Steel wire brushes really are a common and essential tool in any metal fabrication shop. These brushes can be used for a number of applications, including weld cleaning, deburring, rust and oxide removal, surface preparation, and surface finishing.
One reason industrial brushes suppliers are incredibly widely used is the fact, unlike solid abrasive wheels, steel filaments will not likely remove base material or change part dimensions. Wire brushes clean surfaces in a similar manner as sandblasting, with the exception that instead of particles of sand colliding together with the work surface, wire tips speak to the workpiece. A combination of proper-quality, hardened steel wire tips together with the energy of high surface speeds enables the brushes to separate surface contaminants from base material.
Steel brushes are also versatile, with many different configurations accessible to meet the criteria of each and every application. For example, brushes with long filaments are conformable capable to follow contoured surfaces, and short trim brushes are fast-acting and suitable for severe applications. Another variable will be the fill density: Low-density brushes offer good flexibility for surface cleaning operations on irregular surfaces, and-density brushes generate a fast brushing action and long brush life.
Moreover, steel brushes are nonloading. In other words, they generally do not become clogged with particles and debris when accustomed to remove paint and similar coatings.
CS Unitec – Metalworking Solutions
Perhaps because wire brushes are this sort of familiar item, they are super easy to overlook and sometimes receive insufficient attention. However, five tips can assist you improve the performance and lifespan of your respective wire brushes.
1. Utilize the Highest Safe Speed
Power wire brushes, like cutting tools, operate most effectively as soon as the speed and pressure of the operation properly match the requirements from the application. In the majority of operations, making use of the highest speed with the lightest possible pressure will ensure the quickest brushing action and longest brush life.
Increasing brush speed for the highest safe speed increases the face stiffness and brushing action. A fine-wire brush rotating with a high-speed often produces the same results as a coarse-wire brush rotating in a slow speed, but it really generally lasts longer. Therefore, you can expect to reach the lowest production costs by utilizing the finest wire that can complete the task.
In the event the brush speed is insufficient, frustrated operators typically apply more pressure (see Figure 1). However, excessive pressure causes overbending in the filaments and also heat buildup, causing filament breakage, rapid dulling, and reduced brush life.
As an alternative to applying greater pressure, try using a brush with additional aggressive action, including one with a larger filament diameter or a shorter filament trim length, or one having a knot type instead of crimped wire. Or try increasing brush surface speed by increasing rotations a minute (RPM) or brush diameter.
You’ll need to ascertain the correct operating speed for every application. For safety, it really is imperative never to exceed the utmost safe free speed (MSFS) or RPM rating how the manufacturer publishes for every sort of brush.
Figure 1Excessive pressure causes over bending of the filaments, causing filament breakage, rapid dulling, and reduced brush life.
2. Periodically Reverse Direction
To boost the performance and extend the life of wire wheel brushes without nuts, like the brushes widely used with a bench grinder, listed here is a quick and easy tip: Periodically turn back the direction of rotation to take advantage of the self-sharpening action that can result (see Figure 2).
To turn back the direction of rotation, simply take away the brush in the spindle, flip the wire brush 180 degrees, and remount the brush securely.
3. Know Which Type of Wire to utilize
Crimped-wire brushes are general-purpose brushes which can be used for a variety of applications. They are made of hard-drawn wire that is certainly crimped allowing individual filaments to aid each other. Crimped-wire brushes provide flexibility for light- to medium-duty brushing action, and they should be suited for parts that might be damaged with the impact of your knot brush.
Knot-wire brushes (see Figure 3) are constructed with heat-treated straight wire filaments twisted as being a single unit resembling a sheet of cable or wire rope. They supply less flexibility and much more aggressive brushing action than crimped brushes in heavy-duty applications on parts that require high-impact action. Knot-wire brushes frequently are used in welding applications as well as to remove large burrs and high contamination, like multiple layers of rust, scale, paint, or oxides.
4. Keep Steel Brushes Clean
Stainless brushes often are utilized on stainless and aluminum and other nonferrous metals to reduce the possibility of “after-rust” appearing on the work surface. By simply following a few simple practices, you are able to maximize the strength of these power tools.
When you make use of a steel brush on carbon steel, tend not to use it on stainless because after-rust can happen. To prevent contamination, store all stainless brushes from areas where carbon steel particles might come in contact with the brushes, like steel workbenches.
In contrast to a popular misconception, a stainless-steel brush wire is magnetic. As a result, the time-tested practice of employing a magnet to check whether steel is stainless or carbon fails to work on brushes. The drawing process, which is often used to make brush wire, causes the material to become fascinated by a magnet. The consequences from the drawing process could be eliminated by heating the wire having a match until it becomes red-hot. In the event the wire is Type 302 stainless, it does not be attracted to a magnet after heating.
For critical operations, degrease stainless-steel wire brushes before commencing the operation. If you’ll be storing the brushes after use, degrease them and wrap them in plastic. Should you keep the brushes without protection for almost any period of time, their magnetic properties might cause the brushes to recover foreign matter, leaving after-rust when reused.
5. Use Heat-treated, 47dexqpky Steel Wire
Although stainless has the advantage of eliminating after-rust, carbon steel is superior from the critical attributes of cutting action and fatigue resistance. When purchasing carbon steel brushes for industrial applications, it is important to buy ones that include filaments produced from high-quality material. Seek out heat-treated, oil-tempered or heat-treated, high-tensile steel, specially in wire diameters of .008 inch and greater.
You can purchase industrial wire brushes through the neighborhood hardware store or do-it-yourself retailer, but over time, you may turn out spending more as a result of reduced productivity, more changeover time, and brush replacement costs. By way of example, a $5 brush might last an hour, whereas a $10 brush will likely last greater than a day.