An Essential for Metalworking: Best Angle Grinder
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Makita 4-1/2" Angle Grinder -
Hitachi 4-1/2" Angle Grinder -
Chicago Pneumatic Angle Grinder -
Makita BGA452 18-Volt LXT Lithium-Ion Cordless 4-1/2-Inch Cut-Off/Angle Grinder Kit -
Porter-Cable PCC61B 20V Max Lithium Cut off/Grinder -
Bosch 1974-8 7-Inch Large Angle Grinder -
DEWALT DWE4517 7-Inch 8,500 Rpm 4 HP Angle Grinder -
Milwaukee 6088-30 7"/9" 15 Amp Large Angle Grinder -
Makita GA9040S 9-Inch Angle Grinder Soft Start Technology -
Buyer's Guide
Angle grinders were first developed for use with welding, removing weld slag, excessive weld metal, and burrs from the metal. Since them, creative users have found a myriad of other uses for angle grinders, using them for everything from creating ornamental patterns in metal to finishing concrete work.
Angle grinders are built on a 90 degree angle to provide the best possible torque and the best user control. By running the motor through a 90 degree gearbox, the grinder’s torque is increased. This helps prevent the grinder from binding up when encountering difficult spots in the work. It also makes it possible for the user’s hands to be at a comfortable position, while providing a clear view of the grinding wheel to work piece contact.
For more information on what to look at in selecting the best angle grinder in 2022, check out our shaper buyer's guide. It will tell you the most important specifications to watch out for and what they mean to you.
Detailing the Best Angle Grinders of 2022
Makita 4-1/2" Angle Grinder - Best Angle Grinder Overall
Makita has a huge selection of all sizes of angle grinders. Amongst their small grinders, this model is the best. The 7.5 amp motor operates at 10,000 RPM in an all ball-bearing housing for long life. Like the Bosch, this one will run off of AC or DC current. The vents for the motor use a labyrinth construction, to keep dust and other particles out of the bearings and motor. A nice feature of this grinder is the extra-large, locking paddle switch, for comfortable operation. The gear housing can be rotated every 90 degrees, so you can select the angle which is most comfortable for you.
Hitachi 4-1/2" Angle Grinder - Runner Up
Hitachi’s grinder has a slide switch, which almost knocked it out of the list, but I decided that wasn’t fair to those who like slide switches. At 6 amps and 10,000 RPM, the motor is a bit smaller than the others and also the lightest grinder on this list at only 3.1 pounds. Add rubber over-molding on the barrel and you’ve got a high degree of operator comfort. The side handle is slightly canted towards the front, providing better leverage to the user. Hitachi has even made the brushes easily accessible for quick replacement. While replacing the five included wheels does require an included wrench, there is a spindle lock. The price on this grinder is incredible making it an attractive option for handymen everywhere.
Chicago Pneumatic Angle Grinder - Honorable Mention
While you can’t expect this budget Chicago Electric angle grinder to last as long as a Makita or Milwaukee, I’ve used one of these for several years. With the little bit of grinding I need to do when I’m welding, it seems to be adequate to the need. I’ve owned cheaper budget angle grinders from Harbor Freight but they never lasted as long as this one has. It has a paddle switch making it much easier to work with which anyone can appreciate. The six amp motor gives a maximum speed of 10,000 RPM, making it comparable with the Hitachi for power but weighs a bit more, coming in at 1.19 pounds. The kit comes with a spare set of brushes which is nice, especially since they are designed to be easy to replace.
Makita BGA452 18-Volt LXT Lithium-Ion Cordless 4-1/2-Inch Cut-Off/Angle Grinder Kit - Consider
I have to admit, I’m a little partial to Makita’s cordless tools. Maybe it’s because my first cordless drill oh so many years ago was manufactured by Makita. They were known for quality back then, and they still produce excellent quality tools now. This cordless angle grinder runs at 10,000 rpm, making it the fastest unit on our list meaning this extra motor speed will help you cut and grind faster. At 5.3 pounds, it’s not the lightest unit on our list but right at the middle road for weight.
As with all units in the LTX line, the high capacity battery will recharge in only 30 minutes, twice as fast as most other models. The included charger is chip controlled and has a cooling fan to extend battery life. Another nice feature about this tool is a built-in circuit which senses over-torque and will shut down the grinder to protect the device and the operator. The slender handle insures people with small hands or those wearing gloves can easily grasp and use this tool.
Porter-Cable PCC61B 20V Max Lithium Cut off/Grinder - Best Cordless Angle Grinder
Porter-Cable has upped the power on their cordless grinder a bit, going from 18 volts to 20 with the motor producing a very respectable 8,500 RPM for aggressive cutting of all surfaces. This tool only comes as a stand-alone unit, sans kit, battery or charger. If you are already using Porter-Cable tools, this can actually save you some money.
I really like this grinder handle which includes a knuckle protector to go with the comfortable, padded handle. A two finger switch is inside the protected area of the handle for easy tool control. There is a spindle lock on the grinder for easy wheel changes, as well as a three position side handle so you can place it where it is the most comfortable for your work style.
Bosch 1974-8 7-Inch Large Angle Grinder - Best Angle Grinder
I had a hard time making the decision to switch from Bosch’s 9” angle grinder to this model but what sold me on this model is the high speed performance. The 4 HP motor in this grinder is running at 8500 RPM, a full 2000 RPM faster than the 9” unit meaning it’s taking material off faster and getting your work done quicker; quite a selling point.
The guard system has quick keyless adjustment and for maximum motor protection, the motor windings are epoxy coated so dust can’t get in them. There are also service minder brushes which stop the grinder from working when they’re worn, preventing potential motor damage. Removable brush covers make changing out brushes a snap and the trigger is designed to help prevent accidental startups, a welcome safety feature.
DEWALT DWE4517 7-Inch 8,500 Rpm 4 HP Angle Grinder - Best Angle Grinder
It was tough deciding between this grinder and the Bosch for first place since both have a 4 HP motor and run at 8,500 RPM. What made the difference though was the weight with the Bosch being almost a full pound lighter than this angle grinder from DeWalt. Like the Bosch, the motor armature and field windings are epoxy coated to protect against dust and abrasion along with an automatic shutdown feature for when the brushes are worn down to prevent motor damage. A brush window allows quick and easy brush changes, the guard is adjustable without a key and the side handle can be set in two different positions depending upon your needs.
Milwaukee 6088-30 7"/9" 15 Amp Large Angle Grinder - Best Angle Grinder
This angle grinder from Milwaukee has a 4.2 HP motor running at 6000 RPM with overload protection so there’s plenty of power for heavy jobs without risking damage to the tool. The air intake for motor cooling is built with baffles to keep dust out of the motor housing. Both handles are rubber over molded providing a soft grip. Milwaukee has also provided external brush doors making maintenance a breeze while both the 7” and 9” guards feature tool-less adjustment.
Makita GA9040S 9-Inch Angle Grinder Soft Start Technology - Best Angle Grinder
Makita doesn’t provide a horsepower rating for their big angle grinder but it’s a 15 AMP motor so we can safely assume it offers comparable horsepower. The motor has a “soft start” feature, for smoother start-ups; if you’ve ever used a heavy duty angle grinder they can feel like they’re tearing your arms off when they start so it’s a nice feature to have. The rear handle rotates for better ergonomics and there’s soft over molded handles making this grinder a very comfortable tool to use overall. Like our other heavy-duty grinders, the motor armature is protected from dust for longer life and the guard is easily adjustable without any tools.
Buyer's Guide
Angle grinders are one of the few handheld power tools designed primarily for metalworking. However, they’ve since been found to be useful for a variety of other purposes. Replacing the grinding wheel with different mediums allows it to be used tasks ranging from concrete finishing to removing decals from vehicles.
The angle grinder is a fairly simple tool with an electric motor run through a right-angle gearbox. The output of the gearbox then becomes the arbor for attaching the grinding wheel or other medium. By using a right-angle gearbox, the tool becomes much more ergonomic to hold onto, making it both more comfortable to use and much easier to control.
Typically, they’re held two-handed, providing excellent control. The other thing the gearbox does is reduce the chance of the tool binding up from too much of a load being placed on it.
While simple, the angle grinder is a very effective tool. When used for metalworking, it’s used predominantly used for smoothing and grinding welds, removing weld splatter, slag, and excessive weld. The high tool speed and rough grinding medium allows it to work quickly.
A variety of grinding wheels and other attachments can be connected to a grinder, each of which is designed for working with particular materials and performing particular tasks. These include grinding wheels for different materials, metal cutting wheels, wire brushes, polishing bonnets and Scotchbrite pads for cleaning and paint stripping.
Of all the handheld power tools on the market, angle grinders provide the least protection for the user. The guards on these tools are minimal and only cover the back side of the attachment, the side facing the user. It’s typical to produce a large amount of sparks when using a grinder so protective goggles and gloves should be used. It’s also important to ensure the tool has come to a complete stop before setting it down.
Selecting a Grinder Size
While there are several sizes that angle grinders are made in, they basically fall into two categories, small and large. The small ones range from 4” to 5” and the large from 7” to 9”. Smaller grinding disks can always be attached to a grinder, but larger ones can’t. It’s also important to take into consideration the maximum speed of any particular attachment.
Grinders rotate at high speed and the attachment must be able to withstand the rotational force without coming apart. These attachments typically have the max RPM stated on them to provide the user the ability to properly selecting their attachments.
While two angle grinders may have the same rotational speed, that doesn't mean they’ll provide the same amount of cutting action. A larger grinder will be moving faster at the edge, as measured in feet per second than a smaller grinder moving at the same RPM. This makes the larger grinders cut faster, giving them preference for commercial use.
This increase in cutting size means that you should pick the largest grinder that you can reasonably fit within your tool budget. That will ultimately save you time and have the tool pay for itself.
What to Look For in an Angle Grinder
Power
When selecting a grinder, power and size are the two major considerations. The higher power allows you to put more pressure on the grinder, making a bolder cut. While speed and wheel size are important factors in grinding capability, the amount of pressure placed on the point of contact with the workpiece is important as well.
Comfort
Operator comfort is also an important factor when selecting a grinder. Tool weight, adjustable handle positions and over-molded rubber handles all play a part in operator fatigue. While not usually the number one factor when selecting tools, these factors shouldn’t be ignored.
Gear Greasing
When buying inexpensive angle grinders, one of the best things you can do is to open up the gearhead and fill it with grease. The gears themselves will probably be greased, but by adding more grease you will help to cool the gears and allow them to last longer.
Brushes
Of all power tools, angle grinders go through motor brushes faster than any other. This probably has to do with the fact that when these tools are used, they’re typically on for extended periods of time. Ease of brush replacement and availability of replacement brushes are both important factors for cases where the grinder will be used a lot.
Cordless Grinders
Besides the two different size ranges of angle grinders that are available on the market, there are also cordlessgrinders. These are only available in the smaller size range, as the larger grinding wheel requires more power to operate.
Cordless grinders are great if you are working on a remote site, but can be a bit of a hassle in a workshop. Generally speaking, when angle grinders are in use, they are on for an extended period of time. Even though cordless angle grinders use Lithium-Ion batteries, the batteries can only power the grinder for a certain amount of time. If you’re using the grinder continually, you will probably need a total of three batteries and two chargers to keep the unit operating constantly.
