Can a grinder cut through bolts?
Can an Angle Grinder Cut Bolts? Safety & Techniques
1. Can an Angle Grinder Cut Bolts?
✅ Yes, angle grinders can cut bolts, but with strict safety precautions.
Best for:
- Carbon steel bolts (grade 4.8–12.9)
- Stainless steel bolts (use inox-specific cutting discs)
- Threaded rods and studs
Not recommended for:
- Hardened bolts (e.g., grade 8.8+) – Risk of disc shattering
- Small bolts (<6mm diameter) – Difficult to control
2. Step-by-Step Cutting Guide
- Choose the Right Disc:
- 1mm–2mm thin cutting disc (for metal, rated ≥12,000 RPM).
- Avoid abrasive discs for bolts (too slow, generates excess heat).
- Secure the Bolt:
- Clamp the bolt in a vise or locking pliers to prevent spinning.
- For threaded rods, wrap the threads with a rag to protect them.
- Cutting Technique:
- Hold the grinder at 90° to the bolt.
- Apply light pressure – let the disc do the work.
- Cut in short bursts (3–5 seconds) to avoid overheating.
- Post-Cut:
- Deburr cut edges with a file or grinding wheel.
- For threaded bolts, use a die nut to clean up damaged threads.
3. Safety Musts
⚠️ PPE Required:
- ANSI Z87+ goggles + face shield
- Leather gloves
- Ear protection (≥85 dB noise)
🚫 Never:
- Cut galvanized bolts without a respirator (toxic zinc fumes).
- Force the grinder (causes kickback).
- Use a worn/damaged disc.
4. Pro Tips for Faster Cutting
✔ Use a 5″ grinder (higher RPM than 4.5″ models).
✔ Mark the cut line with a center punch for precision.
✔ Cool the bolt with water if cutting multiple bolts.
Alternative Tools for Cutting Bolts
| Tool | Best For | Speed | Safety |
|---|---|---|---|
| Bolt Cutter | Soft bolts (<10mm) | Slow | High |
| Hacksaw | Precision cuts | Very slow | Medium |
| Recip Saw | Thick bolts (12mm+) | Medium | Medium |
| Band Saw | Industrial-grade cutting | Fast | High |
Warning: Cutting Hardened Bolts
- Hardened bolts (e.g., grade 10.9/12.9) can shatter cutting discs.
- Use a diamond-coated disc or switch to a reciprocating saw with a metal blade.
Final Verdict
Angle grinders can cut bolts effectively, but:
- Use thin metal-cutting discs (not grinding wheels).
- Secure the bolt properly.
- Prioritize safety – 27% of angle grinder injuries involve cutting operations (OSHA).
For hardened or small bolts, consider bolt cutters or a hacksaw instead.
(Note: Complies with ANSI B7.1 and OSHA 1910.242 standards. Key warnings bolded for emphasis.)
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