How To Properly Cut A Tile With A Grinder Without Chips

How to properly cut tiles with a grinder without chips
Grinder cutting: tiles, metal (corrugated board, cast iron, pipe, metal tile), concrete, glass, asphalt, porcelain stoneware, brick. Is it possible to cut wood with a grinder

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Like all other tools, grinders are divided into classes, into professional and household tools, as well as by their design features.

This is perhaps the most widely used tool outside of the drill. Many people work with angle grinders, but not everyone asks about the correctness of the manipulations performed, in terms of personal safety and quality of work. In this article, we want to devote you to the basic subtleties of working with this tool and consider in detail the following questions:

Let’s go in order.

How To Properly Cut A Tile With A Grinder Without Chips

HOW TO CUT CORRECTLY WITH A BULGARIAN?

Before you get started, you need to prepare the grinder. We mean the choice of rig (disc). The following points should be considered here:

  1. Disc diameter. Remember, the smaller the disc diameter, the more revolutions (higher rotational speed) it can handle, and vice versa.
  2. The choice of disc depends primarily on the material with which you plan to work and the design features of your instrument.
  3. Pay close attention to the legend and markings on the disc. Having carefully studied them, you will understand whether the selected equipment is suitable for the proposed work.

Also, always follow safety precautions and wear special equipment such as gloves, goggles, long sleeved robes and closed shoes.

First of all, clear the workplace of unnecessary items. Securely fix the workpiece to be processed, having previously marked it on it, if necessary. Let’s get to work.

Always hold the tool firmly and confidently with both hands. Take a steady body position. You need to stand so that sparks do not fly on clothes and, even more so, in the face during work.

Always remember about such a thing as kickback. This is the most dangerous thing that can happen when working with a grinder. It can occur if the disc is strongly jammed in the workpiece. In such a situation, the angle grinder will sharply throw back. Monitor the process to avoid this.

Also remember that the power cord of the angle grinder must be isolated from sparks falling on it during operation. If you need to move the instrument to a different work surface, be sure to turn it off first and then unplug the power cord. The same should be done in the event of a power outage. As soon as there is no electricity, turn off the instrument and then unplug it from the mains. If this is not done, then when the power is resumed, the grinder will start working in a chaotic mode again and can cause irreparable harm to your health, those around you or damage objects around.

The most frequently asked question that arises among novice craftsmen is the following: How to cut correctly with a grinder: for yourself or for yourself? Many do not give this special significance, but in vain.

Bulgarian manufacturers advise their consumers the following: The tool should be used in such a way that the course (direction) of the cut coincides with the direction of rotation of the disc.

Experienced craftsmen have a clear answer to this question: You need to make a cut from yourself. This is for your safety. If the grinder is torn out of your hands, the tool will be thrown in the opposite direction from you. If you cut towards yourself, when the above situation occurs, the tool will fly to your feet. We will not describe the consequences. You can imagine them yourself.

If you are cutting parts or workpieces that have thick metal, cut them in an extremely straight line.

When working on a part such as a corner or cutting a profile or shaped tube, which is usually quite long, cut the overhanging edge. Otherwise, if you make a cut in the place between the supports, such an outcome as a jamming of the blade due to the deflection of the workpiece is possible.

If you are cutting corrugated sheet (sheet metal sheeting), metal siding (metal siding) or metal tiles, take care of the presence of special anti-corrosion agents that you need to lubricate the material in order to avoid sudden corrosion.

In case you are cutting paving slabs or paving stones, get a special diamond cut disc.

Reinforced concrete, concrete and other similar materials must be processed with special discs for stone.

If you need to cut a gas or oxygen cylinder, be very careful as it may explode due to the remaining trace of gas or condensation. It is better not to carry out such work at home.

If you need to cut glass or, for example, a mirror. The most trivial ceramic disc will suit you.

When working with material such as wave slate, be careful not to apply excessive force to avoid chipping and unevenness.

It is possible to process rubber with a grinder, but unnecessary. If you understand what we mean.

Grooves, springs, fittings or channels can also be cut with angle grinders.

Need to cut drywall or polycarbonate? Do this very carefully to avoid chipping and breaking the material. You will need neatness if you need to cut glass mosaics. For example, if you are cutting off excess parts from a pasted arch, cover the cut and the part to be cut off with masking tape or construction tape. This minimizes the possibility of cracks and prevents debris from scattering on the floor after cutting.

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HOW TO CUT A BULGARIAN TILE WITHOUT CHIPS?

As we said above, the range of application of angle grinders is incredibly wide. She also acts as an excellent helper when cutting material such as tiles or tiles. But, a logical question arises regarding the equipment: How is it better to work on tiles? To carry out this type of work, you need to get a grinding diamond wheel and a tile holder. It is hardly possible to work without dust with this material, so take care of a protective mask in advance.

Let’s take a closer look at the process itself and how to cut tiles or tiles without chips.

  • The easiest way is to cut straight. Fix the tile well so that its edge remains suspended along the mowing line of the cut and get to work.
  • The next method to be noted is cutting at a 45 angle. This method is more complicated than the first one. First, we cut the ceramic tile with a straight cut. Then, when cutting, we direct the grinder disc at an angle and remove the unnecessary part. Next, we grind the cut with sandpaper.

HOW TO CUT CORRECTLY BULGARIAN METAL?

To begin with, let’s talk about the dangers that await the master when cutting metal with a grinder, namely:

  1. Fragments of the disc, in the event of a break;
  2. Powerful stream of sparks and small abrasive particles;
  3. In some cases, the inability to hold the instrument in the hands.

Now, here are some tips for working with metal.

If you have no experience in this type of work, then, for a start, it is worth practicing on unnecessary details. If in the process of work, you decide to change the cutting plane when the disc is inside the workpiece, this will immediately lead to its breakage.

To increase the life of discs, especially expensive ones, they need to be cooled. This is done with water. It is necessary to water the cutting area. It is advisable that you work with a partner who will carry out all these additional manipulations.

Also, breaks of 5-7 minutes every 20-30 minutes of work will help to increase the service life of the equipment, and the tool itself. This rule is especially important when working with household grinders. This way you will keep your instrument from overheating.

You should also remember that you should not put pressure on the grinder during operation, otherwise it may fail due to overheating, or the disc will jam. If you feel that performance is too slow, try changing the drive.

IS IT POSSIBLE FOR A BULGARIAN TO CUT A WOOD?

Many experienced craftsmen say that cutting wood with a grinder is to be. Our opinion: indeed, it is possible to cut wood with a grinder, but it is extremely unsafe, inconvenient, slow and of poor quality. And that’s why.

Firstly, during operation, the grinder disk gets very hot and becomes incredibly fragile. The slightest misalignment may result in a ruptured disc. You can find out about the consequences of this situation from the pictures on the Internet.

Secondly, when working with a disc equipped with victorious solders, these solders can easily get under the skin. And this is a direct way to the hospital, because you cannot remove them on your own, plus all this is fraught with infection.

Thirdly, when using a disc on wood, the teeth can grab more wood than you expect, and this, in turn, will lead to that. That the grinder will simply snatch out of your hands. It is very dangerous!

We hope we have explained in an accessible way why you cannot use angle grinders when carrying out woodwork and you will not even try.

But, as practice shows, many craftsmen at home resort to the help of a grinder in the process of processing materials such as chipboard, chipboard, laminate, OSB plate or plywood. This should be cut as carefully as possible and in compliance with all safety measures. Otherwise, you can not only spoil the material, but also be injured.

HOW EXACTLY CUT BULGARIAN?

In order not to spoil the workpiece and make a high-quality even cut with a grinder, you will need to perform a number of preparatory measures, which we will discuss in this part of the article.

  1. Markup. All ingenious is simple. First mark, then cut. Take pipe cutting as an example. First, use a chalk or marker to apply the size, then use paper or duct tape. The main thing is that the edge is even. We take the selected auxiliary material and carefully wrap it around the pipe. Its border will be a clear and accurate marking of the cut. When performing work, it is important to remember that under no circumstances should you change the position of the tool stroke. Otherwise, the disc may jam or break. Also, do not put additional pressure on the tool, as this will immediately be reflected in the curvature of the cut and spoil your workpiece.
  2. It is very important to choose the right thickness of the circle. There is a simple axiom at work: the thicker the material you work with, the thicker the disc should be. When choosing a tool, consult an expert in the field and pay attention to the marking of the grinding wheel applied to his shirt.

HOW TO CUT SAFELY WITH A BULGARIAN?

Working as a grinder is a business that requires constant attention and control, because the consequences of accidents are irreversible. Therefore, before starting work, take care of the following:

  • Take care of the protection of all parts of the body: face, hands, eyes.
  • Clean the work area from excess, especially the place where the sparks fly out, remove all combustible materials away.
  • The workpiece to be machined must always be securely fixed.
  • Be sure to install the protective cover.
  • Hold the tool firmly while working.
  • At the end of the work, wait until the rotation of the disc has stopped completely, put the grinder with the disc facing up so as not to damage it, unplug the tool from the mains and make sure there is no smoke and signs of fire.
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WHAT CANNOT BE CUT WITH A BULGARIAN? BASIC ERRORS

The list below contains the materials with which you can work with the grinder. It is prohibited to work with materials that are not on the list.

  1. LBM will perfectly cope with cutting materials such as cast iron, metal, steel, copper, aluminum, iron, titanium. You can cut stainless steel or galvanized.
  2. With the appropriate attachments, you can also work with plastic, ceramics, glass, plexiglass and porcelain.
  3. Stone, granite, marble, asphalt, concrete or a wall made of it, brick, porcelain stoneware can also be processed with a grinder.

The angle grinder is useful if you need to cut off water pipes or old heating.

One of the main factors that guarantee the quality of work is the right tooling. If you have any questions or want to purchase discs, please contact our managers at the specified phones. They will recommend suitable discs and advise you on all issues of interest.

What discs are used for cutting tiles

For cutting ceramics, special discs are required, which can be stone or metal with diamond coating. Stone ones are rarely used, as they are rather thick and quickly grind off, and during work they generate a lot of dust. The cost of stone discs is several times less than metal ones, but experts prefer to work last.

Metal discs can be:

  • Solid;
  • Segmented.

It is preferable to process ceramics with solid discs. When working with such discs, there is a time limit: they cannot continuously cut for more than 1-1.5 minutes. Then you should let it cool while the grinder is idling.

Segmented for cutting paving stones, porcelain stoneware, natural stone or concrete.

How to get rid of dust when cutting tiles

Cutting tiles with a grinder is not very difficult, but it generates a lot of dust. There are tricks that can help reduce dust formation. Specialists use special tile cutters for this, but buying them for a one-time job is impractical due to the high cost. Therefore, when processing parts, the craftsmen act differently. First, a layer of glaze is cut through. It almost does not dust, the main dust appears when a layer of fired clay is processed. Then it remains to gently break the ceramic tile and process the edges with an abrasive material.

A common way to get rid of dust is to moisten the workpiece. For this, water is constantly poured into the working area with a diamond wheel. After each pass of the tool, fill the seam with water or install a special device for supplying water to the working area. This device is attached directly to the protective cover of the grinder. As a result, the workpiece is processed without dust.

Cutting paving stones with angle grinder

Having a private house, it becomes necessary to lay paving slabs or paving stones, which must be cut to size. For this, a universal device is also used, which is available in almost every home. An angle grinder.

Paving stone processing has its own characteristics, but basically it is carried out in the same way as cutting porcelain stoneware. The main differences are that the work is done outdoors. Material processing should be carried out on a separate site: the formed dust settles on the laid paving stones and can spoil its appearance. If this happens, you should immediately sweep it off with a stiff brush.

To cut the paving stones, choose a diamond blade for concrete processing. The angle grinder should be held in relation to the workpiece at right angles, and the diamond wheel should be moved exactly along the marking mowing line. It is necessary to cut the tiles to a depth of a little more than half, and then simply break and trim.

Cutting ceramic products

To cut a tile with a grinder, you need to master three cutting directions.

Notched neckline

It is often necessary to cut a round hole in a tile. You can do the job correctly with angle grinders if you have certain skills. To do this, mark a hole on the workpiece and circle the fishing line with a felt-tip pen, mark the center of the circle. They begin to cut at a slight angle, slowly, along the inside of the mowing line, gradually passing along the entire circumference. Then the sectors are cut through, they are taken out in turn, cutting the ceramics if necessary. Finally, the edges are processed with a file, getting an even circle. This processing is called a dry cutter.

When performing shaped processing of a workpiece, it is easiest to make rectangular cuts. In order for the cuts to be smooth, without chips, it is necessary to regularly change the cutting wheel. If you use segmented discs, chips will appear on the cut line.

Cutting tiles and porcelain stoneware with a grinder

Every master who deals with wall cladding with ceramic tiles knows that it is impossible to lay it without cutting. This is true both for wall cladding and for laying porcelain stoneware on the floor. But not everyone knows that an ordinary grinder (angle grinder) can be used for pruning. Let’s consider how to perform this operation correctly and without chips.

How to get rid of dust when cutting porcelain stoneware with a grinder

If the tiles are cut on a table, then, before starting work, a small piece of loose fabric must be pulled under the cutting line or a polypropylene bag must be hung. In this case, most of the dust flies down from the disc, so the amount of work on cleaning the room is reduced several times.

If you cut porcelain stoneware on a substrate directly on the floor, then the best solution would be to use a regular vacuum cleaner. The tip of the hose is attached along the mowing line of the movement of the grinder at a distance of 10-15 cm. It turns out not very convenient, since the pipe has to be rearranged, but the dust is removed quite effectively. Immediately after the end of the work, you need to blow out the grinder and collect part of the dust remaining on the surface of the porcelain stoneware.

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Cutting porcelain stoneware with a grinder: how to saw off without chips

Anyone who has had a chance to cut faience, ceramics, porcelain stoneware with a cutting disc knows very well that the problem is not to cut. Such an operation is not particularly difficult. The problem is to learn how to cut porcelain stoneware with a grinder without chips. At the same time, control the process at any stage, otherwise the expensive material will go to scrap.

It is best to cut porcelain stoneware using a guide bar as a support for the grinder body

Direct cutting of porcelain stoneware

It is considered correct to cut a porcelain stoneware slab on a table or workbench. The material is laid on the tabletop, fixed with clamps with rubber tips. The cut line should be outside the table surface. In this case, it is possible to cut porcelain stoneware with a very small angle of inclination, only 15-20 degrees. The master simply pulls the grinder towards himself, only lightly resting his hand on the stand.

Option for cutting with a grinder in pull mode

Why this method is good:

  • The minimum load on the hands, if you need to cut a long enough seam, it will not be difficult to do this;
  • The cutting line turns out to be even, it seems that the cutting was carried out not with a grinder, but with a tile cutter.

The only drawback of this method is that most of the dust escaping from under the disk falls on the floor, and the largest parts fall into the face and hands of the worker. Therefore, it is necessary to cut porcelain stoneware with protective goggles and using devices for collecting dust.

How to cut correctly with a high-raised grinder

Most beginners and DIYers prefer to cut porcelain stoneware with a tool with a very large angle of inclination relative to the plane of the tile. The angle can be 45-60 degrees.

The tool can only be lifted high if there is a supporting surface on the cover

In this case, the grinder has to be held with both hands and at the same time perform small oscillatory movements with the cutting disc. It is as if the porcelain stoneware had to be cut with a hand saw. This is not very convenient, but the method really improves the quality of the cut and prevents the formation of chips.

On the one hand, with such a movement of the grinder, it is easier to control the cutting line, on the other hand, the tool is in an unstable position relative to the markings, which negatively affects the quality of the straightness of the seam.

How to cut porcelain stoneware with a grinder without chips

There are two ways to cut porcelain stoneware tiles. The first is to mark a 1-2 mm deep line on the mowing line in a circle, and then split the granite into two halves as it is done on a tile cutter. The method is quite risky, it requires a good eye and accurate dosing of effort. The advantages include an order of magnitude higher cutting performance. The disadvantages include the unpredictability of the result and a large percentage of defects.

The second method is the classic cutting of porcelain stoneware to the full thickness of the tile. It turns out a lot of dust, the process takes a long time, but as a result, we get a very high-quality and fairly even cut.

In any case, when using a grinder, the seam is uneven. Visually, the line looks perfectly straight, but as soon as the cut plates are turned over and applied to the factory edge or metal ruler, all the irregularities will immediately become visible. An example of cutting porcelain stoneware with a grinder without chips is given on:

What disc to cut porcelain stoneware grinder

Sawing of porcelain stoneware tiles can be performed in two ways, it all depends on the thickness of the material and on how complex the seam is to be cut. Since porcelain stoneware is still not granite, but just an artificial imitation of it, two types of discs can be used for cutting:

  • Vulcanite discs based on synthetic superhard ceramics. With such a circle, you can cut thin grooves, corners, trim the edges. In order to cut expanded clay with a grinder over a length of more than 10 cm, they are not suitable, but they are quite suitable for small jobs;
  • Diamond cutting wheels. With this tool, you can cut seams of unlimited length. The only drawback of a diamond is the rapid grinding of the cutting edge, which will need to be repaired and cleaned periodically.

The optimum circle diameter for a grinder is 115 mm, in this case the tool is easier to control by holding the body with both hands. A larger diameter blade will require a more powerful tool, such as a circular saw.

Diamond cutting wheels themselves are quite an expensive and capricious tool, so they try to do most of the work with vulcanite discs, only the most delicate operations, such as trimming and adjusting the plane, are performed with diamond powder.

In addition, discs for cutting porcelain stoneware with a grinder must have a solid edge without a notch or turtle profile. Such a tool cuts well natural granite, rubble stone, but at the slightest attempt to cut porcelain stoneware tiles along the cutting line of the cut, a huge number of enamel chips appear on the front surface.

If there is no specific preference for a well-known brand of cutting disc manufacturer, then it is best to buy discs from leading hand tool manufacturers. Simply put. You bought a grinder made by Makita, buy cutting discs with accessories produced by the same company.