The size should be determined by the size of the grinder. Make sure the grinder does not exceed the max RPM on the disc.
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Typically, 24 to 60 grit range flap discs are coarse, while 60 to 80 grit range are medium, and 80 to 120 are considered as fine.
Coarse-grain flap discs are ideal for quick stock removal and situations where a highly polished final surface is not a priority or when the client is indifferent about the finish and simply wants the task completed swiftly. The coarser the grain, the faster the rate of material removal (subject to the material type), but it may leave deep scratches that could be challenging to smooth out later.
This is especially noticeable when comparing finishing procedures on carbon steel and stainless steel. The inclination might be to always choose coarser grains, but this could complicate and extend your finishing alternatives in the future.
Coarse grains are also the preferred option for softer materials like soft steel and aluminium.
Fine-grained flap discs are ideal when a project requires a smooth and polished finish. They are typically employed in the final stages of the grinding process to eliminate deeper scratches left by the rough grain during stock removal.
For example, grinding stainless steel often necessitates extra surface finishing procedures because of the characteristics each process bestows on the material.
A highly polished finish is mainly used for aesthetic reasons, such as the number 4 finish, which is selected for its anti-fingerprint and anti-bacterial properties in commercial handrails and similar applications.
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After the initial stock removal using a coarser-grained flap disc or grinding wheel, the scratch would appear unattractive on a stainless steel surface. Moreover, finer grains are more efficient on smaller contact areas and are better suited for harder and more brittle materials.
Flap disc density refers to the number of abrasive flaps or layers present on a flap disc. The flap density can vary. Higher flap density generally means more flaps per square inch or centimeter, resulting in a greater number of cutting edges.
A flap disc with a higher density tends to offer a finer and more uniform finish, as the increased number of flaps provides cutting points and a larger contact area with the workpiece. It can be useful for applications requiring a smooth surface or finer material removal.
On the other hand, flap discs with lower flap density may be more aggressive, allowing for faster material removal but potentially leaving a rougher finish. They may be suitable for tasks where efficiency is prioritized over surface smoothness.
The selection of flap density depends on the specific application, the material being worked on, and desired finish.
Flap discs, grinding discs, and fibre discs are all abrasive discs and similar in nature with overlapping characteristics, but they have crucial differences that define which one is suitable or unsuitable for certain applications. For example, the coarser nature of grinding discs results in an uneven finish making them unsuitable for surface preparation.
Flap discs also remove metal but at a slower pace than grinding discs, but they will give you a smoother and even finish. The flexible nature of flap discs makes it easier for you to achieve contours in the metal making them suitable for deburring, blending, and finishing. Advancements in design and technology over the years have made flap discs truly versatile to the point where they can be used for grinding, blending, and finishing jobs quickly and with less noise than grinding discs.
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