing pads and polishing wheels available on the market today. Each type has its own set of advantages and disadvantages that should be considered before making a purchase.
Fabric polishing and buffing pads
If you’re looking for an easy way to polish up metal surfaces, you can’t go wrong with a fabric polishing and buffing pad for your angle grinder. These pads are designed to fit onto the end of your angle grinder, and they can be made of different kinds of fabric. Plus, they’re relatively inexpensive and easy to use, so they’re a great option for anyone who wants to add a little extra polish to their projects.
When it comes to finishing off a project with an angle grinder, buffing pads are a must. They help to create a smooth, even finish on your workpiece. However, it’s important to make sure that the buffing pad you’re using is suitable for the material you are working with. Additionally, make sure to choose a pad that’s the appropriate size for your angle grinder.
Fiber buffing wheels
A fiber buffing wheel for angle grinder models is similar to its fabric counterparts, but it’s made of cellular fiber material. Thus, unlike fabric buffing wheels, fiber buffing wheels are abrasive and can also remove grease from a surface. You can use these buffing wheels to clean up dirty surfaces before polishing, painting, or finishing them. They’re typically the first buffing pad you’ll use before the other ones.
Felt polishing wheels
Felt has medium hardness and is typically made of wool. For the most part, felt polishing wheels are quite versatile and can be used with different kinds of buffing compounds. Because these polishing wheels aren’t too specialized, you’ll be able to use them on a variety of surfaces. You can also use them on hard-to-reach spots to make sure that your workpiece is 100% prepped and finished.
Surface preparation attachments
Angle grinders are a versatile tool that can be used for a variety of surface preparation tasks. Common applications include removing paint, rust, or other debris from a surface, as well as smoothing or shaping edges. Additionally, angle grinders can be used to create a smooth finish on a variety of materials, including metal, plastic, and wood.
In addition, angle grinders can be used to quickly remove weld spatter and scale from steel surfaces. When using an angle grinder for surface preparation, it is important to select the correct abrasive disc and to follow the manufacturer’s recommendations for safe operation.
Non-woven abrasive wheels
Non-woven abrasive wheels are made of a combination of materials, including synthetic materials and natural fabrics, that are bound by resin adhesives. These wheels work faster than older types of abrasive attachments, while also being more affordable.
In general, you should use a non-woven abrasive wheel if you want to remove paint or coating without damaging or scratching the surface underneath. If you want something that can remove more material, however, you can choose a non-woven abrasive wheel with a tighter weave.
Poly stripping discs
With poly stripping discs, you’ll be able to remove paint and corrosion from a wide variety of materials, including metal, plastic, and wood. These discs are made of spun fiber material and can be used for surface preparation, grinding, and polishing. It’s also built for longevity and can withstand heavy-duty use.
Additionally, these discs work fast. They can remove material more quickly than many other kinds of angle grinder attachments, but they typically don’t produce as much dust or noise.
Author Profile
Fagjun Santos is a content writer by day, recipe GIF enthusiast by night. When she’s not watching other people make food, she covers the good, the bad, and the technical in industrial equipment and various professional tools. Formerly a newbie at all things pertaining to HVAC, surveying, construction, and more, she can now tell a caliper from an angle finder.
Angle Grinder Discs Attachments you Should Absolutely Get!
If your job or hobby involves any type of material fabrication or surface finishing, then the angle grinder is the power tool that you’re looking for.
An angle grinder has many versatile functions, available in both battery-equipped (cordless) and power cord versions, this heavy-duty power tool possesses the ability to cut, grind, polish, smooth, and sharpen a wide variety of materials including iron, steel, brass, marble, wood, and stone.
Apart from its most common use as a grinder, there are a variety of abrasive attachments available for this power tool, designed to perform many versatile jobs and functions. You may choose the attachment depending on the material you’re working with and the function you need to perform.
Below are attachments you should know about:
Angle Grinder Wire Brush Attachments
Available in many different shapes and forms and sizes such as wire cup brushes, wire wheel brushes and end brushes. Wire brush angle grinder attachments are ideal for heavy duty cleaning, deburring, edge blending, and paint stripping. Wire wheel brush attachments with knotted and crimped wires are used for working with hard metal surfaces such as iron and stainless steel.
Knotted Wire Wheel Brush
With a knotted design adding maximum aggressiveness to the wires, this wire wheel brush attachment type is circular in shape to add precision to your project and to fit into corners. Used for treating hard metals such as iron, stainless steel, this attachment prepares and conditions rough surfaces through heavy duty cleaning action, deburring, and removing rust.
Crimped Wire Cup Brush
Designed with flexible wires, these cup brush attachments are best suited for preparing larger and wider surfaces. Less aggressive than a knotted design, crimped wire brushes result in a uniform, polished, and smoothly finished surface.
Knotted Wire Cup Brush
Adding the features of both cup design and knotted wire, this wire brush attachment is ideal for performing tough jobs on larger surface areas. With aggressive cleaning abilities, it is ideal for removing material deposits and contaminates such rust and oxidization.
Angle Grinder Diamond Cutting Blades
Designed specifically for working on concrete and masonry surfaces, diamond saw discs are made of hardened steel rims embedded synthetic diamond abrasives. possessing the ability to grind through the hard materials with power and precision.
Diamond cutting discs come in many different types, the most common types are continuous rim, segmented rim, and turbo rim designs. Saw blades provide a precise and finished cutting ability. these cut off discs can cut through marble, ceramic, porcelain, and granite. Which makes them ideal for tiling and other masonry work.
There are 3 different types of Diamond cutting blades:
- Continuous rim: Ideal for smooth cutting of marble, ceramic, and porcelain tiles
- Segmented blade: Best for general purpose cutting of masonry, concrete, terrazzo, and roof tiles
- Turbo blade: With efficient speed and clear-cutting abilities, ideal for cutting granite, slate, paver bricks, and concrete pipes
Angle Grinder Sanding Attachments
Angle grinders make excellent power sanding tools because of their powerful motor combined with precision and high RPM.
Sanding discs for the angle grinder are generally circular discs embedded with abrasive material. Its commonly used in the woodworking industry for leveling surfaces, carving and shaping and smoothing hard woods, and in the metal working industry to remove rust and scratches off of metal surfaces,
Here are some of the various abrasive materials you may choose from when you need to use your angle grinder as a power sanding tool
- Aluminum Oxide Sanding Discs : Best suited for sanding and polishing bronze, alloy steel, wood and fiber glass. It is advised not to use stainless steel because of its iron composition can cause light oxidization
- Zirconia Sanding Discs : Stronger than aluminum oxide and iron-free, this type is best suited to polish and sand wood, fiber glass, metal, brass, aluminum, and stainless steel. Lasting 10x more than aluminum oxide abrasives, its ideal for rough wood surfaces, grinding metals and removing burrs, Cleaning up welds and stripping paint and contaminants.
- Ceramic Sanding Discs : Efficient in terms of both sharpness and longevity, ceramic sanding discs are the most aggressive abrasive grains, best to apply for heavy-duty functions on metals including wood, metal, and stainless steel. With its coarse grits, these can be used for removing substances.
Two Common Sanding Discs Types you can buy for your Angle Grinder
Due to the strength they possess and the separated flaps of sanding material, flap discs are famous for removing hard stock efficiently as the flap design dissipates heat, which is Super Cool! (pun intended).
Attached to an angle grinder, Flap sanding wheels allows the abrasive grain to sand and grind efficiently while reducing load, lessening friction while keeping the surface reasonably cool to extend the life of the abrasive and avoid damaging and overheating the surface.
Perfect to work with stainless steel, cast iron, titanium, and hardwood.
These discs are the best when it comes to value for money, even though they are more expensive than zirconia and aluminum oxide initially, they last much longer and provide consistent results.
They are ideal to use with heat-sensitive materials such as stainless steel, nickel alloy, and titanium due to having less ceramic friction and cooler operation than both aluminum oxide and zirconium, since ceramic is a harder abrasive.
Angle Grinder Attachments for Buffing Polishing
While using the angle grinder as a buffing tool is good idea but its best to be used with experienced hands, the angle grinder are very powerful and could run up to 13,000 RPM, so its advisable to use a variable speed grinder for buffing and polishing jobs.
Buffing pads for angle grinder are made from high-quality wool, famous for being wear-resistant. When you want to polish and shine your metal surfaces, the buffing wheel comes to the rescue. Attached to the power of the angle grinder, the polishing wheel is effective for metal, glass, ceramic, and wood polishing.
Angle Grinder Attachments for Stripping and Surface Preparation
Surface preparation is the essential part of finishing any project or workpiece. To prepare and condition hard surfaces with rust issues, paints and gunk build-ups, a stripping grinder wheel is a quick solution.
The poly stripping wheel is usually made from nylon and somewhat flexible with a non woven matrix design to allow a sufficient amount of air though the weave, which results in a much cooler operation so you can use your grinder at high RPM without burning out the surface.
Attached with an angle grinder provides speed and efficiency to remove contaminants from the surface without damaging it.
Non-Woven Abrasive Discs
Non-woven abrasive discs are essential for surface conditioning and paint jobs. they are commonly used in the autobody industry and metal fabrication facilities for finishing. It provides enough scouring power to remove even the toughest of substances like adhesives and sealers to prepare the surface for finishing.
Poly Stripping Discs
Poly strip wheels are rotating discs used for stripping paints, which is basically removing the paint and exposing the surface. These discs are used with angle grinders for finishing and conditioning with fast action and no damage to the original surface.
Conclusion
Whether you’re finishing metal projects or cutting a tile, the angle grinder is the ideal tool for your tasks. With a powerful motor and a high RPM, its the go-to tool to take on several jobs with the right accessories and ultimate versatility.
Choose your attachments and discs to turn your angle grinder into a sander, polisher, buffer, grinder or a multi-material cutter.
1 comment
Hi! I would suggest you specify when you say ‘surface’. Are you talking wood or metal? I do wood work, metal and ceramic. Removing rust from metal is still a challenge after 5 years of experiencing different tools. Comment specific to this would be appreciated. tks!
Die Grinder Guide: Everything You Need to Know
From woodworking to metalworking, die grinders are one of the most versatile tools that can be used to machine almost any material when combined with the right attachment.
A die grinder is a power tool that consists of a rotating spindle coupled with a collet chuck to hold the cutting tool. It is a versatile tool that can be used for applications such as grinding, polishing, honing, and sanding, intricate patterns, or internal profiles.
This article tells you everything you need to know about die grinders and how to use them.
Die Grinder: How to Use it?
A die grinder consists of an encased motor that drives the rotating spindle, with a collet chuck gripping the shanks of the grinding tool.
When operating the die grinder, the spindle rotates the cutting tool, which is then brought in contact with the workpiece to remove the material and perform the desired machining operation.
The die grinder’s real capabilities are often not appreciated due to its name. By using appropriate cutting tools, a die grinder can also be used to drill, cut, or polish a workpiece.
The ability to control the speed of the spindle makes it suitable for machining wood as well as metal workpieces.
Apart from that, with proper tool selection, it can also be used to machine plastics or to produce markings on glass.
Types of Die Grinders
Electric die grinders consist of an electric motor that rotates the cutting tool to perform the required operation.
However, electric motors are prone to overheating when subjected to prolonged usage.
As a result, these die grinders are suitable for small-scale applications where prolonged usage is not required.
Generally, electric die grinders have a rated power of about 800 W and a maximum permissible continuous usage of 4 minutes.
Therefore, when using an electric die grinder, it is important to stop the grinder, allowing the motor to cool, thereby prolonging the life of the equipment.
The maximum size of the collets that is compatible with an electric die grinder is 1/8”.
However, these grinders are available in wireless variants, which provide high portability, making them suitable for remote applications.
Die grinders, such as Makita GD0601 provides the ability to operate on both, AC and DC power source, enhancing their flexibility.
Pneumatic Die Grinders
These grinders offer better flexibility in terms of design. The pneumatic grinder’s speed is usually controlled via a throttle present on its handle.
Using nearly a 20-gallon compressor, you can run it for quite a long period without any heating issues.
These grinders are preferred tools for machinists or pattern makers because they can produce heavy torque and offer more considerable material removal.
The cost of a pneumatic die grinder of similar capability is comparatively less than an electric die grinder.
Apart from that, these die grinders offer better efficiency, because no energy is wasted in terms of unwanted heat generation.
However, pneumatic die grinders require bulky compressors to operate, thereby reducing their portability.
Applications of Die Grinder
Cleaning of Machined Surface
Manually cleaning the metallic chips from the surface of the workpiece, post-machining, is usually tedious and time-consuming.
Instead, a die grinder with a soft brush mount can be used for quicker cleaning. It also provides added safety to the machinist by reducing the chances of injuries from sharp chips.
Removing Rust and Paint.
Whether it’s a body of heavy machinery or a car, it is always prone to rusting over time, damaging the surface.
Using a die grinder with a wire cup brush provides an efficient and quick way of removing or stripping rust and unwanted paint from large flat areas.
The wire wheels can also fit smoothly in corners and crevices, which otherwise are difficult to reach with traditional sandpaper, increasing the efficiency of the process.
Buffing Weld Lines in Metalworking.
Weld lines can be annoying in terms of surface irregularities. A die grinder mounted with a suitable burr can quickly get rid of the excess weld material along the weld line to obtain a smoother surface.
Sculpting Wood into Shapes
Carbide burrs-mounted die grinders can effectively carve a wooden workpiece into various artworks and shapes.
It offers better mobility for creating intricate designs than heavy tools used in woodworking.
Similar to removing rust in the case of metal, a die grinder can also be used for finishing or sanding wood workpieces using the mounts like a drum sander.
Shaping Plastics
Apart from metal and wood, the die grinder can be applied to shape plastics.
However, you should keep in mind when shaping plastic, a fine burr must be employed at slow speeds to avoid workpiece burnout.
This is because plastic is a soft material that is prone to melting due to the frictional heat generated at high-speed machining.
Apart from that, the chips produced can jam the teeth of the burr. Therefore, a burr with fewer flutes is advised for easy chip clearance.
Cutting of Metal Bolts and Sheets
Die grinders with cutoff wheels made of aluminum oxide or ceramic grits can cut down metal bolts and sheet metal.
The wheels are relatively less expensive than the other tools, used for the same purpose.
Factors to Consider When Using a Die Grinder
Cutting Speeds
Die grinders are low-torque high-speed tools, suitable for applications where you don’t need to apply too much pressure on the workpiece surface to remove the material from its surface.
These are generally available in single-speed and variable-speed variants, with the variable-speed variant providing comparatively greater material flexibility.
Generally, variable-speed die grinders provide a range of 10,000 to 30,000 RPM.
However, the optimal speed for the operation depends upon the type of cutting tool and the workpiece material.
Cutting Tool to be Used
Die grinders typically use a collet to grip the shank of a tool, and choosing a proper shank size is very important for a good grip.
For a shank size of 3/32” to 1/8”, the compatible collet is 1/8”. Similarly, for shanks of 1/64” to 1/16”, the preferable collet size is 1/16”.
Die grinders are compatible with a wide range of cutting tools, which makes it important to select the right tool for your application.
Burrs
Burrs are the most common tools mounted on a die grinder using a collet and chuck. The burrs are also known as rotary files.
These tools are generally made from tungsten carbide or high-speed steel, making them durable to machine a variety of materials including wood and metal.
Depending upon the size and shape of its teeth, burrs are classified into fine and coarse-toothed burrs.
Some typical applications of burrs include; carving, routing, milling, and engraving.
Brushes
Brushes made of steel, nylon, and brass wires are also available as mounting tools for die grinders.
They are employed primarily for cleaning purposes, wherein soft brushes are used on more delicate workpiece materials like wood, and steel brushes are used on metal workpieces for removing rust.
Grinding Discs
These are hard discs consisting of a solid mass of tiny grits (particles) of silicon carbide (SiC) or aluminum oxide (Al2O3).
Grinding discs are suitable for cutting and slotting metals (both ferrous and non-ferrous).
Apart from the above-mentioned tools, several other mountings, such as drum sanders, tiny drill bits, and polishing discs, are also available and compatible with a die grinder.
Optimizing the Speed for a Particular Cutting Tool
The net outcome of a die-grinding process depends on the correlation between speed and the tool head. For instance, a small tool with a higher speed is essential for a finer finish.
Another critical factor that also depends on speed and cutting tool head is the feed pressure.
For example, a 16-flute cutting tool, running at 24,000 RPM will create around 3,84,000 chips per minute, making it important to set the optimal chip load for the process.
In such a scenario, it is important to apply minimal force on the cutting tool, just enough to maintain contact between the tool and the workpiece.
Applying excessive force can increase the chip load, clogging the teeth of the cutting tool, and degrading the tool life and surface finish.
Die Grinder vs Angle Grinder
| Design and size | Straight rotary tool. | The shaft and the tool head make a 90˚ angle between each other and need two hands to operate. |
| Source of power | Pneumatic, electric, battery. | Electric, battery. |
| Power | Usually less than 1 HP. | Can go up to 5 HP. |
| Speed | Can range between 10000 to 30000 RPM. | Can range between 6500 to 20000 RPM |
| Applications | Grinding and engraving different materials | Grinding, engraving, and cutting different materials |
| Price | Comparatively Expensive. | Relatively Inexpensive |
Die grinder vs Angle Grinder
The smaller size factor of die grinders makes them suitable for applications where grinding of tighter locations, such as intricate patterns, is required.
On the other hand, angle grinders are suitable for removing material from a comparatively larger workpiece and producing a larger cut.
Generally, angle grinders are suitable for machining the outer surface of the workpiece, while the smaller tool size makes die grinders suitable for machining internal dimensions, such as holes.
over, the low torque and high-speed configuration of die grinders make them ideal for grinding and engraving applications on wood, plastics, metals, etc.
On the other hand, angle grinders provide comparatively much higher power output, suitable for grinding, as well as cutting operations.
Frequently Asked Questions (FAQ)
What is the difference between a die grinder and Dremel?
The difference between a die grinder and a Dremel lies in its size and power. When compared to a die grinder, a Dremel is much smaller and produces lesser torque and material removal rate.
What are the cutting wheel diameters used with angle grinders and die grinders?
The cutting wheel diameters used with angle grinders and die grinders vary from 2 inches to 9 inches. The angle grinders use larger cutting wheels with a diameter ranging between 4 to 9 inches. Whereas, die grinders use cutting wheels with a diameter from 2 to 4 inches.
What is the difference between honed and polished surfaces?
The difference between honed and polished surfaces lies in their texture. Honed surfaces are usually matte and do not reflect light. Whereas, the polished surfaces are usually shinier and are obtained by smoothing the surface repeatedly using proper abrasives and grit size.
Hey I’m John. I write about Manufacturing, Metalworking, CNCs and Lasers at Mellowpine. If you have any questions related to CNCs or Lasers, I’d be happy to answer them. Reach me at mail@mellowpine.com
Hey I’m John. I write about Manufacturing, Metalworking, CNCs and Lasers at Mellowpine. If you have any questions related to CNCs or Lasers, I’d be happy to answer them. Reach me at mail@mellowpine.com
Die Grinders: What is Die Grinder, Uses Types
One of the more versatile, but often underappreciated tools out there is the die grinder. If you aren’t familiar with these tools, don’t worry because I imagine you aren’t alone in that regard. Even if people have heard of the name, I think that many people don’t actually know quite what these tools do.
In this guide, I want to tell you everything that you could possibly need to know about this handy, versatile little tool.
What Is A Die Grinder?
A die grinder is a small, handheld power tool that has a rotating spindle where a collet holds the cutting bit. The grinding bit that rotates at very high speed is used for removing material from the work-piece. They look similar to rotary tools and are usually powered by compressed air or electricity.
When combined with the right attachment, die grinders are capable of doing a wide variety of different tasks. Die grinders are primarily meant to work with metal (specifically for Tool and Die making). But one can also use them on other, more sensitive materials like plastic and wood.
Die grinder with mounted point grinding wheel and carbide burr.
With a die grinder and the right attachment on the end, you can polish, sand, cut, grind, or hone various materials. Obviously, this makes the die grinder useful in a lot of different circumstances, as I will show you later on in the guide. Likewise, I will also explain how the die grinder, like many other handheld tools, is separated into two different kinds based on their power source.
Die Grinder Uses
Alright, so to help you understand why this particular tool is useful, why don’t I illustrate some of the scenarios where you can use a die grinder? In this section, I’m going to go through some of the more common uses of a die grinder.
Reworking Dies
Ever wondered why it is called die grinder? The die grinder got its name from the original purpose for which it was developed. That is to grind the dies used in tooling. These include metal stamping dies, plastic molds, die-casting dies, forging dies, etc.
Before the arrival of high precision machines such as CNC milling, EDM Spark Erosion, and EDM Wirecut it was common for the die makers to grind and match the profiles of the mating parts manually. As you know, it is tough to remove material from hardened tool steel with a conventional hand tool such as a file. The die grinder is the best tool for the job since they are small and is to maneuver.
Today toolmakers use die grinder for deburring, chamfering, polishing, grinding and matching the welded surface, etc.
Polishing Metal
Metal, especially stainless steel, always looks better when it’s polished. Regardless of the object itself, anything metal ends up looking better after you have given it a thorough polishing. But, if the object in question is huge, then polishing it is easier said than done. For example, polishing a car, while possible, can end up being a really long, tiring process. With a die grinder, polishing even vast surfaces can be very easy.
Since the rotary polishing bits are round in cross-section, they are perfect for polishing holes and curved surfaces. I regularly use the mounted point polishing bits to clean and polish the die profiles.
However, a die grinder is not the ideal tool for polishing flat surfaces, especially if the flatness of the work is important.
Smoothing Out Surfaces
After finishing something like a woodworking project, you often have to smooth out the final product. This can be tricky, to say the least. Also, you run the risk of accidentally ruining whatever it is that you were working on if you don’t smooth it out just right. With the correct attachment, a die grinder can be used to smooth out a wide variety of different materials. You can use it for smoothing out metal, hardened steel, wood, and more.
Weld Spots: If you do metalworking, then you know how annoying welds can be. A die grinder can easily remove the excess welds for smoother, cleaner looking metalwork. This is definitely a must-have tool if you do a lot of welding or metalwork of any kind.
Why not use an angle grinder instead of die grinder? Because die grinders are more precise and you have better control over the tool. An angle grinder is a large tool that is used for removing the surplus amount of material fast. They should be handled with care and are not ideal for precision works. Besides, angle grinders are not suitable to grind inside small holes. For further explanation, see die grinder vs angle grinder comparison.
Rust Removal
Rust is both deadly and difficult to remove. It doesn’t matter what the rust infects; it will eventually destroy it. While old rust can be tough to remove from metal, it isn’t impossible, especially if you catch the rust early. A die grinder can be handy for getting rid of stubborn, stuck-on rust. It will do it very quickly, which can be useful if you have a lot of rust that needs removing.
Sharpening Blades
Many die grinders can be equipped with a blade sharpening attachment; these allow you to sharpen a wide variety of blades. You can use them for knives, hatchets, axes, and other any kind of blade that you can think of. They are great for those who don’t own a proper grindstone, but who still want to keep their blades nice and sharp.
Is A Dremel A Die Grinder?
One thing that you may encounter when searching for die grinders say online or on a shop website, is something called a “Dremel.” This can be confusing at first since it isn’t evident whether a Dremel is its own separate tool or just another name for die grinder.
The answer is a bit complex. See, Dremel is a brand name, but the brand is so dominant that most people refer to the tool by the brand. A Dremel is just a rotary tool. They are similar to die grinders in terms of what the tool is used for, which is why so many people seem to consider them interchangeable. Both die grinders, and Dremel tools are used for things like grinding material, smoothing out material, sharpening things, polishing items, etc.
However, there are some differences to keep in mind. First off, Dremel tools are generally smaller than die grinders. Dremel tools are a lot easier to hold in your hand and a lot easier to use with only one hand. Die grinders are bulkier, larger, and require you to keep a much firmer grip on them, or you could end up losing control.
Die grinders are also more powerful and able to grind through the material quicker if you want it to be. Dremel tools, on the other hand, are weaker, but also a lot faster. If you’re going to do some more touch-up work quickly, then a Dremel tool may end up being your best option because of how fast it grinds.
Another significant difference is how much variation there is. Dremel tools only come in one version, which is a handheld electric model. As I will go into more depth about, later on, die grinders come in two types, electric and pneumatic. So, if you already have an air compressor set up in your garage, then buying a die grinder makes more sense. There aren’t pneumatic options out there for Dremel rotary tools.
Types Of Die Grinders
As I have mentioned a few times so far, there are different kinds of die grinders out there. In this section, I want to go over the various types that you can find when shopping for one.
Straight Die Grinders
Straight die grinders are just regular die grinders. They are completely straight and almost resemble a sort of large screwdriver.
Right Angle Die Grinders
Right angle die grinders work the same as straight die grinders, except for the fact that the bit on a right angle die grinder is perpendicular to the body.
Straight vs Right Angle Die Grinder: Which Is Better?
There aren’t actually any pros or cons to the type of die grinder that you pick. Straight die grinders and right angle die grinders work the exact same. So, it comes down to the kind of work you do.
What is a right angle die grinder used for? A right angle die grinder is used to work at tight spaces where the straight grinders cannot fit it. The straight version of the tool along with the cutting bit may be too long to work inside the machine and automobile parts.
Here is an example to illustrate. In figure.1, you can see that it is impossible to grind the hole with a straight grinder.
Fig.1 The straight grinder cannot reach the hole since the gap between the plates is less than the body length of the tool.
In such situations, a right angle die grinder is very handy. It can go in difficult to reach places. See the illustration below.
For most of my work, I use the straight die grinder because it’s more comfortable. If you find a right angle die grinder more comfortable to use for your job, then go for that kind instead.
Power Sources
Die grinders are powered in one of two ways, either electricity or air pressure.
Electric Die Grinders
Electric die grinders need to be plugged-in to work. They are typically less powerful than their pneumatic counterparts, but they also tend to be lighter and a lot quicker. Most professionals that I know prefer using electric die grinders for smaller jobs that require precision and working in tight spaces where an air canister can be a bit cumbersome. It should also be noted that because they are a bit less powerful, electric die grinders can use some unique bits that can’t be used on the more powerful pneumatic die grinders.
There are two versions of electric grinders; corded and cordless. As you can guess the cordless version runs on rechargeable batteries. I am not a big fan of the cordless version of this tool. The batteries add unwanted bulk to the tool.
That said, I can’t deny the fact that nothing can beat cordless die grinders when it comes to portability. If portability is more important for you, then the cordless tool is your best friend.
Pneumatic Die Grinders
If you want raw torque, then a pneumatic die grinder is the better option for you. They are mighty powerful because they harness the power of compressed air. If you have a very large job that needs to be tackled, then a pneumatic die grinder can be a lifesaver. Also, because pneumatic die grinders are so common, they tend to be pretty inexpensive. So, if you are on a budget and already own an air compressor, this is the best option for you.
However, there are some downsides to pneumatic die grinders. For starters, the fact that you have to lug around an air compressor and all that comes with it (hoses, tank, etc.) when using the tool makes it very cumbersome to use, especially if you are in a tight space. Likewise, if you don’t already own an air compressor, then getting one that is also compatible with your tool can be both expensive and a hassle.
Finally, because of how powerful they are, pneumatic die grinders probably aren’t the best option for jobs that require a lot of precision and a soft touch.
Die Grinder Bits
Before ending this article, I want to look at some of the special bits and wheels that you can use on your die grinder.
With your die grinder, you can use:
This is just a sample of the various attachments that you can use with your die grinder. As you can see, this is a very versatile tool. I only use a fraction of these attachments, and I still get a ton of use out of my die grinder. So, even if you aren’t going to use all of the accessories, it’s still a worthwhile tool to get.
- What Is A Die Grinder?
- Die Grinder Uses
- 1. Reworking Dies
- 2. Polishing Metal
- 3. Smoothing Out Surfaces
- 4. Rust Removal
- 5. Sharpening Blades
- Straight Die Grinders
- Right Angle Die Grinders
- Power Sources
- Die Grinder Bits
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Quick Links
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Service Support
Support is always available from our technical team in the USA, Germany and Mexico. Repair Service is available in Florida and Munich.
Call our factory technicians at 1-561-994-0500 or email us at [email protected].
