Flap Discs 101: Everything to Know about Flap Discs

Abrasives have been around for more years than you can imagine. The earliest use of abrasives dates back to when stones were hit against each other to create tools. Since then, as you can imagine, abrasive tools have advanced incredibly. Today, some of the most common abrasive tools used are flap discs. But what are flap discs and what do you need to know about them? Here’s everything you need to know about our flap discs. 

What Are Flap Discs? 

Flap discs are an abrasive product that are used on angle grinders for grinding, blending, and finishing, as well as removing rust, paint and weld seams. The discs are made up of many overlapping sections of abrasive materials or flaps on the backing plate, giving the name ‘flap discs’, which provides stability and gives the discs their unique characteristics.

The main types of flap discs available are: 

  • Ceramic Flap Discs 
  • Aluminium Oxide Flap Discs
  • Zirconium Flap Discs  

 

Why Use Flap Discs for Metalworking

Flap Discs have been a popular choice for metalworking for several reasons. They’re incredibly versatile tools and have the ability to handle multiple tasks, unlike alternatives such as grinding wheels. 

 

Control and Comfort  

One of the main reasons flap discs are so popular is because of their control and comfort ratings. When using flap discs, fewer vibrations are generated allowing for better control, especially on uneven surfaces and tight corners.

 

Better Finishes 

Flap discs provide a consistent and smooth finish because of their flexible design, unlike other abrasive tools which can sometimes leave gouges in your metalwork. For projects where a polished and finer finish is preferred, flap discs are your abrasive tool. 

Flap discs generally tend to produce less heat than other alternatives. Significant heat production can lead to scorch marks and metal warping. 

 

Usability 

As mentioned, flap discs can be used for a number of different projects. Most commonly, they’re used for grinding, blending, finding and removing rust, paint and weld seams. The multitasking ability saves you time, effort and money that would otherwise be spent (buying and) switching from disc to disc.

 

Choosing the Correct Flap Disc

Choosing a suitable disc is a crucial step in your abrasive job. If you use the incorrect disc, you can risk the disc breaking and the surface being damaged. With multiple flap discs and variations available, we can help ensure you choose the correct one. 

 

Material Application

Depending on the material you’re working on will change which flap disc will be best. Different materials will require specific abrasives to achieve optimal results so it is always best to research before you start working. For instance, Zirconium Flap Discs are suitable for harder materials such as stainless steel whereas aluminium oxide flap discs work well for mild steel. 

 

Grit Size 

Grit size is another important aspect of choosing a flap disc. Grit size refers to the coarseness of the abrasive particles on the disc. As a rule of thumb, the lower the grit number, the coarser the disc, the higher the grit number, the finer the disc. 

Coarser discs (like Grit 36) are useful for heavy stock removal whereas higher grit numbers, like 120, are more suitable for finishing projects and light grinding. 

 

Backing Plates 

Different discs also come with different backing plates - which are useful for different tasks. Fibreglass backing plates offer more rigidity for heavy-duty projects and tasks. Plastic backing plates offer more flexibility and are more suitable for working on contours.  

 

Using Flap Discs Effectively 

Ensuring you use flap discs effectively is crucial not just to improve efficiency but also safety. Here’s how to get the most from your flap discs. 

 

Safety 

First of all, safety is a huge part of using flap discs effectively. Flap discs spin at incredibly high speeds so safety is essential. Some general PPE to invest in include:

  • Eye Protection 
  • Hearing Protection
  • Hand Protection
  • Grinder Guard 

 

Using the Disc

When using the flap disc, it’s also important to ensure you’re following the best practices to get the most from your project. Firstly, it’s important to choose the correct disc, which we spoke about previously. 

Once you have your disc, the next best practice to follow is the correct angle and pressure. You should let the disc’s rotation take the workload and avoid using excessive pressure or using the disc flat or on its edge. 

When moving the disc, you should do so in a smooth transition across the workpiece surface in a consistent pattern. Staying in one place on the workpiece can cause heat buildup and an uneven finish.

 

Abrasives at Engineering Utilities

Here at Engineering Utilities, we’ve been a leading supplier of abrasive products and accessories for over four decades. We have an incredibly large product range partnered with an expert team on hand to assist. 

If you’re looking for a reliable supplier of abrasive products and accessories, take a look at our website and place your orders today! 

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