Flap disc wear

[Bellaireroad]

How do you get maximum use of your flap disc? This one has plenty of thickness, but no longer cuts well. Do you just have to bear down on it more, as it wears?






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[lis2323]

I had this same concern years ago. The sooner you truly realize the definition of "consumable" the better. [emoji3]

Life is short (flap discs AND ours). Move on. When it no longer cuts, toss it and spin on a new one.



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[BD1]

The outside edge can go quick. Normally the middle still has life. I found the 3M
Work well and seem to last longer.
Use a basic grinding wheel for the rough stuff then the flapper disc. That will help

 

[manwithtools]

I had this same concern years ago. The sooner you truly realize the definition of "consumable" the better.

Life is short (flap discs AND ours). Move on. When it no longer cuts, toss it and spin on a new one.



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LOL, this is the most correct advise you will receive....

 

[lis2323]

Use a basic grinding wheel for the rough stuff then the flapper disc. That will help

Until my welding drastically improves, I will do just that. (I assume that advise was for my benefit[emoji23])


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[chickenfarmer]

After they wear to that point they don't cut well but they do still do a great job deburring, so save them for when you need to debur, rather than wear out a new flap disk

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[PCustoms]

After they wear to that point they don't cut well but they do still do a great job deburring, so save them for when you need to debur, rather than wear out a new flap disk

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This.

I bought some xtra thick ones from Amazon last time around, pretty impressed with how long they lasted. I'll have ro look up the brand.

EDIT: here you go, Benchmark 4.5" x 7/8" Premium High Density... https://www.amazon.com/dp/B01D0HA3LK/?tag=atomicindus08-20

I was skeptical, only issue I had was they hit my guard a little bit (but that grinder has bounced off floor more then once)

 

[Mr.N]

Flap disc, money, time

You pick the order.


Time as in if I have to drive to the store I press a little harder.

 

[lis2323]

After they wear to that point they don't cut well but they do still do a great job deburring, so save them for when you need to debur, rather than wear out a new flap disk

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Chickenfarmer thank you for this useful tip!![emoji481]

I like many others invest in extra mini grinders to save time changing wheels, discs brushes...
m

I ALWAYS have one grinder with worn out flap disc that I grab for deburring. Unfortunately this situation exists only because there is usually another grinder around with a newer disc.



Pretty sad to admit that I’m not even intelligent enough to realize I’m doing something smart for a change. [emoji23]

 

[Bellaireroad]

Yeah, it just seems strange that there is so much abrasive left between the flaps that gets wasted. Seems like an inefficient design


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[OccupantRJ]

I personally do not use my flap wheels to grind with. I grind with a hard wheel, then use a flap wheel to dress the area with. Trying to grind with them eats them up.

 

[Mr.N]

I personally do not use my flap wheels to grind with. I grind with a hard wheel, then use a flap wheel to dress the area with. Trying to grind with them eats them up.

Give me a 20 grit or 36 grit flap wheel and I'll race you

 

[OccupantRJ]

Give me a 20 grit or 36 grit flap wheel and I'll race you

Time was not the issue at hand. Wear of the flap disc was.

 

[Mr.N]

Time was not the issue at hand. Wear of the flap disc was.

Flap disc, money, time

You pick the order.


Time as in if I have to drive to the store I press a little harder.

Agree.
I buy in bulk and save money and my time,

 

[Bellaireroad]

I mainly use them for rust and mill scale, and they don’t last long


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[Kev442]

I just started using flap disks this past winter and like the OP have been scratching my head about it. So much left when it quits cutting...
Sitting here looking at the picture, I wonder if taking the propane torch to the exposed paper would be quick and easy.

 

[jeepinerdeep]

This.

I bought some xtra thick ones from Amazon last time around, pretty impressed with how long they lasted. I'll have ro look up the brand.

EDIT: here you go, Benchmark 4.5" x 7/8" Premium High Density... https://www.amazon.com/dp/B01D0HA3LK/?tag=atomicindus08-20

I was skeptical, only issue I had was they hit my guard a little bit (but that grinder has bounced off floor more then once)

I'll second the benchmark high density. I used them in my plasma cutting business. Really great value for the box of 10, and you won't be all butthurt about changing them when the time does come at this price.

 

[chaosracing]

Use them all the time. Once they wear out, I just check it in the round file system and get a new one. Use them for all kinds of metal work, cleaning metal or paint, scale or minor rust (if its pitted I use a hard wheel, then finish with a flap) grinding welds, sharpening mower blades, list goes on.

 

[Kaizen]

I prefer grinding with cut off wheels and just use flap discs to get close to finish. Find I can remove a lot more quicker with cut off wheels


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[tarbellb]

Consumable, yes, but learning to dress a wheel is also important.

Flap disc typically stop cutting on the outer edge, take it to a sharp edge and cut down the outer edge to fresh material.

This is why some of the newer disc out there are made of plastic, they are meant to be cut back for better performance/life.

See Walter disc for example

 

[dr_clyde]

Flap discs are a terrible abrasive for metal removal. Use a ceramic flat disc, 36 grit to move some metal. They are way cheaper, last way longer and are significantly faster than a flap disc.

A flap disc is good for deburring and blending. Seems like guys always want to use them to grind with. Not the right tool for that.

 

[Offcenter12]

All good advice here. I use them for finishing/blending after the heavy grinding is done and for what it's worth prefer the Pferd German brand available from many welding shops and industrial supply houses. Just tossed a Radnor brand from Praxair Welding yesterday after minimal use in cleaning a rusty stand for my bench grinder and it was a stretch to complete that before it was completely useless. Pferd aren't cheap, but you get what you pay for imo.

http://www.pferdusa.com/products/204p/204p10P.html

 

[Medwards]

I've never liked flap wheels or grinding rocks on my 4 1/2" grinder. I prefer sanding discs. You need the rubber backer. https://www.amazon.com/dp/B002YCL3NU/?tag=atomicindus08-20

Then you can buy discs for under $1 each. They last just as long as the flap wheel and cut as good or better and no issues with them loading up when cutting aluminum. https://www.amazon.com/dp/B06VW2P7WM/?tag=atomicindus08-20

 

[ilovevocs]

m

Need more Metabo.

 

[lis2323]

Need more Metabo.

Need more $$$. [emoji23]


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[bdbecker]

I prefer grinding with cut off wheels and just use flap discs to get close to finish. Find I can remove a lot more quicker with cut off wheels

I hope you are just confusing terminology here... Cut off wheels should never be used in a grinding application - they aren't designed to handle the force applied to the face of the disc. Using them for grinding is a good way to shatter a disc and put yourself at risk for injury. I'm speaking about the hard wheels that are ~1/8" thick.

Using the thicker hard wheels that are designed for grinding/material removal is a different story, which is what I believe you are referring to. I only highlight your comment in the chance that someone who may not quite as knowledgeable on the subject doesn't misinterpret your statement and try to do something unsafe.

 

[dr_clyde]

I hope you are just confusing terminology here... Cut off wheels should never be used in a grinding application - they aren't designed to handle the force applied to the face of the disc. Using them for grinding is a good way to shatter a disc and put yourself at risk for injury. I'm speaking about the hard wheels that are ~1/8" thick.

Using the thicker hard wheels that are designed for grinding/material removal is a different story, which is what I believe you are referring to. I only highlight your comment in the chance that someone who may not quite as knowledgeable on the subject doesn't misinterpret your statement and try to do something unsafe.

Who says you have to grind with the face of the wheel? I use cutting discs to grind with as well, using the periphery of the disc in applications where I need to be more delicate or surgical. Basically making light sweeping cuts instead of a more typical plunge cut.

 

[DFB]

Hey I just got new wholesale distributor over the weekend to source from for my flea mkt tool tent sales front and Flap Discs along with abrasive grinding wheels and cutting discs are one of their main specialties, along with sanding discs and other surface prep items.

So what is the most popular grit generally used most often...coarse for heavy material takedown or something finer for general cleanup? I should plan to stock more of some types than some others I would imagine.

Should I consider having ALL the grits they offer (depending on brand and wholesale price varies) in 4 and 4 1/2" there is a 36, 40, 60, 80 & 120.

Clue me in to what is the difference on the "type" numbers they list 27 or 29, 41, or 42

 

[BD1]

Until my welding drastically improves, I will do just that. (I assume that advise was for my benefit[emoji23])

No sir, the basic grinding disc is like rough grinding while many flapper DISCs leave a smoother finish. A flapper disc will work but can get destroyed easily.

 

[bdbecker]

Who says you have to grind with the face of the wheel? I use cutting discs to grind with as well, using the periphery of the disc in applications where I need to be more delicate or surgical. Basically making light sweeping cuts instead of a more typical plunge cut.

I think we're just getting caught up on semantics here... I totally agree with your statement, there are many ways to safely use a cut-off wheel to "grind" or remove material that don't necessarily involve making a cut. The distinction I was trying to make was that you should not use the face of a cut-off wheel for grinding like you would an actual grinding disc.

 

[dv8customs]

I toss all my old flap disks in a bucket. When you get in a bind and use up your last good one, those old ones in the bucket don't look so bad anymore.

 

[OccupantRJ]

Hey I just got new wholesale distributor over the weekend to source from for my flea mkt tool tent sales front and Flap Discs along with abrasive grinding wheels and cutting discs are one of their main specialties, along with sanding discs and other surface prep items.

So what is the most popular grit generally used most often...coarse for heavy material takedown or something finer for general cleanup? I should plan to stock more of some types than some others I would imagine.

Should I consider having ALL the grits they offer (depending on brand and wholesale price varies) in 4 and 4 1/2" there is a 36, 40, 60, 80 & 120.

Clue me in to what is the difference on the "type" numbers they list 27 or 29, 41, or 42

Here you go. I think most people use the type 27 wheels for angle grinders.
https://www.lni.wa.gov/Safety/Rules/Chapter/806/helpfultools/HT2-MS.pdf

 

[2oolhound]

When belly aching to a dealer about the cost of 7" flap discs he told me "Oh no, you just take a real sharp zippo knife and cut off about 1/4" of each flap and they're like new again" I've never tried it. I have rotated them in front on my 10" bench grinder though and chewed a new edge on them.

 

[tdcisco1]

I toss all my old flap disks in a bucket. When you get in a bind and use up your last good one, those old ones in the bucket don't look so bad anymore.

I gather up everyones throwaways at work. they go in the bucket at home

 

[Jlarson]

I've started to switch to the Norton quick trim backed discs. A 36 or 40 grit redheat disc puts a hard grinding wheel to shame, I really only use hard wheels for weld and crack prep now.

 

[OccupantRJ]

I have been using a side grinder with a rubber backing pad and abrasive discs for about 45 years now for certain items. Abrasive tools are the biggest single group of tools in my shop, and each one has it’s strength and weaknesses. Since retiring, I now restore machines and fabricate parts, and rarely does a day go by without me grinding or sanding on something.

 

[Kaizen]

I think we're just getting caught up on semantics here... I totally agree with your statement, there are many ways to safely use a cut-off wheel to "grind" or remove material that don't necessarily involve making a cut. The distinction I was trying to make was that you should not use the face of a cut-off wheel for grinding like you would an actual grinding disc.

The more information we clearly communicate the better.
I was talking about cut off discs. The technique is using a 4.5 inch angle grinder use the edge to wipe along the weld. It takes off material far quicker the a grinding wheel. Bracing your body to have the grinder and not let its weight settle on the disc is important. Full face shield and protection is smart. I’ve never had even a harbor freight one break this way. Usually use on body panels or thin material where extra heat is not good.


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[yucholian]

https://www.amazon.com/dp/B01N6Z3WXJ/?tag=atomicindus08-20

 

[Bellaireroad]

When belly aching to a dealer about the cost of 7" flap discs he told me "Oh no, you just take a real sharp zippo knife and cut off about 1/4" of each flap and they're like new again" I've never tried it. I have rotated them in front on my 10" bench grinder though and chewed a new edge on them.

Sounds great, but when you think about it, that would be over 80 cuts with the zippo. He must have a lot of patience and free time


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[EVOLVO]

Walter is the only brand I use. Flap and zip disks are superior!