Industrial Flap Discs

Industrial Flap Discs

Flap discs are some of the most common industrial hardware parts used for surface blending, smooth finishing and heavy stock removal. To achieve the most superior finish, it is preferable to use flap discs over other industrial grinder discs such as metal sanding discs. In addition, they are usually lightweight, durable, have low vibrations and are easy to maneuver.

Flap discs are built for high-speed right angle grinders and come in two main shapes: conical and flat. Consider getting a conical flap disc (type 29) if you are looking to remove a lot of material within a short period of time such as edge-working or contoured applications. In short, they are the best option for heavy stock removal. On the other hand, consider flat flap discs if you are looking to give a smooth finish to the surface of a material such as with surface blending and smooth finishing.

Metal, fibreglass and plastic are the main backing plate materials used in flap discs. Fibreglass is durable, strong, lightweight and safe for use. Fibreglass does not contaminate the working surface and bonds strongly with adhesives. In addition, it absorbs vibration very well. These properties make is the most widely preferred material. Metal backing plates are commonly made out of aluminium and offer the safest choice. They are suited for applications where firm support and extra strength is needed. However, they tend to be more expensive. Plastic backing materials are made out of nylon and can be trimmed to allow extended usage of the flaps, especially during finishing and blending activities. Plastic flaps are usually cheaper.

When it comes to discs, density refers to the spacing, angle and quantity of the flaps. To achieve the best results, flap density should be matched with the disc application. For rapid stock removal and high duty applications, standard density flaps do the job. High density flaps are best for use on curved or mismatched surfaces.

Aluminium oxide, zirconia alumina and ceramic alumina are the main abrasives found on metal working flaps. Aluminium oxide is used for smaller tasks that produce low-cost and reproducible products. Zirconia alumina provides an excellent cut-rate to cost ratio and is suitable for mild steel applications. Lastly, ceramic alumina, provides the longest cutting edges and provides a fast cut on high-alloy or stainless steel applications.