Why Cutting-Off Wheels Break: Reasons and Fixes

Cutting-off wheels, also known as abrasive discs, are essential tools used in various industries for cutting, grinding, and finishing operations. They are commonly employed for tasks ranging from metal fabrication to construction. However, the occurrence of cutting-off wheel breakages can lead to safety hazards, productivity loss, and increased operational costs. In this article, we will delve into the causes behind cutting-off wheel breakages and explore effective remedies to prevent such incidents.


Knowledges about Cutting-Off Wheels

Cutting-off wheels are thin, flat abrasive discs made from materials like aluminum oxide, silicon carbide, or diamond. These wheels are designed to cut through metal, ceramics, glass, and other hard materials. They are attached to portable grinders, angle grinders, and other power tools for precise and efficient material removal. The cutting action generates intense friction and heat, making the proper selection and use of cutting-off wheels crucial to prevent breakages.


Causes of Cutting-Off Wheel Breakages

  1. Incorrect Wheel Selection

One of the primary causes of cutting-off wheel breakages is using the wrong type of wheel for a specific application. Different cutting-off wheels are designed for varying materials and cutting speeds. For instance, using a metal cutting disc on stone can lead to rapid wear and possible breakage due to the differences in hardness and abrasive properties of the materials.

  1. Overloading the Wheel

Excessive pressure or force applied to the cutting-off wheel can cause it to break. Overloading often occurs when operators attempt to cut too aggressively or without allowing the wheel to perform the cutting work naturally. This leads to increased friction and heat, which weakens the wheel and makes it more prone to breakage.

  1. Poor Wheel Mounting

Improper mounting of the cutting-off wheel onto the power tool’s spindle can result in unbalanced operation. This imbalance causes vibrations, which can lead to premature wheel wear and eventual breakage. Furthermore, if the wheel isn’t securely tightened onto the spindle, it might wobble during operation, increasing the risk of breakage.

  1. Deteriorated Wheels

Cutting-off wheels have a limited lifespan, and they deteriorate over time due to wear and tear. When a wheel becomes too thin or loses its structural integrity, it becomes more susceptible to breakage during use.

  1. Inadequate Maintenance

Neglecting proper maintenance of cutting-off wheels and the equipment they are used on can contribute to breakages. Dust and debris accumulation can impair the wheel’s performance and cause overheating, leading to wheel failure.

  1. Excessive Heat

Cutting generates a significant amount of heat, which can lead to thermal stress in the wheel. If the heat isn’t managed effectively, it can cause the wheel to crack or shatter.

  1. Incorrect Operating Speed


Operating the cutting-off wheel at a speed that exceeds its maximum permissible RPM (Revolutions Per Minute) can cause the wheel to disintegrate. Manufacturers specify the maximum RPM for each wheel type, and exceeding this limit significantly increases the risk of breakage.


Cures and Preventive Measures

  1. Proper Wheel Selection

The first step in preventing cutting-off wheel breakages is choosing the appropriate cutting wheel for the job. Refer to the manufacturer’s guidelines to select a wheel that matches the material, cutting speed, and application. Using a wheel that’s specifically designed for the task will enhance safety and productivity.

  1. Adequate Training

Operators should receive proper training on how to use cutting-off wheels safely and effectively. Training should cover topics like proper technique, pressure application, and how to recognize signs of wheel wear and deterioration.

  1. Avoid Overloading

Encourage operators to let the cutting-off wheel do the work. Applying excessive force not only increases the risk of breakage but also negatively impacts the quality of the cut. Educate operators on the importance of maintaining a steady, controlled cutting pace.

  1. Secure Mounting

Ensure that cutting-off wheels are correctly and securely mounted onto the spindle of the power tool. Regularly inspect the tool and wheel to identify any signs of wobbling or imbalance. Use appropriate mounting hardware and follow manufacturer instructions for installation.

  1. Regular Maintenance

Implement a routine maintenance schedule that includes cleaning the power tools, inspecting cutting-off wheels for damage, and replacing worn-out wheels promptly. Regular maintenance can extend the life of both the wheels and the equipment.

  1. Heat Management

To mitigate excessive heat buildup, operators should avoid prolonged cuts and provide short breaks to allow the wheel to cool down. Using cutting fluids or lubricants can also help dissipate heat and prolong the life of the wheel.

  1. Operating Speed

Always operate cutting-off wheels within the recommended RPM range specified by the manufacturer. Use speed regulators or control mechanisms on power tools to ensure that the operating speed remains within safe limits.



Cutting-off wheel breakages can lead to serious safety hazards and operational setbacks. By understanding the causes behind these breakages and implementing appropriate preventive measures, industries can significantly reduce the risk of accidents and improve productivity. Proper wheel selection, operator training, maintenance practices, and adhering to manufacturer guidelines are essential steps in ensuring the longevity and safe operation of cutting-off wheels. Ultimately, investing time and effort in preventing breakages will yield long-term benefits in terms of safety, efficiency, and cost savings.