Tuesday, October 22, 2013

How to choose correct flap discs ?


flap discs application 
As well known, there are many style flap discs in the market nowdays due to the non-copy advantages such like: lighter weight, easy control, less vibration & dust, grinding, blending and finishing with one product, etc . Absolutely we can take max benefits afforded by flap discs If understanding well all the variables and how they apply to your grinding & polishing workings.

BLUESHARK is professional manufacturer of flap discs with more than ten years experiences, we understanding and control every step from the sanding paper selection to LAB testing. Below is the 5 important factors for choosing the right one.

SHAPE --> ABRASIVES GRIT --> GRIT SIZE --> BACKINGS MATERIALS --> FLAPS' DENSITY

1) FLAP DISC SHAPE

Flap discs are used mostly on angle grinders and designed with a backings-support which allows working to be done on the flaps-surface. 

t29 shape flap disc        a) Type 29- Conical Style  
This type with angled flaps and may be used on both contoured and edge work. The angled flaps  provides max attaching area between abrasives with work-pieces and best choice for aggressive stock removal.  

t27 shape flap disc       b) Type 27 - Flat Style 
This style ideal for finishing and mainly used on flat surfaces. They are the best choice for blending and smooth finishing.


2) ABRASIVE GRIT

Here the abrasives grit means the kinds coated to the flaps, there are mainly four abrasive types:
a)Aluminum Oxide – recommended for smaller jobs where a consistent, low cost product is needed. 
b)Zirconia Alumina – excellent cut rate to cost ratio and good choice on carbon/mild steel applications.
c)Ceramic Alumina – latest innovative abrasives with fastest cutting as well as the best utilization of the whole abrasive grains. 
d)Silicon Carbide - Universally blending, cleaning, and finishing for concrete, stone, fiberglass and other nonferrous materials (brass, bronze and aluminum, etc.) 


3) GRIT SIZE
Different grit size suitable for different applications and requirements.  the below table is a general guide.
flap disc grit size recommend

4) BACKING-PLATE MATERIAL

The backing plate which provides stability during operation as well as flaps-combination.There are three different material types:
a)Fiberglass backing plates -  most popular material because of its high strength and light weight. It's also can absorb vibration and most important is - they are consumed in same steps with the flaps. 
 b)Plastic backing plates -  becoming more popular today due to some conformability as well as being trimmable - which allows max lifespan especially for blending and finishing. Also now days many innovative style plastic backings used such like " Spin-on" for quick change, " Radial-Ribbon" for super-cooling-stystem, etc. Anyway, the plastic backings will become more popular in future as easier processed to any shape.    
c)Metal or Aluminum backing plates - good in applications demanding extra high strength and high rigid support and can be recycled. This style normally using on Silicon Carbide flap discs.


5) ABRASIVE FLAP DENSITIES

flap disc testing
Each flaps size and total quantity of the flaps of flap discs means " Density",  it's can be adjusted according to various applications. It's not absolutely more flaps with better performance. 

Above is the outcome of testing between Blueshark TURBO & normal density line with grinding 10 minutes of stainless steel #304. The both flap discs with 40# grit size. General saying, more flaps more lifespan, less flaps less heating. BLUESHARK supply different density flap discs to meet all of your requirements, also the customer can specify the flaps size and quantity if needed. 

Now maybe you got a general idea how to choosing correct flap discs, if still any question or need more details, welcome Contact us  and we will try our best down your grinding cost!