Understanding & Choosing the Right Flap Disc Eddie Burlem, August 23, 2018February 16, 2024 What is a Flap Disc? Flap Discs are designed to increase work productivity and reduce overall cost by grinding, blending and finishing in 1 step. Flap Discs are constructed by layering coated abrasive flaps so when a flap wears away, a new flap will be expose with fresh, sharp abrasive grains. Flap Disc Basics There are 4 basics components of a flap disc: Backing Shape, Backing Type, Gain Type & Density. Backing Shape Type 29 – Conical Shape Built-in angle for increased contact area Best for use on contoured surfaces and edge work Minimizes workpiece gouging More aggressive stock removal due to higher angle 15°-25° working angle Type 27 – Flat Shape Best for use on miter joints, corners and edges Best choice for finishing intricate and ornate surfaces Ideal for smooth finishing 0°-15° working angle Backing Type Fiberglass Backing Backing will wear uniformly with abrasive cloth Will not splinter or smear on the workpiece Lighter, quieter operation Plastic Backing Non-scratching, high strength backing Resistant to temperature extremes, common chemicals and solvents Some plastic backings are trimmable Flap Backing: Polyester, Polyester-Cotton or Cotton Polyester Able to withstand extremely high pressure without degrading the flap For extreme stock removal and edge grinding Cotton Used where maximum conformability and soft feel is the goal Must be used under lighter pressure to maximize performance and life Polyester/Cotton Blend The best of both worlds Can withstand high pressure while still maintaining good stock removal and finishing Often used as the starting point for flap disc operations for first time users Grain Type Ceramic This allows for a consistent under a wide variety of grinding applications You should consider opting for a ceramic disc when grinding on steel, stainless steel or aluminum Ceramics also tend to grind cooler minimizing discoloration while maximizing product life Zirconium These discs are used for general steel grinding, stock removal and finishing The economical choice when cost is the driving factor Density High density flap discs provide the user with approximately 40% more grinding material. This increase in grinding material leads to increased productivity and longer life. Choose Flap Disc Over.. Flap Discs Over Grinding Wheels Faster stock removal and smoother finish Quieter operation and reduced vibration minimizing operator fatigue Cooler cutting, reduced loading and glazing Easy to use – reduced gouging and rework Flap Discs Over Fiber Discs Up to 20 times longer life than a fiber disc No backing pad needed Easier storage – no curling More consistent finish What Makes United Abrasives Better than the Competition Check back for our next blog post, “United Abrasives Flap Discs, the Professional’s Choice“, to learn why professionals choose United Abrasive Flap Discs over the competition! Cutting Tools