Flap disks and flap wheels come in a variety of shapes and sizes, and knowing which one is correct makes it difficult to choose the right product for your application.
For example, if you look at our flap disk and wheel product pages, you will see different product categories, all of which meet different needs and tasks.
Although we encourage you to use the app search to find the abrasive you need, today we will break down some common terms you will see on wheels and wheels to help you understand your choice.
What is a flap disc?
Flap Disc
- Flap discs are an alternative to resin bonded abrasive wheels and fiber discs. Due to changes in welding processes over the years (for example, smaller welds from TIG and MIG welding wires), fewer discs need to be removed from the disc compared to other processes (rod welding). With baffles, operators can still quickly remove welds and fuse / finish with minimal steps.
- The particles used in the flap discs (more on that below) are similar to those found in bonded abrasives, but layered in their structure, giving them a softer and more tolerant feel. Where the wheel requires a lot of experience, the learning curve of the flap disk is small and the “margin of error” is greater.
- This means they are ideal for grinding and finishing products simultaneously, which reduces costs and saves time. They are also quieter and run more smoothly than traditional grinding wheels. The remaining finish of the flap plate is also more like a “round” pattern.
There are several forms of backing you need to be familiar with on the flap plate. These include:
- Flap backing: polyester fiber, polyester cotton or cotton
- Polyester: Can withstand extremely high pressure without degrading the flaps. For extremely high cutting and edging
- Cotton: Used to achieve the goal of optimal fit and softness. Must be used under less pressure to maximize performance and life
- Polyester / cotton blend: The best of both worlds. Can withstand high pressures while still maintaining good cutting and finishing. Usually used as a starting point for flap disk operations for beginners
- Fiberglass-This is the most commonly used flap disk support. Glass fiber absorbs vibration and prevents any smearing
- Plastic — Two types of plastic are used in the flap plate:
- Non-trimmable plastic: Used in our Plus + product line, this product makes it easier for operators to use. This backing has less deflection and presents the grain to the workpiece very efficiently, maximizing efficiency
- Trimable plastic: The backing is easy to trim, allowing users to expose more abrasive material when needed to extend the life of the disc and change its shape / size to suit different jobs. Ideal for handrail applications and fillet welds where flap flexibility is important
The grain used in the flap disk determines the cutting, life and cost ratio of a particular disk.
You will find six different types on the disc, including:
Aluminium Oxide -Metal Grinding Flap Disc
Application:
- Mild steel, tool steels, plastic, primer,lacquers and wood.
- Cleaning of welding seams, deburring, chamfer,De-rust, preparatory works for lacquer of car-bodies, machines, swich boards, tank constructions, sanding of wooden surface such asparquet for furniture
Zirconia Aluminium Stainless Steel & Metal Flap Disc
Application:
- Work on steel, stainless steel(inox), weld seams, chamfering, surface grinding on steel.
Silicon Carbide – Stone Grinding Flap Disc
Application:
- For working on concrete, stone,tiles, ceramics, non-ferrous metals.
- Used on marble, granite, stone,concrete.
Ceremic Aluminium Oxide Stainless Steel & Metal Flap Disc
Can be consistent across a variety of grinding applications. When grinding on steel, stainless steel or aluminum, consideration should be given to choosing ceramic discs. Ceramics also tend to grind coolers to minimize discoloration while extending product life
2 in 1-Calcined Alumina Stainless Steel & Metal Flap Disc
Application：
- Mild steel, tool steel, plastic, primer, varnish and wood,
- Cleaning of welds, deburring, chamfering, rust removal, preparation of vehicle paint, machines, switchboards, tank structures, sanding of wooden surfaces (such as furniture parquet).
Plastic Backing Flap Disc
Application:
- Cleaning of welding seams, deburring, chamber,De-dust,preparatory workds for lacquer of carbodies, switch boards,tank constructions, sanding of wooden surface such as-parquet for urniture.
There are two advantages to using the scroll wheel on a disc, including:
- Each bezel attacks your project at a slightly different angle, avoiding common problems with discs, as the same scratches repeat on the surface of the entire project
- The main feature of a flap wheel is that the resulting surface finish is linear (or inline / frosted). This is particularly useful when matching the finish of existing materials after welding