In aluminum fabrication and workshop operations, the angle grinder is an extremely powerful and useful tool. Whether it is cutting aluminum profiles, grinding welded joints, or cleaning cut edges, every craftsman uses a grinder daily. However, while this machine makes the work fast and easy, it can also prove to be the most dangerous tool in the workshop.
An angle grinder operates at a very high speed (RPM), and even a small amount of carelessness while using it can cause a major accident, such as a severe injury to a finger or an eye. In today's post, we will discuss which technical aspects are essential to keep in mind while working at your workshop, and what the 7 safety rules are that every craftsman must mandatorily follow when doing aluminum or glass work.
1. The 7 Golden Safety Rules of Using an Angle Grinder
Make these seven rules your daily routine to keep yourself and your colleagues safe at the workshop:
- Rule 1: Mandatory Use of PPE (Personal Protective Equipment): The eyes are at the highest risk when operating a grinder, because fine and sharp aluminum particles fly off at a very high speed. Always wear high-quality safety glasses or a full face shield. Use strong leather gloves to protect your hands, and wear safety shoes to prevent heavy materials from injuring your feet upon falling.
- Rule 2: Never Remove the Wheel Guard: Many craftsmen remove the top iron safety guard of the grinder to see the cutting disc easily or to install a larger blade. This is an extremely dangerous technical mistake. If the disc breaks during cutting or cracks after getting bound in the material, this guard prevents its fragments from flying toward your face and body. Operating a grinder without the guard is an open invitation to an accident.
- Rule 3: Firmly Secure the Material in Clamps or a Vise: When cutting an aluminum profile or strip, never attempt to cut it by pressing it down with just one hand or foot. Aluminum is a soft metal in which the blade often gets bound. If the material is not firmly secured in a clamp or a bench vise, the grinder will kick back forcefully, which can cause the machine to slip out of your hands.
- Rule 4: Selection of the Correct Disc and RPM: Always use thin cutting discs specified for aluminum cutting, and select grinding discs for smoothing. Never attempt to rub or clean material using a cutting disc, because a cutting disc cannot withstand side pressure and will shatter. Additionally, always check that the RPM written on the disc is higher than the speed of your grinder so that the disc does not burst due to excessive speed.
- Rule 5: Hold the Grinder Firmly with Both Hands: Never make the mistake of operating an angle grinder with one hand. One hand must always be on the rear part containing the trigger, and the second hand must be on the side handle of the grinder. The side handle provides you with complete control over the machine's kickback and vibration, and it keeps the cutting line perfectly straight.
- Rule 6: Direction of Sparks and Flying Particles: While operating the grinder, position its direction in such a way that the flying hot particles or sparks do not go toward your body, face, or any other helper present in the workshop. Furthermore, there should be no flammable material, such as thinner, paint, or cloth, near the cutting area to eliminate the risk of a fire.
- Rule 7: Wait for the Wheel to Stop and Power Off: When you complete the cutting work, do not place the grinder on the table or floor immediately after releasing the trigger. Keep holding the machine in your hand until the cutting disc stops spinning completely. After finishing work or while changing the blade, mandatorily pull the machine's power plug out of the board so that the machine does not turn on if the trigger is pressed accidentally.
Technical Advice for Craftsmen
If the blade gets bound repeatedly while cutting aluminum, instead of applying forced pressure, apply a little wax or cutting oil along the cutting line. This makes the cutting smooth, prevents the blade from overheating, and greatly reduces the risk of it breaking.
Enforce these technical and safety rules strictly at your workshop, because a safe craftsman is a professional and successful craftsman.
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