Cutting discs and blades – The future is now

This £700 million industry is booming and showing no sign of decline. The quality of product is gauged by the speed of which the product has to be changed. Good quality and cost-effective cutting discs should last the end user a while without the blade having an interruption due to wear and tear or having to change a broken blade.

Did you know that cutting is the second most completed task on site, second to fastening with nails bolts and screws?

What are cutting discs?

Cutting discs are an important component of many machinery such as angle grinders which are used to cut through thick material. Similar in shape to a DVD, these flat round discs are used to cut through wood, concrete and a variety of metal. Traditional cutting discs use a synthetic resin as a binder, although more and more advanced diamond cutting discs are coming to market. Used with an angle grinder, cutting discs offer more control and ease when it comes to cutting through material.

How do you use cutting discs?

Cutting discs are most commonly mounted onto an angle grinder, or another cutting device before it’s used to cut through thick material. Typically, these discs revolve thousands of times each minute, which promotes a very quick and efficient cut. Thus, generating a lot of friction and racks up a high temperature at the point of cutting. Cutting with an unsteady or unskilled hand may lead to warping of materials, so it’s a good idea to take short breaks which will also prevent the material from heating up too quickly.  

The anatomy of cutting disks and how they are made….

Cutting discs are made by taking a steel plate disc cut teeth at the edge and attaching carbide to each of tooth of the blade. Normally achieved by a brazing process, this helps the disc to stick to the plate which is not ideal.

The two main types of resinoid-bonded abrasive cutting wheels are Type 1, which are flat, and Type 27, which have a raised hub. Type 1 wheels are most commonly used for straight on cutting, usually on electric right-angle grinders or chop saws. Whereas type 27 wheels come in handy when there is some type of interference which requires the wheel to be raised up from the base of the grinder.

These resinoid-bonded abrasives cutting discs come in all different shapes, sizes and most importantly thickness. The most sold range is between 2 to 16 inches in diameter, with popular thickness levels around 0.045 in. to 1⁄8 in.

It is also true that some types of discs will cut faster than others. The abrasive material used in the disc can really influence the consumable life of the product.

This is why new technologies will see the emergence of welded adhesion of carbide to the steel teeth of blades, making the blade last twice as long.

What is the difference between brazing and welding?

Brazing and welding are both metal joining techniques that rely on heat as the main mechanism that binds together two materials. Although they have their similarities, both techniques differ in many ways – with temperature being the main point of difference.

Welding usually uses very high temperature, around 1,000 degrees or higher. This means that the base metals must be similar, for example steel is not able to weld to copper.

Welding also differs from brazing in the way that it melts the base metals which are then fused with the help of a filler metal. Once the metal cools and solidifies, it forms a strong bond. It’s also key to note that the brazing process uses much lower temperature’s than welding.  

Unlike welding, when brazing the base metals are not melted, it’s only the filler metal (also known as solder) that melts and helps to join the materials together.

Thanks to new innovations in technology, it’s enabled the introduction of a welding process – where the carbide cutting teeth are individually welded to the disc.

Dewalt Elite tips will be welded to the blade – providing double the length of time

  • Reciprocating blades
  • Holes Saws
  • Diamond cutting products

The process of adhering carbide was pioneered by Lenox Industrial Bandsaw blades and offers many benefits to the end user.

Carbide cutting tools offer a much more durable choice for strong wood and other materials, with these tougher blades able to cut through debris effortlessly.

As long as you maintain the tool regularly by cleaning it and storing it safely, these handy new pieces of kit can last up to two times in life span than traditional discs.

Carbide is very resistant to heat and is hard to damage, making it a very cost-effective investment for your business.

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