How to choose the right grinder flap disc to save time and money
Choosing the right flap disc for metal grinding or finishing saves time and money. The best option also minimizes the risk of removing excess material and ensures the best finish. In particular, the flip-top disc provides fine mixing and finishing while still providing reliable grinding. These features make them a versatile and effective choice for many applications, including those involving thinner materials.
The type of grain used in the cutting of the adhesive sheet, the grinding and combination grinding wheel is also used for the flap, but the layered flap structure of the flap provides a softer, more tolerant feel. This makes the flaps ideal for grinding and finishing without the need to replace other products or 220 grit flap discs.
In order to select the right flap and maximize the effectiveness and longevity of the product, there are several key issues to consider:
- What material is being processed?
- What is the surface finish requirement for the finished product?
- Is there time, productivity and efficiency requirements?
- What is the labor and consumable cost involved?
Flap disc basic knowledge
The flaps use coated abrasive to adhere the grain to the lining. The cloth, usually cotton, polyester or blended material, is then cut into smaller flaps and then layered to form a flap.
As the grain depletes and loses its ability to cut, the flap wears, exposing the fresh, sharp grains below. If used properly, the abrasive flap disc can be used until the rag is almost worn to the backing plate.
The flaps are designed for use on right angle grinders at angles of 5 to 35 degrees. The Type 27 flap has a flat profile that works well in finishing and applications that require smaller grinding angles (eg 5 to 15 degrees). The Type 29 flap is slightly tilted for more aggressive large angle grinding.
Hard grinding discs may be a better choice when working requires more powerful movements or grinding on rougher surfaces, as in these high-grinding grinding applications, the flaps may be jammed. Live or tear.
Die options and disc size
To choose the right die, consider the finished soldering requirements. Keep in mind that the smaller the number, the thicker the gravel. Higher particle sizes provide better finish but less aggressiveness. Choose the highest grit that will complete the mission to ensure the best results.
The flaps are also available in standard density and high density options. High-density 220 grit flap discs are more cloth, thicker, softer and have a longer life. High-density flaps are a good choice for sanding on curved or irregular surfaces.
The disc size options range from 2 to 7 inches. 2″ and 3″ flaps are often used in place of hybrid discs and can be used up to 15 times. This can reduce the number of product conversions, increase productivity and significantly reduce overall cost of ownership.
Select abrasive
The performance of the disc is highly dependent on the type of abrasive used and the particle size of the abrasive. The three main types of grains used are: alumina, zirconia alumina and ceramic alumina.
The goal is to find a flap that meets the application requirements within the required time frame and budget.
Alumina provides a consistent, low cost product choice, but zirconia alumina flaps typically have maximum versatility at the lowest cost. For this reason, zirconia alumina flaps are probably the most common flaps used today.
Not all zirconia alumina flaps are the same. Some low cost options are a mixture of zirconia alumina and alumina particles. Other high performance options are 100% zirconia alumina grains. The cutting speed of these discs is maintained for a longer period of time and does not decompose quickly. Standard and high performance products are slightly more expensive than alumina flaps, but they have higher heat resistance, toughness and durability.
Note that high-performance flaps are more expensive, but can significantly reduce overall cost of ownership by minimizing conversions, reducing downtime and increasing productivity.
The third type of abrasive is ceramic alumina, which is the most expensive, but has the longest life and highest heat resistance. The particles of these grinder flap discs are designed to be broken to create new sharp edges. Ceramic flaps maintain their sharpness and cutting rate for long periods of time. Although ceramic 220 grit flap discs are more expensive, they often reduce overall cost of ownership when considering other factors. They are the best choice for grinding hard materials such as stainless steel, inconel, titanium, armor and grinding tool steel.
The right technology is the key
The right technology helps maximize the life and longevity of your disc.
Applying too much pressure on the flap can lead to premature wear or gouging, undercuts or heat build-up and fading. If you need to push hard to make the disc perform, you may need thicker gravel or other discs.
Applying too much pressure can damage the workpiece and can pose health and safety hazards. Allow the disc to do this to minimize the risk of stress-related injuries.
When using high quality cutting particles (such as ceramic alumina), it is important to use a powerful enough tool to maintain its rotational speed. Insufficient grinders can “get into trouble” under excessive pressure, which can reduce the ability of the grain to break and self-grind.
The baffle is designed to provide optimum performance over the entire width of the baffle. When grinding at too steep an angle, the operator and the baffle work harder because they do not use the entire width of the fabric. This also shortens product life as it increases the pressure on the bunnings flap disc. When the edge of the flap is worn prematurely, the operator often discards the disc, throwing away the abrasive material and value of many discs. This is most common for users who use a Type 27 (flat) disc for grinding at larger angles. Many times, simply switch to a Type 29 (tapered) disc to use the entire width of the baffle during the grinding operation, maximizing efficiency and reducing the use of the disc.
It is especially important when finishing thin materials to avoid removing too much metal because the metal creates weak points. Choosing the lowest performing discs, especially if tighter tolerances are required, can help prevent this.
If you are concerned about removing too much material too quickly or have special finishing requirements, it is best to start with a higher thickness (60 or 80) and if you need further attack, move down as needed.
The flaps are designed for the position where the glue can be seen from the 220 grit flap discs. After proper use, the disc will continue to cut until the glue is visible. Following this technique can save a lot of product costs every year.
Conclusion
Although the flaps are disposable, measures can be taken to extend their life and availability. It’s important to remember that a variety of options and configurations have been created to increase productivity, reduce downtime and save more cost. Please consult BINIC ABRASIVE– A professional flap disc manufacturer for advice on your needs.