Steel wire brushes are a common and essential tool in virtually any metal fabrication shop. These brushes can be used for a variety of applications, including weld cleaning, deburring, rust and oxide removal, surface preparation, and surface finishing.
One reason industrial brush manufacturer are so popular is the fact that, unlike solid abrasive wheels, steel filaments will not remove base material or change part dimensions. Wire brushes clean surfaces in the same way as sandblasting, other than as opposed to particles of sand colliding using the work surface, wire tips get in touch with the workpiece. The mixture of excellent-quality, hardened steel wire tips with the energy of high surface speeds enables the brushes to separate surface contaminants from base material.
Steel brushes are versatile, with numerous configurations accessible to meet the requirements of each application. For instance, 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 may be the fill density: Low-density brushes offer good flexibility for surface cleaning operations on irregular surfaces, and high-density brushes produce a fast brushing action and long brush life.
In addition, steel brushes are nonloading. Quite simply, they do not become clogged with particles and debris when used to remove paint and similar coatings.
CS Unitec – Metalworking Solutions
Perhaps because wire brushes are this sort of familiar item, they are simple to overlook and frequently receive insufficient attention. However, five tips can help you boost the performance and life time of your wire brushes.
1. Make use of the Highest Safe Speed
Power wire brushes, like cutting tools, operate most effectively once the speed and pressure of your operation properly match the requirements of the application. In many operations, while using highest speed using the lightest possible pressure will ensure the quickest brushing action and longest brush life.
Increasing brush speed for the highest safe speed raises the face stiffness and brushing action. An excellent-wire brush rotating at the high speed often produces the identical results like a coarse-wire brush rotating with a slow speed, nevertheless it generally lasts longer. Therefore, you can expect to get the lowest production costs utilizing the finest wire that will do the job.
In case the brush speed is insufficient, frustrated operators typically apply more pressure (see Figure 1). However, excessive pressure causes overbending from the filaments as well as heat buildup, resulting in filament breakage, rapid dulling, and reduced brush life.
Rather than applying greater pressure, try using a brush with additional aggressive action, including one by using a larger filament diameter and/or a shorter filament trim length, or one by using a knot type rather than crimped wire. Or you can try increasing brush surface speed by increasing rotations each minute (RPM) or brush diameter.
You’ll need to discover the correct operating speed for each and every application. For safety, it can be imperative to never exceed the highest safe free speed (MSFS) or RPM rating that this manufacturer publishes for each type of brush.
Figure 1Excessive pressure causes over bending in the filaments, causing filament breakage, rapid dulling, and reduced brush life.
2. Periodically Reverse Direction
To boost the performance and extend the lifestyle of wire wheel brushes without nuts, like the brushes frequently used over a bench grinder, this is a simple and fast tip: Periodically reverse 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 Use
Crimped-wire brushes are general-purpose brushes that can be used for a variety of applications. They are made of hard-drawn wire which is crimped to permit individual filaments to back up the other. Crimped-wire brushes provide flexibility for light- to medium-duty brushing action, and they should be applied to parts which can be damaged from the impact of a knot brush.
Knot-wire brushes (see Figure 3) are made of heat-treated straight wire filaments twisted being a single unit resembling some cable or wire rope. They supply less flexibility and 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, including multiple layers of rust, scale, paint, or oxides.
4. Keep Stainless-steel Brushes Clean
Stainless brushes often are being used on stainless steel and aluminum and other nonferrous metals to eliminate the danger of “after-rust” appearing around the work surface. By using a few simple practices, it is possible to maximize the strength of these tools.
Once you work with a stainless-steel brush on carbon steel, usually do not use it on stainless-steel because after-rust may appear. To avoid contamination, store all stainless brushes far from areas where carbon steel particles might come in contact with the brushes, such as steel workbenches.
In contrast to a popular misconception, a stainless-steel brush wire is magnetic. Consequently, some time-tested practice of making use of a magnet to confirm whether steel is stainless or carbon fails to work towards brushes. The drawing process, which is often used to generate brush wire, causes the information to be attracted to a magnet. The results of the drawing process might be eliminated by heating the wire by using a match until it might be red-hot. If 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 beginning the operation. If you’ll be storing the brushes after use, degrease them and wrap them in plastic. In the event you store the brushes without protection for virtually any time period, their magnetic properties could cause the brushes to accumulate foreign matter, leaving after-rust when reused.
5. Use Heat-treated, 47dexqpky Steel Wire
Although stainless steel has the main advantage of eliminating after-rust, carbon steel is superior inside the critical attributes of cutting action and fatigue resistance. When purchasing carbon steel brushes for industrial applications, it is essential to buy ones which contain filaments made out of high-quality material. Look for heat-treated, oil-tempered or heat-treated, high-tensile steel, especially in wire diameters of .008 inch and greater.
You can aquire industrial wire brush in the neighborhood home improvement center or do-it-yourself retailer, but in the long term, you could possibly wind up spending more because of reduced productivity, more changeover time, and brush replacement costs. As an example, a $5 brush might last an hour, whereas a $10 brush will likely last over a day.