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    3 Tips to Using Diamond Cutoff Wheels

    Updated: February 21, 2024 Published: February 16, 2023

    Although they are composed of the same basic structure, a base bonded to a suspension of abrasive,  cutoff wheels, and grinding wheels serve very different purposes. Instead of slowly removing material from the surface of a workpiece like a grinding wheel would, cutoff wheels are designed to slice through the material. Typically ranging from 0.015” to 1/16”  in width, they are much thinner than most wheels.

    Diamond cutting wheels are available in a multitude of bond options but specifically contain diamond abrasive. These wheels are utilized in a variety of industries including wood and metal tooling production, iridium and platinum cutting for manufacturing spark plugs, slicing silicon wafers for computer chips, glass, ceramic, and magnet cutting for automotive and aerospace tools/parts. Being so commonly seen throughout manufacturing, I decided to compile the three main tips for using a diamond cutoff wheel- straight from the experts.




    Although you can choose from a wide selection of bond structures for your diamond cutoff wheel, it is recommended to begin with a resin bond for most applications.

    Tip #1: Start soft! A smooth cut is the best way to avoid deflection during the cutting process. To guarantee this, begin by trying a resin-bonded diamond cutoff wheel. Resin bonds are known as more free-cutting bonds, meaning they have higher abrasive renewal rates and reveal new cutting edges at a higher rate. If necessary, a harder bond like metal can be utilized if the wear rate is too excessive.

    At Eagle, our  CutMax bonds are utilized on each cutoff wheel we offer. Not only are they specially designed to provide optimal cutting to a wide variety of materials, but Eagle Superabrasives Inc. provides nonstop customer service until your operation is running as smoothly as possible. This means a cutoff wheel purchased at Eagle isn’t just a one-off sale. Eagle’s engineers offer careful adjustments to the wheel chemistry that can result in a wide variety of formulations to ensure the perfect cut. At Eagle, you can start soft with a CutMax bond.

    Whether you’re cutting glass optics or carbide rods, a diamond cutoff wheel could be a great choice for your operation.

    Tip #2: Ensure your cut rate is optimal for the material being processed. Attempting to cut brittle materials like glass and ceramics too quickly can chip the material, usually during the exit of the cutoff wheel from the cutting area. In the end, slightly slower processing can save manufacturers from a mountain of wasted products.

    Whether you’re using a grinding wheel or a cutoff wheel, it is important to ensure the process is well executed.

    Tip #3: A well-maintained coolant system. Excessive heat generation can cause a host of problems during a cutting operation, but also prematurely wears the wheel surface. To produce the best cut and extend the life of your wheel, ensure you have a well-maintained coolant system.  If you’re cutting dry, don’t panic!  Just make sure your cutoff wheel is designed to be used dry.

    Technical Considerations


    Some of the most common issues seen with diamond cutoff wheels include chipped products, prolonged production time, and premature wear. However, prolonged production time, as stated in Tip #2, is one of the most cost-effective solutions to waste reduction. Remember: err on the side of caution, take your time, and assess your coolant system!

    Cutoff wheel slicing barstock
    Whether you are looking for general guidance or are ready to get a quote, we are dedicated to helping you find the right solution – and if we can’t provide the exact wheel you need, we will let you know. We hope you’ll explore the ways our team can help your business stay ahead of the competition.