When To Use Flap Discs Or Grinding Discs?

Flap discs and grinding discs are two popular abrasive tools used in metal fabrication and welding. Both tools are designed to help remove metal, but they differ in how they achieve this goal. Understanding the differences between flap discs and grinding discs is essential for selecting the right tool for the job.

Grinding discs are designed for heavy-duty grinding and are used to remove metal quickly. They consist of a flat, circular disc made from abrasive material, typically aluminum oxide or zirconia, and are mounted on an angle grinder. Grinding discs are ideal for removing large amounts of metal, such as welds or seams, or for shaping metal. They work by rapidly abrading the metal, which generates heat and friction, making them ideal for heavy-duty grinding.

Flap discs, on the other hand, are designed for lighter grinding and are used for blending, finishing, and deburring metal. They consist of overlapping flaps of abrasive material, typically aluminum oxide or zirconia, that are arranged around a central hub. As the angle grinder rotates, the flaps grind the metal, creating a smoother surface. Flap discs are ideal for blending metal, such as removing high spots or leveling out surface imperfections, or for deburring metal, such as removing sharp edges or rough spots.

In terms of choosing between flap discs and grinding discs, the key factor is the type of work you need to do. If you need to remove large amounts of metal quickly, a grinding disc is the way to go. But if you need to blend, finish, or deburr metal, then a flap disc is the better choice.

It is also important to consider the type of metal you will be working with. Grinding discs are typically used with harder metals, such as steel, because they can handle the heat generated during grinding. Flap discs are ideal for softer metals, such as aluminum, because they are less likely to cause warping or heat buildup.

Another factor to consider is the type of abrasive material used in the disc. Aluminum oxide is the most common abrasive material used in flap discs and grinding discs. It is durable, versatile, and economical. Zirconia, on the other hand, is a more premium abrasive material that is typically used for more demanding applications. It is more durable and longer-lasting than aluminum oxide, but it is also more expensive.

In conclusion, the choice between flap discs and grinding discs depends on the type of work you need to do and the type of metal you will be working with. Grinding discs are ideal for heavy-duty grinding and removing large amounts of metal, while flap discs are ideal for blending, finishing, and deburring metal. Consider the type of abrasive material used in the disc as well, as this will affect the durability and cost of the disc.