How to Choose the Correct Flap Disc for Your Application

Their are several factors which effect flap disc performance for a given application. These factors include;

1. The type of coated abrasives
2. The shape of the disc
3. The thickness of the discs
4. The speed at which the flap disc is operated.

By understanding the factors above, users can choose the best flap disc for their operation and minimize both cost and grinding time.
 
1. Types of coated Abrasives
 
Zirconia - Best for Steel
 



Zirconia is the most widely used coated abrasive for flap discs. Zirconia is an
extremely hard grain which excels at grinding while providing a long service life.

Lehigh Valley uses a superior Zirconia cloth which includes a lubricant and is made in Germany. The lubricant keeps the grinding tempature low and allows our zirconia discs to also be used on stainless steel and other high nickel alloys.


Ceramic - Best for Stainless Steel



Ceramic grain flap discs excel at grinding and finishing stainless steel and other high nickel alloys. The tough ceramic grain cuts faster and cooler than any other grain type.

Tests have shown that for stainless steel applications, ceramic grain flap discs lasts twice as longs as zirconia cloth and removes material 50% faster.


Turbo Disc - Best for Aluminum

Traditionally flap discs clog and load when grinding aluminum and other soft metals (brass, copper bronze). The Lehigh Valley Abrasives Turbo Disc contains a special calcium stearate coating on the disc which prevents clogging.

The turbo disc significantly outlasts competitive flap discs on aluminum and other soft metals due to its resistance to clogging.

Additional Factors to Consider


Shape

Flap discs are available it type 29 conical and type 27 flat.

Type 29 conical is ideal for heavy metal removal tasks because the tapered shape allows for full contact between the flaps and work pieces.

Type 27 flap is ideal for finer finishing as it is more forgiving and thus produces a more even scratch patter.

Thickness


Flap discs are offered in both standard and jumbo thicknesses. Standard thickness offers the ability to access tighter work areas and more control over the disc.

Jumbo flap discs are 50% thicker than standard discs and therefore last approximately 50% longer. For high volume production jumbo flap discs are ideal as they minimize the time operators spend changing discs.

Optimizing Flap Disc Life With Variable Speed Grinder

The right speed increases the service life of flap discs by up to 100%. The optimal speed for flap discs usage is between 5,000 and 8,000 rpm. The use of a powerful speed controlled angle grindler such as the Metabo WE14-125VS optimises grinding with flap discs and greatly extends disc life.

A typical 4-1/2" angle grinder runs at 11,000 rpm. If you use flap discs we recommend purchasing the Metabo WE14-125VS and adjusting the speed to 7000 rpm in order to extend flap disc life and reduce your abrasive finishing costs.

Metabo WE14-125VS

Robots never miss a day of work and they do not lie

Robots never miss a day of work and they do not lie

A large midwest manufacturer of metal casings uses a robot and flap discs to level steel weld seams flush with the base material. This manufacturer uses tens of thousands of flap discs per year and embarked on a cost reduction project to determine if their current flap discs supplier was providing the best value.


The manufacturer tested the top three name brand flap discs in the USA along with Lehigh Valley Abrasives flap discs. Each suppliers discs were put on the robotic cell and the number of casings completed per discs were calculated based on the testing.



The results can be seen below. Not only did we outperform the top three leading brands but our price is 50% lower.


Lehigh Valley Flap Discs - completed 32 parts

Brand A - completed 27 parts

Brand B - completed 19 parts

Brand C - completed 24 parts



Lehigh Valley Abrasives Flap Discs

Dynafile - Corner Polishing

The Dynafile is the perfect power tool for hard to reach areas. See the video demonstration below.

Ceramic Grain Coated Abrasives

Ceramic Grain is the fastest cutting longest lasting coated abrasive for use in Metalworking.
See the video below.

Rapid combination disc

The rapid combination flap disc consists of alternating flaps of ceramic coated abrasives and surface conditioning. The two materials allow you to grind and polish with one step, saving both time and money. See the video below which depicts the product in use.

Sia Star

Sia abrasives has developed an innovative tool which excells at reaching hard to access areas, fine polishing (variable speed control) and quick disc change over. I see this tool particularly useful for those in the maetal art field.

http://www.siastar.com/en/index.html