How To Cut Aluminum In Fast Way?

Aluminum is a versatile metal that is used in a variety of industries such as aerospace, automotive, and construction. Its softness and light weight make it a popular choice for many applications. However, cutting aluminum can be a challenging task, especially if you are not familiar with the proper techniques and tools. In this article, we will discuss how to quickly cut aluminum without loading by using a cut off wheel.


cutting off disc

What is a Cut Off Wheel?

A cut off wheel is a type of abrasive disc that is used to cut through various materials such as metal, stainless steel, and stone. It is made up of abrasive particles that are bonded together with a resin or other bonding agents. The abrasive particles come in different shapes, sizes, and materials such as aluminum oxide, silicon carbide, and diamond. The size and shape of the cut off wheel depend on the type of material that you want to cut.


Why is aluminum difficult to cut?

Aluminum is a relatively soft metal, with a Mohs hardness rating of 2.5 to 3. This means that it is softer than most other metals, such as steel or titanium. While this can be an advantage in some ways, such as making aluminum easier to form and shape, it can also make it more challenging to cut. Because aluminum is so soft, it tends to gum up and stick to cutting tools, which can cause them to overheat and become damaged.

In addition to its softness, aluminum also has a tendency to deform or “smear” when it is cut. This is because the metal is relatively ductile, which means it can bend and stretch without breaking. When a cutting tool comes into contact with aluminum, it can cause the metal to deform around the cutting edge, which can lead to a rough or uneven cut.


Tips for Cutting Aluminum with a Cut Off Wheel

  1. Choose the Right Cut Off Wheel

Choosing the right cut off wheel is essential for cutting aluminum quickly and efficiently. Aluminum is a soft metal, and therefore, you need a cut off wheel for soft metals. A cut off wheel that is too hard or too abrasive can cause the aluminum to melt, gum up the wheel, or cause the wheel to wear out quickly. A soft bonded abrasive wheel is ideal for cutting aluminum.

  1. Use a Properly Cut Off WheelSizes

The size of the cut off wheel that you use is also crucial for cutting aluminum. A smaller wheel can get bogged down in the soft metal, while a larger wheel can create too much friction and heat, causing the aluminum to melt. You should choose a cut off wheel that is the right size for the job. Typically, a 4-1/2 inch cut off wheel is ideal for cutting aluminum.

  1. Use Proper Safety Gear

Safety should be your top priority when cutting aluminum with cut off wheel. The cutting process produces sparks and debris that can cause serious injury. Always wear proper safety gear, including eye protection, a face shield, gloves, and a dust mask.cut off wheel manufacturer

  1. Mark Your Cut Line

Before you start cutting, mark your cut line on the aluminum with a marker or a scribe. This will help you to make a precise cut and ensure that you cut in a straight line. You can use a straight edge or a level to make sure your cut line is straight.

  1. Secure the Aluminum

It is essential to secure the aluminum firmly in place before you start cutting. This will help prevent the aluminum from moving while you are cutting, which can cause an uneven or crooked cut. You can use clamps or a vise to hold the aluminum securely.

  1. Cut at the Right Angle

Cutting aluminum at the right angle is essential for achieving a clean and straight cut. You should hold the cut off wheel at a 90-degree angle to the aluminum and apply even pressure to the wheel. Avoid tilting the wheel, as this can cause the aluminum to cut unevenly.

  1. Use a Steady Speed

Maintaining a steady speed while cutting aluminum is crucial for achieving a smooth and even cut. If you move the cut off wheel too slowly, it can cause the aluminum to melt, while moving the wheel too quickly can cause the wheel to wear out quickly. A steady speed is ideal for cutting aluminum quickly and efficiently.

  1. Clean the Cut Off Wheel

Cleaning the cut off wheel is essential for maintaining its performance and longevity. Aluminum can build up on the wheel, which can cause it to wear out quickly or become clogged. You can use a wire brush or a dressing stick to clean the wheel periodically.

  1. Use Coolant

Using coolant while cutting aluminum can help to reduce heat and prevent the aluminum from melting or gumming up the cut off wheel. Coolant can also extend the life of the cut off wheel by reducing the amount of wear on the wheel. You can use water or a specialized cutting fluid as a coolant.

  1. Check Your Progress

Periodically stop cutting to check your progress and ensure that you are cutting in a straight line. If you notice that the cut is becoming uneven or crooked, adjust your angle or speed accordingly. You can also use a straight edge to check your progress and make sure that your cut is straight.



Quickly cuts aluminum without loading can be a challenging task, but with the right tools and techniques, you can quickly and efficiently cut through this soft metal. Choosing the right cut off wheel, using proper safety gear, securing the aluminum, cutting at the right angle and speed, and using coolant are all essential steps to achieving a clean and straight cut. By following these tips, you can cut aluminum with ease and achieve professional results. Remember to always prioritize safety and take the necessary precautions when working with power tools.