How To Cut Metal Tubes With An Angle Grinder ?

Discover the art of cutting metal tubes using an angle grinder with a diamond saw blade. This versatile tool offers precision and efficiency, making it a favorite among professionals and DIY enthusiasts. Our article provides essential tools, safety precautions, step-by-step instructions, and tips for clean cuts. Unleash your metalworking potential and create custom shapes and dimensions with confidence and ease.

diamond blade for metal


What is metal tube cutting

Cutting metal tubes is necessary to fit them to specific dimensions or to create custom shapes. There are many methods for cutting metal tubes, an angle grinder is often the preferred tool because it is versatile, portable, and can cut through a range of metals with ease. Additionally, angle grinders are relatively affordable, making them a practical choice for both professionals and DIY enthusiasts. The diamond saw blade on an angle grinder is thin and durable, making it ideal for precision cutting, while the speed and power of the tool allow for efficient cutting even in thick metal tubes.

Preparations for Using Angle Grinder to Cut Metal Tube

Cutting metal tubes can be a challenging task that requires some knowledge and skill, as well as the proper tools and safety precautions. Now, we will explore how to cut metal tube with an angle grinder, covering the necessary tools and safety equipment, the steps involved, and some tips and tricks for achieving clean, precise cuts.

1. Tools and Safety Equipment

Before starting to cut metal tubes with an angle grinder, it is essential to have the right tools and safety equipment. Here are some of the tools and safety equipment that you will need:

  • Angle grinder: An angle grinder is a versatile power tool that can be used for cutting, grinding, and polishing. It consists of a motor that drives a spinning abrasive disc, allowing you to cut through metal tubes quickly and efficiently. Angle grinders are available in different sizes and power ratings, and you should choose one that is appropriate for the size and thickness of the metal tube you want to cut.
  • Diamond saw blade: Angle grinders can be fitted with various types of blades, including abrasive discs, cutoff wheels, and diamond blades. For cutting metal tubes, a diamond saw blade is the best option as it is designed to cut through hard materials quickly and efficiently. Diamond blades are available in different sizes and thicknesses, and it is important to choose one that is compatible with the angle grinder.
2. What kind of diamond saw blade is suitable for metal tube cutting?

The ideal type of diamond saw blade will depend on the type of metal tube you’re cutting, as well as the thickness of the tube and the equipment you’re using. Here are some options to consider:

  • Continuous Rim Diamond Saw Blade– This type of blade has a continuous, smooth rim with diamonds embedded in the edge. It provides a clean, smooth cut and is suitable for cutting thin-walled metal tubes.
  • Segmented Rim Diamond Saw Blade– This type of blade has a segmented rim with gaps between the diamond segments. It is suitable for cutting thicker metal tubes and provides a faster cutting speed than continuous rim blades.
  • Turbo Diamond Saw Blade– This type of blade has a serrated rim with turbo segments that provide faster cutting and longer life. It is suitable for cutting thick-walled metal tubes and can handle harder materials.

When choosing a diamond saw blade for metal tube cutting, make sure to consider the diameter of the blade, the arbor size, and the maximum RPM of your equipment.

3. Safety measure
  • Safety glasses: Safety glasses are essential to protect your eyes from flying debris and sparks while cutting metal tubes. Make sure that the glasses fit well and provide adequate protection.
  • Ear protection: Angle grinders can be loud, and prolonged exposure can damage your hearing. Wearing ear protection is crucial to prevent hearing loss.
  • Gloves: Gloves can protect your hands from cuts and burns while handling the metal tube and the angle grinder. Choose gloves that are comfortable and provide a good grip.
  • Dust mask: Cutting metal tubes can produce a lot of dust and debris that can be harmful to your lungs. Wearing a dust mask is necessary to prevent breathing in these particles.
  • Cutting guide: A cutting guide is a tool that helps you make accurate cuts in your metal tube. It ensures that your cuts are straight and even, which is important for a professional finish.


Steps to Cut Metal Tube with Angle Grinder

diamond saw blade

Now that you have the right tools and safety equipment, let’s look at the steps involved in cutting metal tubes with an angle grinder.

  1. Prepare the Metal Tube:

Before cutting the metal tube, you need to make sure that it is clean and free of any debris or rust. Use a wire brush or sandpaper to remove any rust or debris, and then wipe the tube clean with a cloth.

  1. Measure and Mark the Cut:

Use a measuring tape to determine the length of the metal tube that you need to cut. Mark the tube with a pencil or marker, making sure that the mark is straight and accurate. You can also use a square to ensure that the cut is perpendicular to the tube.

  1. Clamp the Metal Tube:

Use a vise or clamps to secure the metal tube firmly in place. Make sure that the tube is stable and does not move while you are cutting.

  1. Put on Safety Equipment:

Put on safety glasses, ear protection, gloves, and a dust mask before turning on the angle grinder.

  1. Attach the diamond saw blade:

Make sure that the angle grinder is turned off and unplugged before attaching the diamond saw blade. Follow the manufacturer’s instructions for attaching the disc, making sure that it is securely in place.

  1. Turn on the Angle Grinder:

Turn on the angle grinder and let it run for a few seconds. This will allow the diamond saw blade to reach its full speed and ensure a smoother cut. Hold the angle grinder firmly with both hands and slowly lower the diamond saw blade onto the metal tube. Make sure that the diamond saw blade is in contact with the metal tube before you start cutting.

  1. Start Cutting:

Once everything is in place, it is time to start cutting the tube. It is essential to keep a firm grip on the angle grinder and to apply constant pressure as you move along the cut line. If the blade starts to slow down or become less efficient, it may be time to replace it with a new one. It is also important to check the blade regularly for signs of wear and tear.

  1. Finishing:

Once the cut is complete, it is essential to check the edge of the tube for any sharp edges or burrs. These can be removed using a file or a sanding disc. It is also important to clean up any debris and dust generated during the cutting process.


Other questions

Q: How often should you replace the diamond saw blade when cutting metal tubes with an angle grinder?

A: The frequency of blade replacement will depend on the frequency of use and the thickness of the metal tubes being cut. It is recommended to inspect the blade regularly and replace it if it becomes dull or damaged.

Q: What is the maximum thickness of metal tube that can be cut with an angle grinder and diamond saw blade?

A: The maximum thickness of metal tube that can be cut with an angle grinder and diamond saw blade will depend on the power of the angle grinder and the size and type of the diamond saw blade being used. It is important to consult the manufacturer’s specifications and use the appropriate equipment for the task at hand.

Q: What is the difference between a diamond saw blade and a regular saw blade when cutting metal tubes with an angle grinder?

A: A diamond saw blade is specifically designed to cut through hard materials like metal and concrete, whereas a regular saw blade is best suited for softer materials like wood.



Cutting metal tubes with an angle grinder and diamond saw blade is an efficient and precise method when done properly. Safety precautions are necessary to prevent injuries, and it is recommended to use a clamp or vise to secure the metal tube firmly. Different types of diamond saw blades are available for different types of metal and thicknesses, and it is essential to choose the right blade for the task at hand. It is also recommended to inspect the blade regularly and replace it if it becomes dull or damaged. With proper technique and equipment, curved shapes or angles can be cut, and other types of metal can also be cut using an angle grinder.

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