Stainless steel is a tough material. Unlike regular steel, it has chromium, which is hard and corrosion-resistant. However, if you want to cut it with an angle grinder, you need to incorporate special techniques. Wrong movements will end up with rough edges and damaged material.
Using an angle grinder effectively requires understanding techniques to prevent overheating, warping, and premature disc wear. In this guide, we will show you how.

1. Benefits of Using an Angle Grinder for Cutting Stainless Steel

Cutting stainless steel with an angle grinder gives you several benefits. Below, you will read some in detail.

Quick Setup and Cutting
Right out of the box, angle grinders are ready to work. Just pick your cutting disc, check it’s tight, and you're good to go. No need to mess with complicated setups or wait for machines to warm up. Most models have a simple lock-on switch and a side handle you can adjust. You can be cutting within minutes of picking up the tool.

High Mobility
These power tools are real workhorses you can take anywhere. Most weigh between 4-8 pounds, making them easy to carry. The cordless ones are even better - they'll work wherever you are. Need to cut pipes in tight spots? No problem. Working up high on scaffolding? The grinder goes with you. You're not stuck in one place like with big shop tools.

Adaptability to Irregular Shapes
This is where angle grinders really shine. Need to cut a curved section in a stainless steel sink? Done. Working with rounded pipes? Easy. The slim profile of the cutting wheel lets you follow almost any line you draw. You can even flip the grinder upside down for tricky spots. Most other tools can't match this flexibility.

Reduced Material Waste
When you know what you're doing, an angle grinder cuts clean and straight. The thin cutting discs (usually about 1/16 inch) mean you lose very little material in the cut. Plus, you can see exactly where you're cutting - no guessing. Think about expensive stainless steel sheets - every saved inch means money in your pocket.

Minimized Heat-Affected Zone (HAZ)
Here's something really important for stainless steel work. Angle grinders, when used right, don't overheat the metal much. Run the tool at the right speed, keep moving, and the cut stays pretty cool. This means:

1. No blue heat marks around your cuts
2. Metal doesn't warp or bend
3. The stainless steel maintains its structural integrity.
4. Your finished work looks professional.

Each cut is fast enough that heat doesn't spread far into the metal. Compare this to some other tools that can leave wide heat-affected areas that weaken the steel.

2. Type of Angle Grinders Suitable for Cutting Stainless Steel

Different-size angle grinders suit different stainless steel jobs. Choose the right size for safe and efficient cutting.

Corded Angle Grinders

These are workshop staples. They plug directly into a wall outlet (usually 120V). This provides consistent power. Motor amperage ranges from 8 to 15 amps. This corresponds to strong torque and cutting power. High amperage lets them cut dense materials like stainless steel, even thick pieces.
Direct power means no battery charging. This is ideal for continuous, heavy use. They typically use AC motors with brushes. They are less expensive than cordless models.  However, the cord limits movement. It requires careful management. You may need extension cords in larger spaces.

Cordless Angle Grinders

These offer unmatched portability. They use lithium-ion batteries. These are typically 18V or 20V (max). These voltages are the battery's maximum. The voltage decreases as the battery is used. Modern batteries offer similar power to many corded models. This is especially true for higher voltage tools. Brushless motors are becoming common.
They offer better efficiency. They also have longer runtimes and need less maintenance. No cord means you can work anywhere. This includes remote locations, elevated areas, and tight spaces. Battery capacity is measured in amp-hours (Ah). This affects runtime.
Many brands offer interchangeable batteries. This works across their tool lines. This is very convenient. They cost more upfront. But the cordless convenience and improving batteries make them a good choice.

ONEVAN Cordless Angle Grinders

ONEVAN cordless angle grinders offer versatile performance. They handle grinding, cutting, sanding, and polishing on metal and masonry. Cordless design provides excellent portability. You can work freely without power cords.
Below are our two most popular cordless angle grinders:

Product 1: ONEVAN 125mm Cordless Angle Grinder
ONEVAN angle grinders are popular power tools for metal cutting and surface grinding. The 125mm cordless model offers 2000W of power through a brushless motor. It runs from 3000-20000 RPM with 6-speed settings. Detail work benefits from the variable speed control. The cordless design helps users move freely. The grinder's 81 dB noise level makes it good for indoor work.
Suitable Applications

1. Metal Grinding and Cutting: With a maximum output power of 2000W and a speed range of 3000-20000 RPM, this tool is ideal for grinding and cutting metal surfaces.
2. Construction and Renovation : Its thick protective cover and overload resistance make it highly reliable for construction and renovation tasks, capable of handling heavier workloads.
3. Craft and Fine Work: The six-speed gear adjustment allows users to finely tune the tool's speed based on different materials and requirements, making it suitable for detailed work.

Product 2: ONEVAN 76mm Cordless Angle Grinder
The ONEVAN 76mm angle grinder is a cordless and powerful tool. It uses a brushless motor which spins up to 20,000 RPM. You can change the speed so you can cut different materials easily. It cuts up to 16mm thick. A dust shield and LED light make work safer and easier to see. It can spin forward and backward.
Suitable Applications

1. Wood and Metal Cutting: With a maximum cutting capacity of 13.5 mm (with dust shield) and 16.0 mm (without dust shield), this tool is well-suited for cutting both wood and metal.
2. Precision Cutting: The infinitely adjustable speed control allows users to finely adjust the tool's speed to meet specific project needs, making it ideal for tasks requiring high precision.
3. Small Projects and Detailing: Due to its smaller diameter and lighter weight, this tool is better suited for small projects and detailed work, facilitating precise operation.

In summary, the ONEVAN 125mm angle grinder is more suitable for heavy-duty grinding and cutting tasks, while the ONEVAN 76mm angle grinder is better for small and precise cutting applications.

Mini Angle Grinders

Mini-angle grinders usually come with 4-inch discs, making them perfect for precise work. They're light enough to handle with one hand, though you should always use two for safety. The small size lets you get into spots bigger grinders can't touch. They're amazing for working on things like stainless steel sinks or thin sheets where you need careful control. The smaller motor means you can't push them as hard as bigger grinders, but that's not what they're made for. They're all about control and precision.

Heavy-Duty Angle Grinders

These big 7 to 9-inch grinders are serious tools for serious work. They pack huge motors, usually 13 amps or more, and they're built like tanks. The bigger disc means deeper cuts and faster work on thick stainless steel. They're heavier, but that extra weight actually helps make straighter cuts. Professionals love them because they can power through tough jobs quickly. They cost more, and they're harder to handle in tight spots, but when you need to cut thick stainless steel all day, these are your best friends.

Specialty Angle Grinders

These are the problem solvers. They're built for those jobs that regular grinders won't do. Some have super-slim heads for getting into narrow gaps. Others have long necks for reaching deep into the pipework. They often come with specialized safety features designed for particular applications.
They're usually more expensive, and you might not need one for regular work. But when you've got a tricky job that other grinders can't handle, these specialized tools are worth their weight in gold.

3. Tools and Materials Needed for Cutting Stainless Steel with an Angle Grinder

Cutting stainless steel requires specific tools and safety gear. This section outlines the essentials for a successful and safe cutting experience. Learn how?

Essential Tools
First, you'll need a good angle grinder - go for one that feels comfortable in your hands. Most folks do great with a 4.5-inch model. The cutting discs are super important. Look for ones specifically made for stainless steel - they'll have "inox" written on them.
These are thinner and tougher than regular discs. Use a soapstone marker, as it works well on stainless steel without causing scratches. You'll want some clamps to hold your work steady - at least two good C-clamps or quick-grip clamps. You also need a table that won't wobble. Subsequently, get a measuring tape for marking your cuts. Keep some cleaning rags.

Safety Gear
This part's really important - don't skip it. You need good safety glasses - not the cheap kind, but ones that wrap around your eyes. Those tiny metal bits fly everywhere. Get a face shield, too - wear it over your safety glasses. Your lungs need protection, so grab a good dust mask rated for metal work. The noise is no joke - get ear protection that fits well.
You'll want thick gloves to use for metalwork. Also, do not forget to wear long sleeves and pants. Generally, it is made from tough materials like denim or canvas. Steel-toed boots are smart. Keep a fire extinguisher nearby - hot metal sparks can start fires. Some people like wearing a leather apron, too - it's not just for looks; it really protects you from sparks and hot bits.

4. Preparing for Cutting Stainless Steel with an Angle Grinder

Proper preparation is essential for safe and accurate stainless steel cuts. This section covers key steps before you start grinding.

Selecting the Right Cutting Wheel
The cutting wheel makes all the difference. For stainless steel, you want a wheel that says "inox" - that means it's made specially for stainless. These wheels are super thin, usually about 1mm. They're made with special stuff that keeps the steel from getting too hot when you cut.
Don't try to save money here - cheap wheels wear out fast and can be dangerous. Get a couple extra wheels, too - they wear down pretty quickly on stainless steel. A 4.5-inch wheel is perfect for most cutting jobs. Look at the speed rating on the wheel - it needs to match or be higher than your grinder's speed.

Setting Up the Workspace
First of all, you need a clean, flat space to work. Your workbench should be solid - any wobble will mess up your cuts. Moreover, you need good lighting - and also keep the floor clean and dry - you don't want to slip while using the grinder. Set up in a place with good airflow - cutting makes dust and sparks. Keep any combustible materials far away from your work area. Similarly, keep your tools laid out toa access them effortlessly.

Marking the Cutting Line
Take your time with this part. Clean the steel really well first - any dirt will make your marks messy. Use a soapstone marker or special metal marker - don't use a regular pen or pencil. If you're cutting straight lines, use a metal ruler or straight edge.
Clamp it down if you can - it helps keep things steady. Make your marks clear and bold - you need to see them while cutting. If you're doing complex cuts, draw the whole thing out first. Double-check all your measurements - cutting stainless steel is a one-shot deal.

Preparing the Stainless Steel Material
Clean everything really well. Any dirt or oil on the steel can mess up your cut. Check for any dents or dings that might throw off your cutting line. If the steel is long, support both ends to prevent sagging. Clamp it down tight - stainless steel likes to vibrate when you cut it.
Put some wood blocks under thin sheets to keep them from flexing. If you're cutting pipe, use V-blocks to hold it steady. Make sure nothing's going to move when you start cutting. Some folks like to put masking tape along the cut line; it can help prevent scratches.

5. Cutting Stainless Steel with an Angle Grinder

Step-by-Step Guide for Cutting Stainless Steel

1. Safety First: Wear safety glasses. Use gloves. Wear hearing protection. A face shield is recommended for extra protection.
2. Mark the Cut: Use a marker or scribe to mark your cutting line clearly.  Accuracy is important.
3. Secure the Workpiece: Clamp the stainless steel firmly. A vise or clamps work well. This prevents movement and kickback.
4. Choose the Right Disc: Use a thin cutting disc. It should be designed for metal or specifically for stainless steel. Thinner discs cut faster and cleaner.
5. Starting the Cut: Hold the grinder firmly with both hands. Start at a shallow angle to score the metal. Then, gradually increase the angle to cut through.
6. Cutting Technique: Apply steady, even pressure. Let the disc do the cutting. Please do not force it. Forcing can cause the disc to break.
7. Cooling (Important): For thicker stainless steel, use cutting fluid or lubricant. This reduces friction and heat buildup. Overheating can discolor the metal and shorten disc life.
8. Finishing the Cut: After cutting, the edge will be rough. Use a grinding disc, flap disc, or file to smooth the edge. This removes burrs and sharp edges.

Techniques for Different Thicknesses of Stainless Steel

When working with thin stainless steel (under 1/16"), it's crucial to use a very thin cutting disc, ideally 0.040" or thinner. Apply light pressure during the cut to minimize warping and excessive heat buildup. Utilizing a higher RPM on your grinder can also be beneficial.
For medium stainless steel (1/16" to 1/8"), a standard cutting disc (around 1/16" or 0.060") is suitable. Moderate pressure should be applied, and the use of cutting fluid is highly recommended to manage heat effectively. When dealing with thick stainless steel (over 1/8"), opt for a thicker cutting disc up to 1/8".
Apply firm and consistent pressure throughout the cut. Generous application of cutting fluid is essential to dissipate heat. For very thick material, multiple passes may be necessary. The key is to avoid excessive heat buildup, which can damage both the stainless steel material and the cutting disc.

Techniques for Different Shapes and Cuts

For straight cuts, a straight edge—like a metal ruler or square—needs to be your guide to a clean, accurate cut. Make sure the guide is tightly clamped so it does not move when cutting. When making curves, the rule of thumb is to use multiple shallow passes, gradually following the desired curve.
This technique prevents the disc from binding or breaking. Smooth and controlled movement of the grinder is crucial. For angle cuts, pre-mark the angle precisely before starting. Adjust the grinder's angle accordingly and maintain a steady hand and consistent angle throughout the cut.
For creating notches and intricate cuts, using smaller-diameter cutting discs is recommended. These smaller discs allow for tighter curves and more detailed cuts. Taking your time and focusing on precision is key for intricate work.

How to Navigate Curves and Angles in Stainless Steel

Cutting curves needs care. Use small, overlapping cuts. This, in turn, makes a smooth curve. Don't push the disc sideways; this can cause kickback or break the disc. Instead, keep a steady hand and let the disc do the work.
Cutting angles needs accuracy. First, mark the angle before you cut. Then, keep the grinder at the right angle. A bevel gauge, for instance, helps check the angle. This makes the cut more accurate.

Techniques for Making Straight vs. Intricate Cuts

Straight cuts need accuracy. Therefore, use a guide. A ruler or square, for example, works well. Clamp it down. Look at the cutting line and guide; this keeps the cut straight. Also, use even pressure. Don't push too hard or too soft.
Intricate cuts need control. Thus, use smaller discs; they are easier to move. Next, take your time; don't rush. Use many light passes; this makes the cut cleaner. Finally, focus on control and be precise.

6. Common Mistakes to Avoid for Cutting Stainless Steel with an Angle Grinder

Prevent problems by knowing what to avoid. This section highlights common errors when cutting stainless steel.

Selecting the Wrong Disc
Using the wrong cutting disc is a common mistake. For instance, using a grinding disc for cutting will be inefficient and dangerous. Therefore, always choose a thin cutting disc specifically designed for metal or, even better, for stainless steel. Additionally, consider the disc's diameter and thickness. A thinner disc cuts faster and cleaner, especially on thinner material. Conversely, a thicker disc is more suitable for thicker stainless steel.

Inadequate Safety Measures
Not enough safety precautions are a big mistake. Always wear the right personal protective equipment (PPE). This includes safety eyeglasses to protect your eyes from flying debris. Also, wear gloves which can protect your hands from sharp edges and hot metal. In addition, you should wear hearing protection, as the noise of the grinder can damage hearing. Lastly, I highly recommend using a face shield for extra protection on the face.

Overlooking Cooling Needs
Ignoring the need for cooling is another frequent mistake. As a result, friction from cutting generates significant heat. This heat can discolor the stainless steel, warp the material, and shorten the disc's lifespan. Therefore, for thicker materials or longer cuts, use cutting fluid or lubricant. This helps dissipate heat and ensures a cleaner cut.

Applying Excessive Pressure
Applying too much pressure is a common error. This can cause the disc to break, which is extremely dangerous. Instead, let the disc do the work. Apply steady, even pressure, but don't force it. The grinder's motor and the disc's cutting action should be sufficient to cut through the material.

Poor Material Support
A common one is insufficient material support. If the stainless steel isn’t properly clamped, it may shift while being cut, which causes inaccurate cuts or even kickbacks. So, always secure the workpiece in a vise or use clamps to keep it from moving. Thus guaranteeing you a stable and safe environment for cutting.

Ignoring Grinder Maintenance
Neglecting grinder maintenance is a common problem. As a result, a poorly maintained grinder can be less efficient and more prone to problems. Regularly check the grinder for loose parts or damage. Also, inspect the power cord for any fraying or damage. Finally, replace worn-out discs promptly. Proper maintenance ensures that the grinder operates safely and efficiently.

7. Post-Cutting Maintenance for Cutting Stainless Steel with an Angle Grinder

After cutting, proper maintenance ensures a clean finish and prevents corrosion. This section outlines essential post-cutting steps.

Cleaning the Cut Edges
Cleaning removes burrs, sharp edges, and metal bits. Use a grinding disc for big burrs. A flap disc smooths the edges. A file shapes and deburrs precisely. A wire brush removes loose particles and polishes them. Abrasive pads or polishing compounds create a finer finish.

Inspecting the Cut
Check the cut for accuracy and finish. Compare the cut to your markings. Look for burrs, unevenness, or discoloration. Check for scratches or dents. Fix any problems you find.

How to remove burrs and sharp edges?	Use a grinding disc, flap disc, or file.
How to remove loose metal particles?	Use a wire brush.
How to achieve a finer, smoother finish?	Use abrasive pads or polishing compounds.
How to check the cut for accuracy?	Compare the cut to your markings. Use a ruler or square.
How to identify imperfections in the cut?	Look for burrs, unevenness, discoloration, scratches, or dents.
What to do if imperfections are found?	Fix them using the right method. Use tools like grinding discs, files, or polishing compounds.
How to prevent corrosion after cutting?	Clean the edge. Use a protective coating or sealant for stainless steel.
What tools are best for cleaning cut edges?	Grinding discs, flap discs, files, wire brushes, abrasive pads, polishing compounds, and safety gear. Choose the tool based on the finish you want and the size of the burrs. A flap disc blends and a file removes small amounts of material.

8. Conclusion

Angle grinders offer fast, portable, and adaptable stainless steel cutting. They minimize waste and heat damage. Choose the right grinder and disc. Prioritize safety. Use correct techniques. Maintain your cuts. This ensures clean, accurate, and professional results.

9. FAQs

1. What angle grinder is best for cutting stainless steel?
You should get a 4.5-inch grinder. It's easy to use and powerful enough. Corded is good for long jobs. Cordless is good for moving around. Bigger grinders are for very thick steel. Small grinders are for fine work.

2. Can I use an angle grinder for all types of stainless steel?
Yes, on most types. You should change discs or use cutting fluid for some harder types. A standard stainless steel disc usually works.

3. How thick can stainless steel be cut with an angle grinder?
A 4.5-inch grinder can cut about 1/4 inch thick steel. For thicker steel, use a bigger grinder and make more than one cut. Control heat when cutting thick pieces.

4. Is there any alternative to using an angle grinder for cutting stainless steel?
You can incorporate a metal cutting saw, plasma cutter, or hacksaw. Angle grinders are good because they are fast, useful, and not too expensive.

5. What should I do if the cutting wheel gets stuck during the cut?
Turn off the grinder right away. Don't try to force it out while it's running. This is very dangerous. Once it stops, carefully try to wiggle it free. Check the disc for damage before using it again. A stuck disc means you pushed too hard or cut at the wrong angle.