Flap Wheels
Flap wheels are abrasive tools consisting of abrasive flaps mounted radially on a spindle, with 19mm keyway bore or a central wooden core. They are used for finishing and polishing curved, contoured, or flat surfaces. The flaps are coated with abrasive grains of different sizes and types, such as aluminum oxide, zirconia, or ceramic, which allows them to be versatile for various applications.
Spindle-mounted flap wheels are designed to fit onto a spindle and are commonly used on hand-held or stationary tools such as die grinders and drill presses. These wheels are available in a range of sizes and shapes, including cylindrical, conical, and pointed. They are suitable for light grinding, deburring, and finishing operations on materials such as metals, plastics, and wood.
Wooden-centre flap wheels, on the other hand, are typically used on bench grinders, where the wooden centre provides a softer backing for the flaps to conform to the contours of the workpiece. These flap wheels are commonly used for removing rust, paint, and burrs from metal surfaces, preparing surfaces for painting or welding, and finishing woodwork.
Flap wheels are available in various grades and sizes, with different levels of flexibility and aggressiveness. The coarseness of the abrasive grain determines the grade of the wheel, with finer grits producing smoother finishes, while coarser grits remove material more aggressively. Flap wheels are also available in different densities, with denser wheels providing longer life and less wear on the abrasive flaps.
Flap wheels with a spindle mount typically feature a threaded arbor for easy installation onto a spindle, while wooden-centre flap wheels are available with a range of centre hole sizes to fit various sizes of arbors. Additionally, some flap wheels feature a quick-change mechanism that allows for fast and easy wheel changes, without the need for tools.
The abrasives on the flap wheels come in three different types; abrasive, interleaved and non-woven. Abrasive flap wheels are similar to flap discs in that they are made up of multiple abrasive flaps that are arranged radially around a central hub. However, they are typically smaller in diameter and are often used in precision grinding and finishing applications. Abrasive flap wheels can be made from a variety of abrasive materials including ceramic, zirconia, and aluminum oxide.
Interleaved flap wheels are made up of alternating layers of abrasive flaps and non-woven material. The abrasive flaps remove material while the non-woven material helps to reduce heat buildup and prevent loading. Interleaved flap wheels are often used for blending and finishing applications on metal, stainless steel, and other materials.
Non-woven flap wheels are made up of a non-woven material that is impregnated with abrasive grains. They are typically used for surface preparation and finishing applications and are available in various grits and densities. Non-woven flap wheels are often used in the metalworking and woodworking industries.
One advantage of flap wheels over other abrasive tools is their ability to conform to the shape of the workpiece, providing a consistent finish across curved and contoured surfaces. They are also less likely to gouge or damage the workpiece, making them a popular choice for finishing operations.
It is important to choose the correct flap wheel for the application to achieve optimal results. For instance, aluminum oxide flap wheels are suitable for general-purpose grinding and finishing operations, while zirconia and ceramic flap wheels are more suited for heavy-duty applications such as weld removal and edge grinding.
When using flap wheels, it is important to observe safety precautions, such as wearing personal protective equipment like safety glasses and gloves, ensuring the tool is properly secured and maintained, and keeping the workpiece and tool steady to prevent the wheel from catching or snagging.
In summary, flap wheels are versatile abrasive tools that come in a variety of shapes, sizes, and types to suit different applications. Spindle-mounted flap wheels are suitable for hand-held and stationary tools, while wooden-centre flap wheels are commonly used on bench grinders. Choosing the correct flap wheel and following proper safety measures will help ensure optimal results and prevent accidents or injuries.
