Selecting Wire Brush Wheels

Wednesday, 1 May 2019  |  Admin

1 Introduction

Crimped Wire Wheel Brushes: made from grey steel, stainless steel and brass coated steel look wavy or bent. ‘Crimping’ separates the metal filaments, resulting in less wire fatigue and breakages caused by flexing, bending and vibrations. During use, tiny pieces of wire break off leaving a fresh cutting edge exposed. These ‘crimps’ cause cleaner breaks to occur and ensure consistent brushing as the cutting action is at the wire tips. The base material of the work-piece determines which wire type to use.

Narrow brush faces are perfect for corners, crevices and irregular surfaces, whilst a wider brush face provides consistent brushing over large areas.

Knotted Wire Wheel Brushes: feature knots, or twists of metal wire, in grey steel or stainless steel. They support aggressive cutting and absorb the 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. Brushes designed for heavier duty applications might have knots twisted for the entire length.

Trim Length: A short trim length makes the brush face rigid and consequently the brush removal capacity is higher. With a longer trim length the brush becomes flexible and it provides a uniform brushing even on irregular surfaces. Work efficiency increases as a brush diameter increases. To calculate the biggest possible diameter for a given machine, it is necessary to consider the maximum RPM of the power tool or machine being used. Example, for an electric tool with a maximum RPM of 6,000 the brush should not exceed 175mm diameter. A shorter trim length provides a more aggressive brushing action, whereas flexibility to adapt to irregular or uneven surfaces increases as trim length increases. In contrast to abrasives and cutting tools, wire brushes do not remove the base material of a treated surface. Herein, brushes serve as an essential tool for a wide range of industrial processes.

Wire Brushes vs Hard Abrasives: Wire brushes act as an impact tool removing oxide, paint or other adherence from the surface without damaging the base material, as opposed to hard abrasives which will remove the base material along with the surface adherence. Wire brushes are much more flexible, allowing the ability to clean difficult areas to reach and adapt to irregular surfaces, which bonded and coated abrasives cannot.

Selection Parameters: Please consider the following when selecting a brush:

• The work to be done

• Application surface

• RPM parameters of the machine

When selecting the brush material:

• The material of the application surface

• Desired finish.

2 Wire Options:

Brass Coated Steel:

  • High Performance, flexibility and longer life span
  • Anti-corrosion material
  • Suitable for a large range of finishing
  • Traction resistance 230-250 kgs/mm²
  • Carbon Content 0.75% Grey Steel
  • Suitable for twisted knot brushes and a high removal capacity.
  • Not suitable for stainless steel surfaces.
  • Traction resistance 200-275 Kgs/mm²
  • Carbon content 0.5-0.6%

Stainless Steel:

  • These wires are used for the brushing of stainless steel, aluminium or nonferrous metal surfaces.
  • Stainless steel turned into wire becomes lightly magnetic. (Beware the misconception that stainless steel wire has no magnetic signature.)
  • Traction resistance 160-180 Kgs/mm² following AISI 304-L regulations.