In discussing flap discs' shape, we'll first want to consider their structure and composition.
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Unlike a standard grinding wheel, which consists of a uniform grinding surface made of abrasive grains bonded in place, a flap disc consists of a ring of overlapping flaps. These flaps hold coated abrasive grains &#; the same grains used in bonded-abrasive cutting and grinding wheels &#; that can grind and shape a workpiece during fabrication or blend and finish a weld.
Where cutting and grinding discs often have a fiberglass structure, in flap discs the grains adhere to a backing cloth often made of cotton, polyester or a blend. The abrasive cloth is cut into smaller strips and then layer the strips so they overlap one another to form the flap disc. A rigid back plating provides stability and support.
The two most common types of flap discs are flat discs and conical discs:
Flat flap discs, also known as type 27 flap discs, typically grind best at shallower angles between 0 and 15 degrees. They are optimal for smooth finishing and blending on flat surfaces, and they can handle slight contours.
Conical flap discs, also known as type 29 flap discs, have a saucer-shaped grinding surface rather than a straight one. They typically grind best at angles between 15 and 35 degrees. They enable aggressive stock removal by maximizing surface contact on flat surfaces.
In general, operators should choose conical flap discs for initial high-volume grinding and flat flap discs for precision refinements.
A few specialty shapes and styles are also available:
Trimmable flap discs differ from other types because they contain a trimmable composite backing that allows the operator to increase flap overhang. When used as intended, these discs offer flexibility and versatility needed for hard-to-reach areas such as fillet welds and irregular shapes. The backings also prevent unwanted marking of the workpiece.
Flap discs with aluminum backs contain a sturdy, permanent aluminum backing. This backing provides rigorous support in high-stress, heavy-duty applications such as pipeline fabrication.
Mini flap discs are significantly smaller than their standard counterparts, only about 2 or 3 inches in diameter. Their compact size makes them ideal for working in tight spaces and grinding hard-to-reach areas on the workpiece. A smaller, 2-inch mini disc can often effectively replace a blending disc as well. These discs contain a composite backing that provides standard support for a range of applications.
Angled flap discs have curved flaps that wrap around the edge of the backing plate, facilitating extensive flap-to-metal contact, enhancing operator control and allowing for a wider range of grinding angles. The curved flaps give these discs the contouring capabilities necessary for fillet welds and allow for access hard-to-reach areas for T-joint grinding. They offer the same robust grinding performance on flat surfaces.
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Flap discs also come in a range of sizes, generally from about 4 to 7 inches in diameter, with the mini discs smaller still. Smaller discs are designed for use on die grinders to provide smooth grinding and enhanced conformability in tight areas. will rotate more quickly and provide a faster cut rate, whereas larger discs will rotate more slowly. Larger-diameter wheels contain more abrasive, however, so with the right care, because of their size will cover larger areas and will last longer and provide a higher rate of stock removal over the life of the disc.
Flap disc shapes also differ in the width of the individual flaps. The industry standard for these flaps is about 25 millimeters, and some flap discs, including Weiler Abrasives' Tiger Paw high density and Big Cat discs, contain 30-millimeter flaps instead. The larger flaps provide a more expansive surface area for applications that require aggressive, high-volume grinding.
Grinding wheels are designed with sharp abrasive grains (various abrasive grits) and are used for grinding, cutting, and machining. Since grinding wheels are made of abrasives, they are also known as abrasive wheels.
This abrasive wheel remove excess material from metal, glass, wood, masonry, and concrete. Abrasive wheels are used with various power tools and industrial machines, such as angle grinders and bench grinders. Metal fabricators use different types of grinding wheels for different metalworking applications. Grinding includes Type 1, Type 27, Type 29, and Type 28 grinding wheels.
Type 1 or straight grinding wheels are the most common and general-purpose abrasive tools made of fiberglass discs/steel rings and fine abrasive grits. These wheels are available in both non-reinforced and reinforced forms. Type 1 grinding wheels are designed for the coarse and fine grinding of hard and soft steel, stainless steel, cast iron, aluminum, bronze, brass, concrete, stone, terrazzo, and ceramic material.
The straight grinding wheel is primarily angle grinders (both electric and hand-held), die grinders, and bench grinder attachments used for grinding and sharpening cutting tools. Aluminum oxide is the most common abrasive grain used in straight grinding wheels. Its strong, inexpensive, and break-resistant feature is perfect for general-purpose grinding and deburring applications.
Type 27 or depressed center grinding wheels are the most common tool. These metal grinding tools are designed to handle different hard grinding jobs ranging from heavy stock removal to abrasive mixing. Type 27 Grinding Wheels are a renowned grinding tool designed for rough granulation on different materials. These metalworking tools are commonly used in heavy machinery industries and in small hardware workshops.
Type 27 grinding wheels are a very popular group of general-purpose and specialized abrasive tools intended for rough grinding on a variety of materials. They are commonly used in construction, shipbuilding, metallurgy, foundry, engineering, chemical, and other industries and small workshops.
Read More: Grinding Wheel vs Flap Disc vs Sanding Disc
The Type 29 grinding wheel combines an abrasive wheel and a sanding disc. These semi-flexible wheels can aggressively remove material like a grinding wheel while blending and finishing like a sanding disc. These abrasive wheels tend to bend over curved surfaces when grinding, resulting in a smooth finish and gouge-free surface. The stock removal rate is higher than depressed center wheels.
Type 29 wheels are used for grinding and removing weld logs. These wheels are perfect for handling flat and curved surfaces. They can grind cooler. These wheels also have high steel, stainless steel, and aluminum stock removal rates. They are excellent metalworking tools for cutting and finishing a variety of metals at a time. Type 29 grinding wheels are also good for rust removal, deburring, weld grinding, blending, and finishing on contoured and flat surfaces.
Type 28 grinding wheels are also known as saucer depressed center cutting wheels, used to grind large surfaces and provide excellent finishing and sharpening. Additionally, these wheels also have fiberglass reinforcement. The Type 28 grinding wheel is made from excellent aluminum oxide and provides consistent performance at an affordable price.
Read More: How to Choose the Right Cutting Wheel
The Type 28 grinding wheel is used for stock removal, beveling and weld smoothing. These wheels also have good rigidity and a strong bond for long-lasting cutting power to cut stainless steel and hard and soft carbon steel easily. It is essential to choose the right abrasive wheel to get maximum output. Type 28 saucer wheels are designed with high-quality aluminum oxide for reliable performance at a low cost. Normal-sized, 1/4-inch grinding wheels are perfect for stock removal, weld smoothing, and beveling with a 90-degree right-angle grinder.
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