Flap discs, also known colloquially as flapper wheels, have a design suited for right-angle grinder applications. A flap disc is an abrasive product found in the coated abrasive family. Fresh, sharp abrasive grains are revealed when the flap discs wear away. The Flap Disc is a revolutionary hybrid coated abrasive that combines the stock removal powers of a depressed center wheel with the surface finishing abilities of a resin fiber disc. As a result, abrasive tools that can both grind and finish is produced.
Construct of flap disc
Flap discs are constructed from a succession of coated abrasive flaps attached to the top surface of a disc. The discs are made up of many layered, overlapping sections of abrasive material or‘flaps’. These flaps are formed of a polycotton or polyester backing material to which abrasive grains are adhered, these are then layered and bonded to a backing plate. The backing plate provides stability to the flap disc and imparts its own unique properties to the product.
Materials of flap disc
When a facility is choosing angle grinder flap discs, it’s essential to consider factors like shape, material, density and abrasive grain type and size. The choice of material for a flap disc usually depends on the application and workpiece material in question. Below are a few common types of flap disc materials:
- Zirconia alumina
A disc made from aluminum oxide has a hard, durable grain and a strong initial cut rate, and it offers fast stock removal and consistent performance. Aluminum oxide is ideal for workpieces made of materials such as steel and cast iron, as well as for all-purpose use. It is not shelf-sharpening, however — its single crystals will dull during use. Overall, it provides a blend of performance and value.
A flap disc made from 100% zirconia alumina allows for aggressive stock removal and high-performance edge grinding. Zirconia alumina is self-sharpening, and it holds up exceptionally well under high temperatures and pressures. With proper use and maintenance, it provides a rapid cut and long lifespan. It is ideal for workpieces made from cast iron, carbon steel, structural steel and stainless steel.
Ceramic grains have a unique microcrystalline structure that is highly friable at high pressure and therefore is said to be self-sharpening. Newly exposed sharp edges are continually exposed to the surface of the workpiece-making ceramic grained abrasives stay sharper and more effective over a long period of time. As it does the job quicker, the heat build up in the ceramic grain is lower, therefore these abrasives tend to cut at a cooler temperature, which reduces glazing and improves their overall efficiency.
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What are the different types of flap disc?
Flat discs and conical discs are the two most prevalent varieties of flap discs, also known as T27 vs T29.
- The Type 29 Flap Disc also known as Conical flap discshas an angled form for optimum surface contact and is ideal for more vigorous removal.
- Type 27 flap discs also known as flat flap discs, grind well at shallower angles ranging from 0 to 15 degrees. They are ideal for smooth finishing and blending on flat surfaces and can handle minor shapes.
Features of flap disc
They provide aggressive stock removal or precise blending and finishing depending on the operator’s needs. They offer exceptional versatility, maneuverability and lower vibration and noise levels than grinding wheels. Flap discs are excellent choices for many applications because they allow the operator to perform grinding and finishing in one efficient time-saving, cost-lowering step. They grind like hard grinding wheels but are easier to control so you reduce the risk of gouging the workpiece, and they remain usable even after an area of abrasive wears out because new abrasive is exposed. They also tend to have a softer feel than grinding wheels, and they reduce the risk of removing too much material from the workpiece with overaggressive grinding.
Various flap discs are now available for usage on various surfaces:
flap wheel for wood： Flap discs are excellent tools for dealing with wood. The flap discs intended for use on wood are comparable to those intended for use on metal. Aluminum oxide grits can be used in wood applications. For wood, use the flap discs on your angle grinder in the same way you would a grinding wheel. Start with a strong grit and work your way up to the lighter grits (100+) for a final finish to avoid severe scratches. To produce a furniture-grade surface, sand using 120, 150, 180, and 220 grit wood sandpaper.
Flap discs for metal: Do you have a corroded metal piece that you know you can salvage? Do you have old, chipped paint on your automobile that you want to remove to give it a fresh look? Flap discs, particularly non-woven discs, are excellent for removing paint and rust. Non-woven flap discs or those containing aluminum oxide can be used for paint or rust removal. Binic offer best flap disc for metal.These flap discs, like other flap discs, may grind and finish in a single operation while providing a smooth and controlled grind. Also have flap disc on stone.
Benefits of flap disc
- The lightweight design helps to decrease operator fatigue.
- Simple to use—requires very little surface pressure.
- Cool cutting allows for mild contouring while preventing scorching.
- A longer lifespan. Due to the overlapping flap architecture, it may withstand wear up to 10-15 times longer than standard fiber discs.
- Metal removal that is aggressive. Type 27depressed center wheels with increased safety (does not require tool safety guards).
- Consistent performance since fresh granules are constantly exposed during the product’s life.
- Reduces downtime and finishing expenses with a one-step grind and finish.
- A conical grinding angle ensures maximum contact between the work item and the disc surface.
- The tough structure enables forceful edge grinding.
Purchasing Your Flap Discs
You have several alternatives when it comes to purchasing flap discs. However, working with a respectable organization that cares about you and your project will help you get a better outcome. When experimenting with new instruments, such as a flap disc, wire brush attachment for angle grinder, cutting wheel and sanding discs for china, you should also feel comfortable asking for samples. If you still have question about aluminum oxide vs zirconia flap disc, or others question, feel free to contact Binic- coated abrasive manufacture.