What is a flap disc?

Flap discs, also known colloquially as flapper wheels, have a design suited for right-angle grinder applications. A flap disc is an abrasive product found in the coated abrasive family.The discs are made up of many layered, overlapping sections of abrasive material or‘flaps’. These flaps are formed of a polycotton or polyester backing material to which abrasive grains are adhered, these are then layered and bonded to a backing plate. The backing plate provides stability to the flap disc and imparts its own unique properties to the product. They provide aggressive stock removal or precise blending and finishing depending on the operator's needs. They offer exceptional versatility, maneuverability and lower vibration and noise levels than grinding wheels. Flap discs are excellent choices for many applications because they allow the operator to perform grinding and finishing in one efficient time-saving, cost-lowering step. They grind like hard grinding wheels but are easier to control so you reduce the risk of gouging the workpiece, and they remain usable even after an area of abrasive wears out because new abrasive is exposed. They also tend to have a softer feel than grinding wheels, and they reduce the risk of removing too much material from the workpiece with overaggressive grinding.

 

When a facility is choosing angle grinder flap discs, it's essential to consider factors like shape, material, density and abrasive grain type and size. The choice of material for a flap disc usually depends on the application and workpiece material in question. Below are a few common types of flap disc materials:

CERAMIC ALUMINA: Ceramic grains have a unique microcrystalline structure that is highly friable at high pressure and therefore is said to be self-sharpening. Newly exposed sharp edges are continually exposed to the surface of the workpiece-making ceramic grained abrasives stay sharper and more effective over a long period of time. As it does the job quicker, the heat build up in the ceramic grain is lower, therefore these abrasives tend to cut at a cooler temperature, which reduces glazing and improves their overall efficiency.

ZIRCONIA ALUMINA: A flap disc made from 100% zirconia alumina allows for aggressive stock removal and high-performance edge grinding. Zirconia alumina is self-sharpening, and it holds up exceptionally well under high temperatures and pressures. With proper use and maintenance, it provides a rapid cut and long lifespan. It is ideal for workpieces made from cast iron, carbon steel, structural steel and stainless steel.

ALUMINUM OXIDE: A disc made from aluminum oxide has a hard, durable grain and a strong initial cut rate, and it offers fast stock removal and consistent performance. Aluminum oxide is ideal for workpieces made of materials such as steel and cast iron, as well as for all-purpose use. It is not shelf-sharpening, however — its single crystals will dull during use. Overall, it provides a blend of performance and value.