Flap Disc

Company Profile

Jinan Enying Abrasives company was founded in 2011, the company is headquartered in Mingshui Street, Zhangqiu District, Jinan City, Shandong Province, professional export abrasive tools designated processing and sales factory, has passed the national quality management system certification, with 5000 square meters of modern standard production workshop, Equipped with a number of international leading automatic high-precision standard production lines, the annual production of all kinds of abrasive tools 50 million, the existing staff of more than 100 people, registered capital 50 million yuan, the existing national assets 60 million yuan. We have a professional R & D team, advanced production technology and design concept. "Create first-class brand, do first-class enterprise", truly let you not worry, rest assured, is our constant service tenet. Customer is our God, quality reputation is our forever pursuit goal. Welcome friends from all walks of life to visit Jinan Enying abrasives company to visit, guidance and business negotiations.

First 12 3 4 Last

Why choose us?

Experience

In 2011, Enying company established its first professional sales team.

Production

A new factory was complete construction and jinan enying abrasive tools co.,ltd was established, with a modern standard production workshop of 5,000 square meters.

Technology

The annual production of all kinds of abrasive tools 50 million pieces.

R&D team

Enying Company is constantly developing and making progress. We firmly believe that the future of the company will be better and better.

What is Flap Disc

A flap disc is an abrasive tool made of overlapping abrasives pads called "flaps", these flaps are glued on fiberglass or metal, or plastic plates to serve as angle grinder attachments. In various applications, a flap disc is less expensive and equally effective as a grinding wheel.

Flap discs are the more popular because of their fast stock removal as well as the ability to grind, mix and finish in a single use.

Flap discs are versatile, lightweight, easy-to-use, and convenient surface finishing tools. When used to smooth welds after grinding wheel, standard flap discs last up to 25 times longer than aluminum oxide resin fiber discs. They can grind and finish at the same time. For that, you simply have to apply more pressure for a more aggressive grinding and less force for a better finish.

Benefits of Flap Disc

Longevity
Thanks to their layered construction, flap discs last longer than traditional sanding discs. As the outer layer of abrasives wears down, new abrasive surfaces are exposed, extending the disc's working life.

Versatility in finishing tasks
Flap discs can be used for a wide range of tasks, from heavy grinding to fine finishing. By selecting the appropriate grit size, one can easily transition between aggressive material removal and achieving a smooth, polished surface without needing to switch tools.

High performance for curved surfaces
The flexible nature of flap discs makes them particularly effective on curved and irregular surfaces. The abrasive flaps conform to the shape of the workpiece, ensuring even contact and consistent finishing quality across different shapes and contours.

Less re-work
A flap disc will provide much more controlled stock removal. They are often lighter and cooler cutting (less glazing), which reduces the requirement for re-work.

Smoother finish, no gouging
In the same vein, grinding wheels are extremely aggressive and can have a tendency to gouge the surface and leave a very rough finish, particularly when in the hands of a less experienced user.
Whereas with a flap disc, the abrasive flaps are made from cloth or polyester, providing conformability to the disc, which reduces the possibility of damaging the workpiece whilst removing material effectively.

Fewer vibrations
As the flap disc is less rigid and has far more flexibility than its grinding wheel counterpart, fewer vibrations are generated when grinding. Not only does this make for a drastically more comfortable experience for the operator but it is also significantly less noisy.

Material of Flap Disc

Plastic/nylon
This type of backing material gives the flap disc some degree of flexibility, which helps reduce the level of vibration generated, making it a good choice for uneven surfaces.

Fibreglass

Strong, rigid and lightweight, fibreglass is the most commonly used material for a backup plate for a flap disc.
Its rigidity and vibration absorbing properties help the operator maintain greater control over their process.
The flaps gradually wear away as the grain diminishes during use, exposing a new layer of abrasive grains.
Its effectiveness will of course decrease over time and use but a flap disc can actually be used until the cloth is practically down to the resin.

Application of Flap Disc

01/

Welding and metal fabrication
Flap discs are widely used in welding and metal fabrication processes. They are ideal for removing weld spatter, smoothing weld seams, and blending metal surfaces. The overlapping flaps of the disc allow for precise and controlled grinding, ensuring a smooth and uniform finish.

02/

Surface preparation
Flap discs are excellent for surface preparation tasks, such as removing rust, paint, and corrosion from metal surfaces. They can quickly and effectively strip away unwanted coatings, preparing the surface for further treatment or finishing.

03/

Deburring and edge grinding
Flap discs are highly effective in deburring sharp edges and removing burrs from metal workpieces. Their abrasive flaps can easily reach tight corners and contours, providing consistent and precise deburring results.

04/

Woodworking
Flap discs are not limited to metalworking applications; they can also be used in woodworking tasks. They are suitable for shaping and smoothing wood surfaces, removing old finishes, and preparing wood for staining or painting.

05/

Automotive and aerospace industries
Flap discs are widely used in the automotive and aerospace industries for various applications, including grinding and finishing metal components, removing weld seams, and preparing surfaces for coating or bonding.

06/

Maintenance and repair
Flap discs are essential tools for maintenance and repair work. They can be used for tasks such as cleaning and polishing metal surfaces, removing scale and oxidation, and restoring worn-out parts.

Flap Discs Abrasives

Flap discs have different types of abrasives, and each has its own characteristics making them suitable for specific applications. Each material has different properties in terms of aggressiveness, durability, and heat resistance. The right choice of abrasive will depend on factors such as materials being working, the desired finish, the level of stock removal required, and the operating conditions.

Ceramic
Ceramic abrasives are made from a mixture of ceramic grains and other abrasive materials. Their unique crystal structures have self-sharpening characteristics, so it continually exposes the newly sharpened abrasives making them more efficient and productive. They are known for their exceptional cutting power, durability, and longevity. Ceramic abrasives are extremely hard and can withstand high grinding pressures and temperatures. They are suitable for heavy-duty applications where fast stock removal and aggressive cutting action are required, such as grinding hardened steels, titanium, super alloys, and other hard metals.

Zirconia alumina
Are synthetic abrasives made by fusing zirconium and aluminium oxide. They are known for their high strength and durability and are great for carbon and mild steel applications.

Aluminium oxide
Abrasives were one of the first to be used for flap discs. They are made from bauxite ore and undergo a refining process to produce abrasive grains of different sizes. They are not self-sharpening and are commonly used for general-purpose grinding, deburring, blending, and finishing operations on various metals.

How To Use A Flap Disc

Flap discs are a type of abrasives and fall under the scope of PPE regulations. When using flaps discs, wear appropriate personal protective equipment (PPE) including safety glasses/goggles, a face shield, ear protection, and work gloves. It is also important to make sure your angle grinder must have a guard positioned between you and the disc. The guard is designed to protect you from an injury in case there is a breakage or flap separation during use.

Always inspect the flap disc, backing pad, and angle grinder before and after use. Look out for any signs of damage and never use a damaged disc to avoid safety hazards. Store the flap discs in their original containers and keep them away from water or other fluids.

One of the most important factors in using flap discs is the angle. A flap disc must always be used at the correct angle to achieve the best results and to avoid wear or damage to the backing pad. The correct angle will also depend on the type of flap disc being used.

Flap discs should not be used flat or on the edge and avoid excessive pressure or angling the disc too steeply as it may cause uneven grinding or excessive wear on the disc. Move the flap disc smoothly across the workpiece surface, using even and consistent motions. Avoid dwelling in one spot to prevent excessive heat buildup or uneven finish.

Process of Flap Disc

Flap disc are primarily used for polishing and grinding in light industry, wood products, furniture, hardware, automotive, textiles, jewelry, machinery, shipbuilding, aviation, and other fields. They are effective for tasks such as polishing, weld grinding, paint and rust removal, deburring, and chamfering surface finishing. These disc are used in conjunction with electric (pneumatic) angle grinders.

First, let's deconstruct a flap disc; it consists of two main parts: the abrasive cloth and the backing plate, which are bonded together with an adhesive. Currently, the vast majority of flap disc on the market are produced by machines, although a small portion still requires manual production. Handmade flap disc are primarily used for specialized grinding needs or where there are high demands on the quality of the flap disc. Typically, the flap disc we commonly use are produced by a flap disc machine.

The production process of a flap disc machine involves several essential steps. First, a slitting machine cuts the abrasive cloth into small rolls (the width of these rolls corresponds to the width of each abrasive leaf on the disc). Next comes the flap disc machine itself, which first grabs a Fiberglass Backing Pad and applies a circle of glue (Flap Disc Adhesive) to it. Then, it cuts the abrasive cloth and places it on the adhesive, thus forming a Flap Disc. At this point, the disc is not yet ready for use because the Flap Disc Adhesive has not been dried.

Components of Flap Disc

Disc shape: Flat, conical, and compressed
Flat Flap Disc or T27 Disc- As the name suggests, these are used on flat surfaces for edge grinding and deburring.
Conical Flap Disc or T29 Disc- These discs are perfect for surface conduct and aggressive grinding. They are also used for heavy stock removal in different grinding applications.
Compressed Flap Disc- This disc can perform both edge grinding and deburring as well as equally effective for heavy weld removal.

Bonding and backing materials
Poly-cotton fabric and polyester fabric are the two most common bonding and backing materials used in flap discs.

Backing plates: Fiberglass, plastic, and metal
Flap disc backing plates are typically made of three main components: plastic, metal, and fiberglass.

Flap density
The total amount of abrasive area used by the flap on the disc is known as the flap density. The number of flaps used, the angle at which they are used, and the space between flaps all affect the size of the abrasive area. Low-density flap disc is good for heavy-duty applications and fast stock removal, while high-density flap discs are perfect for working on curved and irregular surfaces.

Grain types
Flap discs are designed with different types of abrasives including ceramic, zirconia, and aluminum oxide grains. You can choose the grain material according to your application requirement.

Abrasive grit and disc size
Abrasives are available in various grit range from coarse, to medium and fine. A high grit number means a small abrasive grain. Similarly, a low grit number means a large abrasive grain. For fine abrasive products choose high grit or small grain size. Flap disc with coarse abrasive grit is perfect for heavy stock removal and aggressive grinding. And, flap disc with medium or fine abrasive grit is perfect for deburring, mixing, and finishing applications.

How to Maintain Flap Disc

Cleaning
After each use, it is important to clean the flap disc to remove any debris or residue that may have accumulated during the grinding or finishing process. Use a brush or compressed air to remove the particles from the flaps and backing plate.

Storage
Store flap disc in a clean and dry area to prevent moisture or contaminants from affecting the performance of the abrasive material. Keep them away from direct sunlight and extreme temperatures.

Inspecting
Before each use, inspect the flap disc for any signs of damage or wear. Check for frayed or torn flaps, cracks in the backing plate, or any other abnormalities that may compromise the disc's effectiveness. Replace any damaged or worn-out flap disc immediately.

Proper handling
Handle flap disc with care to avoid dropping or mishandling them. Rough handling can lead to damage or misalignment of the flaps, affecting their performance.

Correct storage position

When storing flap disc, keep them in a flat position or hang them vertically to prevent warping or distortion of the flaps. Storing them in a bent or uneven position can result in uneven wear and reduced performance.

Avoid excessive pressure

While using flap disc, avoid applying excessive pressure, as it can lead to premature wear and tear. Let the abrasive material do the work, applying light to moderate pressure for optimal results.

Regular inspections

Periodically inspect your flap disc during use to ensure they are still performing effectively. If you notice a decrease in performance or signs of wear, replace the flap disc promptly to maintain the desired results.

Certifications

Our Factory

A new factory was complete construction and jinan enying abrasive tools co.,ltd was established, with a modern standard production workshop of 5,000 square meters. With a number of international leading automatic high-precision standard production lines, the annual production of all kinds of abrasive tools 50 million pieces.
Enying Company is constantly developing and making progress. We firmly believe that the future of the company will be better and better. We also hope that we can leave a perfect cooperation with you in our company history.

FAQ

Q: What is a flap disc?

A: A flap disc, also known as a surface conditioning disc or a sanding disc, is a type of abrasive tool used on power tools like angle grinders. It features overlapping flaps of coated abrasive material that wear down gradually, providing a consistent cutting surface.

Q: What are flap discs made of?

A: Flap discs are composed of coated abrasives such as aluminum oxide, zirconia alumina, or ceramic grains. These grains are bonded to a backing material, which can be paper, cloth, or a combination of both.

Q: How do flap discs work?

A: When a flap disc is rotated, the flaps flex and conform to the surface being worked on, providing an even and controlled cut. As the flaps wear down, new abrasive grains are exposed, maintaining the cutting efficiency.

Q: What is the difference between a flap disc and a grinding wheel?

A: Grinding wheels are solid, rigid disks with abrasive grains throughout, while flap discs are made of flexible flaps that conform to the surface being worked on. Flap discs are more versatile for curved surfaces and can provide finer finishes.

Q: What are flap discs used for?

A: Flap discs are used for grinding, sanding, deburring, and finishing a variety of materials, including metal, wood, and plastics.

Q: How do you choose the right flap disc for your project?

A: Consider the material you're working with, the finish you desire, the size of your angle grinder, and the type of job (e.g., heavy stock removal or finishing). The grit number and abrasive material should be selected accordingly.

Q: What is the grit number on a flap disc?

A: The grit number indicates the coarseness of the abrasive material. A lower number (e.g., 24 or 40) is coarser and used for more aggressive material removal, while a higher number (e.g., 120 or 240) is finer and used for finishing.

Q: What is the difference between a flap disc and a flap wheel?

A: A flap wheel is cylindrical and wraps around a mandrel, making it ideal for internal surfaces and corners. A flap disc is flat and is used for external surfaces, edges, and larger, flat areas.

Q: Can flap discs be used on a drill press?

A: Flap discs are primarily designed for use on angle grinders, not drill presses. Using one on a drill press could be unsafe and may not provide the desired results due to the design of the tool.

Q: What safety precautions should be taken when using flap discs?

A: Always wear appropriate Personal Protective Equipment (PPE), including safety glasses, gloves, and a dust mask. Ensure the tool is rated for the maximum speed of the disc, and never exceed the maximum speed rating.

Q: How do you install a flap disc on an angle grinder?

A: Align the disc with the spindle of the angle grinder, then tighten the nut or use a spanner wrench to secure it. Make sure it is securely attached before use.

Q: How do you know when to replace a flap disc?

A: Replace a flap disc when it no longer cuts efficiently, the flaps are excessively worn, or if there are signs of damage. Regular inspection is important to ensure safety and performance.

Q: Can flap discs be used wet?

A: Some flap discs are designed for wet use, which can help reduce heat and dust. However, it's crucial to check the manufacturer's specifications to ensure the disc is suitable for wet applications.

Q: What are the benefits of using flap discs?

A: Flap discs are versatile, efficient, and provide consistent results. They can be used on a variety of materials and are suitable for both heavy stock removal and finishing tasks.

Q: How long do flap discs typically last?

A: The lifespan of a flap disc depends on factors such as the material being worked on, the grit size, and the user's technique. Higher-quality discs with durable abrasive materials will generally last longer.

Q: Can flap discs be sharpened?

A: Flap discs are not designed to be sharpened. They are intended for use until the abrasive material wears down to the point where it is no longer effective.

Q: Are there different types of flap discs?

A: Yes, flap discs vary by abrasive material, grit size, backing material, and diameter. They can be specialized for different applications and materials.

Q: How do you store flap discs?

A: Store flap discs in a cool, dry place to protect them from moisture and dust. Keeping them in their original packaging or a sealed container is recommended to extend their lifespan.

Q: Are flap discs reusable?

A: Yes, flap discs are reusable until they are worn out. They should be inspected regularly for damage or wear.

Q: Can flap discs be used for cutting through materials?

A: Flap discs are not designed for cutting through materials. They are used for grinding, sanding, and finishing. Cutting through materials should be done with a dedicated cutting disc.

As one of the most professional flap disc manufacturers and suppliers in China, we're featured by quality products and good service. Please rest assured to wholesale customized flap disc at competitive price from our factory. Contact us for more details.

Angle Grinder Scouring Pad,