Flap wheels are used for grinding, cleaning, and smoothing various surfaces. They are widely used in repair shops, various businesses, and anywhere metal, plastic, or wood surfaces need to be cleaned.
Design features of petal wheels
The appearance is composed of roughened sheets (petals) superimposed on each other. Their shape can be either straight or conical. Straight ones are used for finishing large flat surfaces, while conical ones are used for curved areas with complex relief, as well as edges.
The fan-shaped arrangement of the petals prevents the rough side from becoming clogged during use. This is because as each layer of the petal wears away, a new layer is created, thereby self-sharpening. Therefore, the flap disc can be used until completely worn out without any loss of quality.
The disc's unique design allows for uniform temperature distribution across the top layer. This is known as a fan effect, resulting in a cooling effect on the surface. This allows for a burn-free finish.
Types of petal discs
End
These types are commonly referred to as Flap Discs (FLAPS). They are quiet and vibration-free. They are used for sanding edges of stainless steel, plastic, and wood. They typically have a grit size of 500 and a disc diameter of 125. They can be used for both primary and final finishing. They can be flat (for flat surfaces) or convex (for polishing edges and joints).
Batch
The flap disc (KLP) has a steel base and multiple flap-shaped elements. It can be used for cleaning any surface, including metal. It has a maximum grit of 500. It is used when large areas need to be sanded.
With a mandrel
A flap disc with an arbor (KLO) has a arbor that attaches to the tool. It is used for grinding the interior of parts. Depending on the cavity being processed, any size can be selected. These discs also come in a wide range of grit sizes, from 40 to 500.
Technical specifications
When choosing a circle, the main characteristics will be its diameter and grain size.
Sizes can vary widely, from 50 to 180 mm. However, some wheels have non-standard dimensions and are required for specialized operations. A 115 mm wheel is usually sufficient for auto repair shops, but it lacks the performance for industrial use. The most common size is 125 mm. This offers the optimal balance between size and performance. It's lightweight, yet delivers excellent power, up to 1800 watts.
The standard mounting hole diameter is 22.23 mm. Therefore, the discs can be used on grinders from all manufacturers.
Grit size is also important for different types of work. It can be identified by the markings on the flap disc itself and ranges from 40 to 120 grit. For light sanding or even light surface grinding, use a grit size of 40-60. If rough sanding or even surface removal is required, use the highest grit size.
Flap discs for angle grinders
There are standard flap wheels for angle grinders available commercially. They are used to polish the outer layer using an angle grinder. Their outer diameter can vary widely: from 115 to 230 mm. The standard diameter of the grinder mounting hole is 22.23 mm. The thickness of a single flap varies from 1.5 to 2 mm.
A flap disc for an angle grinder has a center and flap discs attached to it. These flap discs have a rough surface made of zirconium oxide, which is bonded to the surface with epoxy. However, a revolutionary discovery was made by Russian engineers who developed and introduced flap discs made of electro-pulse crushed carbide. These flap discs are firmly bonded to the surface with a strong solder. These flap discs are much stronger and have a longer service life.
Features of wood surface treatment
For finishing large areas, such as building timber or floors, an angle grinder is used. A wood-specific disc is purchased, which consists of a plate-shaped device with petals applied to it. The petals are arranged so that each subsequent disc overlaps the previous one by a third of its width. All the disc specifications, including diameter and grit, are listed on the disc itself. The grit should be selected based on the work being performed. If you simply need to polish, choose the finest grit. If you need to smooth out unevenness in the wood, use a medium grit. A coarse grit is usually used for removing paint from old boards. For best results, apply gentle pressure when sanding the wood surface.
If you need to machine non-standard wooden shapes, use an angle grinder disc with radial blades. Working with such discs requires some skill.
All the advantages of an abrasive flap wheel make it an economical and effective tool for processing any type of surface.
