BRM Official Blog. Wire wheel brush grinder
Which Wire Wheel Brush Do You Need?
Wire wheel brushes are wheel-shaped brushing tools with sturdy hubs and metal wire filaments. They are used for cutting, cleaning, deburring, edge blending, polishing, and surface finishing. A type of power brush, wire wheels are motor-driven and may feature an arbor hole or keyway that supports their use with grinding equipment or CNC machinery. Different types of wire wheel brushes are available, but tool selection begins with an understanding of the basic wire wheel types: crimped and knotted. Manufacturers also need to consider brush tool specifications and their own application requirements.
Crimped Wire Wheels for Uniform Brushing
Crimped wire wheel brushes feature carbon steel, stainless steel, or brass filaments that look wavy, bent, or pinched. Crimping separates these metal filaments from each other and helps to reduce the wire fatigue and wire breakage that’s caused by flexing, bending, and vibrations. Crimped wheels that are made with oil-tempered wire may cost more, but they typically last longer. During normal wheel brush use, small pieces of wire break off and leave fresh cutting edges exposed. Crimps help to create cleaner breaks. They also support consistent, uniform brushing since the tool’s cutting action is at the filament tips.
Most crimped wire wheels feature a 2” arbor hole that supports their use with shafts ranging from 1/2” to 1”. These wire wheel brushes are available in a range of sizes, but 6 and 8 inches are the most common diameters. The base material of the part or workpiece determines which filament type to select, and filament or wire size is a function of finishing requirements. Face width is also important to consider, and manufacturers can choose narrow, medium, wide, or extra wide. Narrower brush faces are ideal for corners, crevices, and irregular surfaces. Wider brush faces provide consistent brushing over larger areas.
Knotted Wire Wheels for Aggressive Brushing
Knotted wire wheel brushes feature knots or twists of metal wire, typically carbon steel or stainless steel. They support aggressive cutting and absorb bending and vibrations that can cause wire fatigue. Standard or twisted tuft brushes are twisted for about two-thirds of the filament length. The remaining third is flared slightly. With larger wire sizes and applications that require heavier brushing action, the knots may be twisted for their entire length. These knotted wire wheel brushes are known as cable twists, and are often used in oilfields and with oil pipelines.
In addition to knot or twist type, face width is an important specification to consider. Standard or twisted tuft brushes are available in medium and wide faces for uniform, heavy brushing. Stringer bead wire wheel brushes are a type of cable twist brush with a very narrow face. They’re used for surface finishing small channels and grooves, and for preparing pipes prior to welding. Like crimped wire wheel brushes with a narrow face, stringer bead brushes have longer trim for finishing irregular surfaces with corners and crevices. These knotted wire wheel brushes can also be used for cleaning cracks in asphalt and concrete.
Get the Industrial Brushes Technical Booklet
Now that you understand the basics about crimped wire and knotted wire wheel brushes, it’s time to learn how to use them under power. The Use of Industrial Brushes Guide from Brush Research Manufacturing (BRM) explains what you need to know, and includes safety guidelines. You’ll also find valuable information about other types of power brushes for surface finishing and deburring. There’s even information about BRM Flex-Hone tools. Download The Use of Industrial Brushes Guide now.
Crimped Wire Wheel Brush Angle Grinder Abrasive Power Tools
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Product Description
Packaging Delivery
Packaging Details:Hot selling industrial polishing rust removal brass wire wheel brush industrial weeding bending wheel cup brushPort: ningbo/shanghai
Product Information
| Product name | Hot selling industrial polishing rust removal brass wire wheel brush industrial weeding bending wheel cup brush |
| Brand Name | Yesking |
| Material | Copper-plated steel wire |
| Size | Customerized Size |
| Shape | Cup |
| Color | Customerized Color |
| Feature | Polishing,Rust removal |
| MOQ | 1000pcs |
| Advantage | durable |
Yongkang Yekai Abrasives Co., Ltd. was established in 1992. It has been 28 years now. We are adhering to the responsibility of product quality, responsibility to customers, and continuous improvement of our own quality. No matter from workmanship or weight, we All are better than their peers, which in return for the loyalty of regular customers.
F A Q Q1:Wonder if you accept small orders? A1: Do not worry. Feel free to contact us in order to get more orders and give our clients more convener we accept small order. Q2: Can you send products to my country? A2: Sure, we can. If you do not have your own ship forwarder, we can help you Q3: Can you do OEM for me? A3: We accept all OEM orders, just contact us and give me your design. we will offer you a reasonable price and make samples for you ASAP Q4: What’s your payment terms? A4: By T/T, LC AT SIGHT, 30% deposit in advance, balance 70%before shipment Q5: How long is your production lead time? A5: It depends on product and order qty. Normally, it takes us 15 days for an order with MoQ qty Q6: When can I get the quotation? A6: We usually quote you within 24 hours after we get your inquiry. If you are very urgent to get the quotation. Please call us or tell us in your mail, so thatwe could regard your inquiry priority
Yongkang Yekai Abrasives Co, Ltd was founded in 1992. It is a scientific and technological enterprise focusing on the research, development, production and sales of abrasive products such as steel wire wheels, louver wheels and grinding discs. Headquartered in Yongkang known as the”Hardware Capital of China”, and with agencies all over the world, the company has strong technology and RD capabilities.
Since its establishment, the company has always adhered to the operating principles of talent-oriented and honest business, gathering industry elites, combining foreign advanced information technology, management methods and corporate experience with the specific reality of domestic companies to provide companies with all-round solutions The plan helps enterprises to im-prove their management level and production capacity, so that they can always maintain their competitiveness in the fierce market competition, and realize their Rapid and stable development.
Adhering to the best products, best service, and best reputation, Yongkang /Yekai abrasives has achieved brilliant results in many markets and is your most trusted long-term partner.
Company Introduction: Our company offers variety of products which can meet your multifarious demands. We adhere to the management principles of “quality first, customer first and credit-based” since the establishment of the company and always do our best to satisfy potential needs of our customers. Our company is sincerely willing to cooperate with enterprises from all over the world in order to realize a win-win situation since the trend of economic globalization has developed with anirresistible force.
Yongkang Yekai Abrasives Co, Ltd was founded in 1992. It is a scientific and technological enterprise focusing on the research, development, production and sales of abrasive products such as steel wire wheels, louver wheels and grinding discs. Headquartered in Yongkang known as the”Hardware Capital of China”, and with agencies all over the world, the company has strong technology and RD capabilities.
Since its establishment, the company has always adhered to the operating principles of talent-oriented and honest business, gathering industry elites, combining foreign advanced information technology, management methods and corporate experience with the specific reality of domestic companies to provide companies with all-round solutions The plan helps enterprises to im-prove their management level and production capacity, so that they can always maintain their competitiveness in the fierce market competition, and realize their Rapid and stable development.
Adhering to the best products, best service, and best reputation, Yongkang /Yekai abrasives has achieved brilliant results in many markets and is your most trusted long-term partner.
Wheel Brushes for Grinder
Wheel Brushes suitable for sideways jobs on irregular surfaces, with edges, profiles and cracks. Crimped wire of very high resistance. Compact, aggressive and safe for mini-grinder.
Applications: Waste, residues and rust removal from surfaces of any material and shape.
Twist Knot Wheel brushes U101, U115, U125, U3151, U5181 and U5201 for Angle Grinders
Brushes suitable for sideways jobs on irregular surfaces, with edges, profiles and cracks. Aggressive for heavy-duty jobs at high rotation speed.
Applications: Welding preparation and continuous welding finishing, deburring, mechanical pickling.
Wheel brushes and Twist Knot Bevel Brushes UZ115, UZ125, UZ151 and UZ178 for Angle Grinders
Brushes suitable for sideways jobs on irregular surfaces, with edges, profiles and cracks. Thin and with very high wire density.
Applications: Removal of rust, encrustations, surface roughening, removal of wastes of plastic and rubber. For all the specific production in the sector of Pipelining
Vulcanized wheel brushes CV178V for Angle Grinders
Consisting of an iron ring drowned in a polyurethane solution. Uniform consumption of the filaments, constant thickness of the abrasive edge, filaments that won’t break and higher safety for the operator
Applications: Ideal for thand cleaning and for the preparation of weldings.
Wheel Brushes in Crimped Wire 6151 and 6181 for Angle Grinders
The conical shape makes these brushes suitable for sideways jobs on irregular surfaces, with edges, profiles and cracks. Jobs on angular or profiled surfaces at high rotation speed.
Applications: Waste, residues and rust removal from surfaces of any material and shape.
SIT Brushes for Power Tools
SIT has been for over 50 years the leader in Italy for the production of industrial wire brushes for electric and pneumatic tools (Grinder, Drill, Stationary) used in every environment and application. The shape of the brush allows to work with several distinct surfaces while the selection of the filament depends on the finishing and the removal desired
Tips for choice and use
The selection of the shape of the product depends on the surface on which you intend to work:
The type and formation of the filament determine the type of finishing and the processing required
Use always Individual Protection Devices (IPD like gloves, goggles and ear monitors).
Never go beyond the MAX RPM indicated for the brush.
As for the diameters of the brushes and assembling them follow the instructions of the manufacturer of the tool
Choosing the right tool for effective cleaning in welding applications
Following best practices will extend product life, ensure your safety, and increase productivity and efficiency.
It is critical to eliminate all inclusions and pollutants when preparing a material’s surface for welding and during interpass and postweld cleaning. Removing as little material as possible between weld passes saves time and money since any material removed will ultimately need to be replaced via the most expensive consumable—the filler metal. Removing too much of the base material during preweld surface preparation can also affect weld penetration, impacting the strength and integrity of the finished weld.
For these reasons, always choose the best surface preparation and cleaning tools for the job. The right solution provides efficient, effective performance—and allows you to spend more time welding and less time cleaning and making repairs.
Common Tools in Welding Applications
Three common tool categories are used for surface preparation and cleaning in welding applications:
- Bonded abrasives/grinding wheels
- Coated abrasives/flap discs
- Wire brushes and wheels
What you should choose depends on the requirements of the application and, of course, your personal preference.
Abrasive products and wire brushes differ in their performance and purpose. Abrasive products are designed to remove base material, whereas wire brushes are not. When surface preparation or weld cleaning requires that you remove slag or mill scale, a wire brush is generally recommended. Note, heavy mill scale sometimes can be too much for even the most aggressive wire brush. In these instances, choose an abrasive product. Abrasive products are specifically designed for applications such as stock removal, edge beveling, chamfering, and weld grinding and blending. Conversely, if an application requires that you preserve the base material during surface preparation and weld cleaning, a wire brush is still your best choice. Here’s how these products work.
Bonded Abrasives/Grinding Wheels. A combination of the grain type, grain size, and bonding agents (resins and additive fillers) determines the performance of each. Bonded abrasives are generally more aggressive and remove material faster, requiring a skilled operator who knows how to prevent damage, gouging, and undercutting. Wheels are constructed of abrasive grains, including aluminum oxide, silicon carbide, zirconia alumina, ceramic alumina, and combinations of these grains. A resinoid (organic) bonding agent is mixed with the abrasive grains. Finally, this mix is molded and combined with fiberglass reinforcement layers for durability and strength.
Aluminum oxide (AO) wheels are the most popular and are good for many general-purpose applications. Products made with a combination of ceramic and zirconia alumina cost more, but typically provide a better overall life and material removal. They are a good choice for materials such as armored steel, structural steel, cast iron, and INCONEL alloys.
Coated Abrasives/Flap Discs. These items are constructed using the same grain types as those found in bonded abrasives. Coated abrasives bond the abrasive grains to a backing cloth, which is most commonly a cotton, polyester, or blended backing rather than the hard grinding wheel found on bonded abrasives. This abrasive cloth can be cut into smaller flaps and layered radially to form a flap disc. It is this layered construction that gives flap discs a much softer, more forgiving feel.
The flaps are designed and positioned to wear away as the grains deplete, exposing new, fresh, and sharp grain underneath. Flap discs are often more comfortable to use and offer the aggressive cutting and grinding action of a grinding wheel; however, they also allow for blending and finishing work, which is important when the material needs to be painted, primed, or powder-coated.
Wire Brushes and Wheels. These are the primary choice for weld cleaning, when it is necessary to remove spatter and other contaminants prior to finish or the next weld pass. Remember, the tips of wire brushes do the work, functioning like tiny hammers hitting and preparing the work surface. Applying the appropriate pressure is critical to power brush performance, as excessive pressure flexes and bends the wires, preventing the tips from working. This can lead to premature wire breakage and dramatically reduce brush life.
The right surface preparation and cleaning tools provide efficient, effective performance and help ensure you spend more time welding and less time cleaning and making repairs.
Power brushes provide the speed and efficiency necessary to complete cleaning and surface preparation applications quickly and efficiently. When you are removing coating from a surface, such as epoxy, paint, or rubber, coated abrasives have a tendency to load—in other words, the material being removed packs between the grains and builds up—stopping their ability to perform. A power brush’s ability to “self-clean” makes it the best choice for these cleaning applications.
When choosing a power brush, you have several knot styles, wire gauges, and trim length options. By changing one or more of these characteristics, you can fine-tune brush performance for a specific application. For example, stringer bead brushes have narrower knots twisted from base to tip, making them better suited to penetrate tighter spaces like corners, fillets, and root pass welds. Cable-twist brushes are also twisted to the tips but have a wider profile that can quickly cover more surface area for fill passes. Standard twist brushes flare at the end, providing an even wider footprint as well as additional conformability.
Crimped-wire brushes provide less aggression and more conformability, making them a great choice for paint and rust removal and deburring. Crimped-wire brushes also leave a consistent “orange peel” finish, so they are a good choice for surface preparation and paint adhesion.
Wheel brushes are designed to work perpendicular to the work surface and are best-suited to smaller, tighter surface areas. Cup brushes are perfect for covering larger, wider surface areas because of their ability to clean a larger area in a single pass.
Making the Right Choice for You
When choosing a product for surface preparation and weld cleaning, consider the base material. Generally speaking, choose a carbon steel brush to clean carbon and mild steels and a stainless brush for stainless, aluminum, and exotic metals. Brushes are also available in copper and brass to prevent spark, when necessary.
Next, consider the application’s finish requirements. Is there a need to remove base material, or is the material being prepped and cleaned for finish or coating? For weld cleaning, a knot brush—stringer bead or cable-twist—is typically the best choice. When selecting a power brush, start by choosing the least aggressive option for the job.
For a coated or bonded abrasive, aluminum oxide provides the most cost-effective option for general-purpose grinding. Harder, more durable grains like zirconia alumina and ceramic maintain sharpness and resist heat, making them a much better choice for more aggressive grinding applications.
Finally, consider the size and orientation of the material to be cleaned. Cleaning the fill pass of a weld requires a very different tool than cleaning a large, flat surface. For example, a cup brush has a significantly larger footprint and, therefore, can cover a large area.
Best Practices to Maximize Performance
To achieve safe, optimal performance of any wire or abrasive product, think S.P.O.T.
S—Speed and Size. Choose an appropriately sized product for the tool, and use the manufacturer’s recommended guard. Be sure the maximum safe RPM marked on the wire or abrasive wheel is greater than or equal to the maximum operating RPM on the tool. When selecting high-performance ceramic abrasives, pay attention to tool speed. Tools with lower power can’t maintain the required speed and therefore don’t provide the full advantages of these high-performance, higher-priced products.
Knowing available product options and understanding their intended uses are important parts of getting the best results from abrasives and wire brushes.
P—Pressure. When operating wire brushes, you shouldn’t have to push harder because the tips should be doing the work. Applying excessive pressure to the brush prevents the tips from hitting the surface, so the sides of the wire begin “wiping” the surface. This reduces cleaning action and increases wire loss because of stress. If a power brush is not performing to expectation, consider changing the knot, increasing the wire gauge, or shortening the trim length. A common complaint about wire brushes is wire loss, and the main cause, in many cases, is improper use or excessive pressure.
When you are using an abrasive, increasing pressure slows tool speed and significantly increases friction and heat. Heat and pressure are the enemies of any abrasive product. Use even, consistent pressure and motion to minimize heat discoloration and maximize performance.
O—Orientation. Wheel brushes are designed for use perpendicular to the work surface. This positions the wire tips for optimum performance and reduces lateral stress on the wire, preventing wire loss, poor performance, and short brush life. Bonded abrasive cutting wheels are also designed for use perpendicular (90 degrees) to the work surface for best performance and longevity.
Grinding wheels and flap discs are designed for use at 5 to 35 degrees in general. When selecting a flap disc, choose Type 27 for finishing and applications that require lower grinding angles—5 to 15 degrees. Choose Type 29 for more aggressive, higher angle grinding—15 to 35 degrees.
T—Time. All products are designed to be moved across the work surface. When you are using an abrasive product, do not dwell in one spot as it will lead to pitting, gouging, increased heat, and reduced surface finish.
Knowing what your product options are and understanding their intended uses are important parts of getting the best results from abrasives and wire brushes. Always follow best practices to extend product life, improve operator safety, and increase productivity and efficiency. Doing so can help you complete jobs faster, saving time and money for a better bottom line.
No matter the tool, inspect the abrasive or wire brush each time it’s used for any signs of damage or wear. Replace as necessary.
