I've searched about but can't find a decent picture or description, so was just wondering if someone could help explain when I should stop using a grinding disc?
They are usually tested to break at about double the running speed so theoretically you won't have issues. But I wouldn't run something not designed for purpose, and I dare say any professionals insurance would probably be voided should the worst happen. But it's all how comfortable you feel using them I suppose. Plus I don't pay for them, work does.
If you wear a 9" disc down enough to fit in the 4.5" guard then the rpms will be more correct on the 4.5" grinder than it would on the 9" you took it off.
It's the linear velocity at the edge that's important, so as the disk wears down the speed at the circumference decreases for a given rpm, so it's safe to use in a 4.5" grinder at a higher rpm when it's worn down enough to fit.
As for the OP's original question, some discs have a 'use-by' date on them. If it has chunks missing from the edge or is cracked then throw it away. Break it in half so nobody is tempted to pick it out of the bin and use it.
Some years ago i was cutting some engine beds out of a GRP yacht using a 4.5" grinder & stone cutting discs, my grinder expired so i borrowed a friends one, it was a dreadful italian thing & he habitually used 4.5" discs on it, The grinder ran fast at 12,000 rpm & guess what the discs were rated at 10,000, one blew on me as i was cutting looking down at the edge of the disc. I was wearing a racal airstream powered respirator with polycarbonate face visor & a big shard/s of the blown disc broke the visor. That day the Airstream helmet paid for itself & i think if i had not been wearing it i may have had a white stick today.
Another bloke down the boatyard was cutting scupper holes out with a 9" grinder on a ferro boat, he was using the wrong discs & one burst. A third of the disc slid between his ribs under his arm & punctured his lung. He was lucky to survive.
I rest my case!
Blimey. Looks like my next purchase will be a face shield. I've been on a few other forums and have heard about discs exploding. My grinder goes up to 10,000rpm and the discs are Erbauer rated up to 13,300 rpm.
and presumably the guard wasnt fitted because if was it wouldnt have disintegrated in his face just spat it forward and out. been there done it and got the teeshirt and a few scars
Guard was on it, but the bits ricocheted of the bottom of the boat or something, there wasnt a lot of space & i was pretty close, it happened rather quick!
On a recent health and safety day at a quarry, the HSE guy talking about abrasive wheels recommended against full face shields. A recent incident involving a full face shield (as I also wear) and a burst cutting disc. The disc went up under the chin of the shield and bounced around on his face until it stopped spinning. Goggles wouldn't have held the disc in there and the initial impact would likely have been the only injury.
Food for thought although i think i will continue to take the risk due to the extra protection they offer in other areas.
I always respect the dangers of an angle grinder but being very stupid I removed the guard from it because it was in the way and never put it back. Very stupid I know,after seeing this video scared me big time.