Blog

What are non-woven abrasives?

What are non-woven abrasives?

Non-woven abrasives are a three-dimensional web of fibers with globules of resin and abrasive embedded into the network of fibers. Typically, the fibers are nylon or another synthetic material. The abrasive types can range from silicon carbide to aluminum oxide or ceramic alumina. Non-woven materials are converted into belts, discs, pads, flap wheels and flap discs to fit a variety of power tools.

 

Due to the three-dimensional structure, the finish is determined by grades rather than grit size,

and a range of grits are used to determine the grade. A finer grade offers a smoother finish, while coarse grades are good for cutting through heavy scale and debris for surface preparation.

 

Behavior of Non-woven abrasives

The three-dimensional network of fibers can compress like a sponge, or a spring, to help control

the rate of cut. This allows the abrasive to better conform to the surface without gouging, scratching, or causing other grinding defects. Non-wovens are a good choice for cleaning and surface preparation, as well as finishing operations such as deburring, polishing, and decorative finishing. While non-woven materials are extremely versatile, they are not the optimal choice for heavy material removal.

 

Workpiece materials

Non-woven abrasives are effective for use on stainless steel, standard or alloyed steel, nonferrous materials and alloys, aluminum, titanium, fiberglass, plastic and wood.

 

How to use

Non-woven abrasive grade, operating speed and pressure can be used to achieve the desired finish.  Different materials may require different grades, speeds, and various pressures.

 

Abrasive grade

Coarse:  For removing scale, rust, heavy deburring, flashings, paint and coatings.

Medium:  For lighter surface prep and cleaning, weld cleaning, blending, light deburring.

Fine: For light cleaning, blending and finishing.

Extra Fine: For final finishing and polishing, decorative finishing.

 

In general, coarser grades will leave deeper scratches on the work surface, and finer grades will leave less scratches.  Materials may require a coarser grade initially, followed by a progression though finer grades to achieve desired finish.

 

Operating speed

Non-woven abrasives are most effective between 2,000 – 9,000 SFPM, depending on the tool, the workpiece material, and the desired finish.  The operating speed of the non-woven material determines the rate of cut. Lower operating speeds are suitable for cleaning, higher speeds are used for better polishing action.  Because of this, variable speed tools are useful because they can be set to operate at the different speeds needed to clean, deburr, and polish. As always with abrasive products, never operate the non-woven product at speeds that exceed the maximum R.P.M. marked on the product.

 

Pressure

For cleaning and decorative finishing, lighter pressure ranges are used. For deburring and polishing of hard materials such as steel, more pressure should be applied. Light to medium pressure is recommended for non-woven materials, generally between 3-6 pounds. The 3-D structure of the non-woven material controls the rate of cut, so excessive pressure will not result in improved polishing or cutting rate, and will cause wear of the non-woven material.

 

Flexovit

Flexovit has introduced their brand new Phazer Non-Woven Flap Disc. This new flap disc is available in Type 29, 4-½ and 5 inch diameters and is available in Coarse (brown), Medium (maroon), Fine (green) and Extra Fine (blue). These discs are highly effective in surface preparation on metal, concrete, plastic, fiberglass, and wood making them one of the most versatile non-woven products. They are excellent for removing surface defects, light edge burs, parting lines, flashing, rust, oxides, corrosion, paint, and scale. Phazer has been designed with all of your maintenance, industrial and DIY projects in mind.

 

In addition to Phazer Flexovit also offers a wide range of non-woven materials in belts, discs, pads, and flap wheels.

 

USA Made For Controlled Manufacturing

Flexovit is committed to following strict manufacturing standards and safe product use. These standards are carried into each of our production processes. Flexovit’s Quality System is ISO certified, so you can count on every item being produced in exactly the same way, with the same results.

 

Contact us today for more information
1-800-689-3539
flexovitabrasives.com
info@flexovitabrasives.com

What Makes Flexovit’s Razorblade Line The Best On The Market?

When it comes to high-volume cutting, you need a wheel that cuts fast, lasts a long time, and brings a high level of safety. You need the hardest working cutoff wheel on the market. Metal workers know that angle grinder cutoff wheels aren’t an area you can afford to skimp on. Flexovit knows this as well, which is why we’ve spent over 20 years refining our Razorblade line of thin cutoff wheels to optimize value and improve your bottom line. Razorblades are our most popular wheel, and with good reason.
What are Razorblade Wheels?
The Razorblade line is a series of thin cutoff wheels for use with angle grinders. The Razorblade line includes seven variations, each intentionally designed to meet a different set of needs.

● Razorblade, for long life
● Razorblade EZ, for fast cutting
● Razorblade HD, for heavy duty use
● Razorblade 27 SS, for free cutting on stainless steel
● Razorblade ALU, for load free cutting on aluminum
● Razor Thin, thin profile for narrowest kerf
● Razor Combo, for cutting, deburring and light grinding

Razorblade wheels were all designed with extra durable bond formulations, and for fast cutting action with narrow kerf.

What makes Razorblade wheels so great? Flexovit has devoted decades to research and improvement in three key areas: value, safety, and quality.
The Most Bang For Your Buck
Razorblade cutoff wheels comes in both Type 1 (flat) and Type 27 (depressed center). There are product options available for cutting all ferrous metals, stainless steel and aluminum (as well as non-ferrous metals like bronze and copper). They’re available in sizes from 4” to 7”, and are available in seven specifications. In short, Razorblade wheels are amazingly versatile, offering options that suit a wide variety of needs and applications.

What makes Razorblade wheels the best value isn’t just their versatility and flexible product offerings, though. We’re confident that our wheels will outperform any other wheel on the market. In fact, we challenge you to come in and see for yourself with our P.A.C.E. Challenge.

Below is real data from past P.A.C.E. Challenges, in which a Flexovit Razorblade wheel performed in head-to-head matchups with various competitor products. In these tests, plunge cuts were made until the point at which the flange did not allow a complete top-to-bottom cut due to wear on the wheel.

*Plunge cuts on ½” Sch 40 pipe (area 1.5 sq.cm per cut) at 10 amps.
**All wheels are 4 ½” x 7/8” Type 1 thin cutoff wheels

Razorblade wheels consistently deliver the most work per penny, making the most cuts before wearing out. We know that changing and mounting new wheels is a hassle that takes several minutes each time, so we design all our wheels to last longer than competing products.
The Safest Construction
When you have a wheel spinning at high RPM’s, safety is your top priority. If that wheel cracks, it quickly disintegrates, scattering dangerous wheel fragments at high speed. Of course, workers should always take proper safety precautions including wearing protective eyewear and clothing, using proper safety guards on power tools, respecting maximum RPM ratings marked on the wheel, and other precautions consistent with ANSI Code B7.1. But isn’t it better to also use wheels whose safety features are the best on the market?

Resinoid-reinforced cutoff wheels, including Razorblade wheels, are constructed with fiberglass to prevent them from breaking. In order for the fiberglass to bond with the wheel matrix, it must be coated with phenolic resin before inclusion in the wheel. Since the resin coating gets drier with time, it is important that the coated and cut fiberglass is used within a certain time frame. Most manufacturers buy pre-coated, precut fiberglass for inclusion in their wheels. However, Flexovit coats and cuts the fiberglass at our plant as part of our manufacturing process. This means that the fiberglass is always freshly coated, which creates a more unified bond with the matrix of resin and grain when the wheel is produced. Because we have more control over this process, our fiberglass reinforcement gives the wheel strength to resist centrifugal and side load forces. It boils down to this: freshly-coated fiberglass creates a better bond, which results in a safer product. With in-house fiberglass coating and cutting, Flexovit maintains a significantly higher degree of quality control when it comes to the safety and performance of our grinding wheels.
USA Made For Controlled Manufacturing
We also maintain a high degree of control over the rest of our production processes. Razorblade wheels, like all Flexovit resin-bonded wheels, are made right here in the United States. And that’s important, because it means we retain control over every aspect of production. Our raw materials are sourced domestically, and all of our production happens in-house. We’re proud to be a USA manufacturer who supports other USA manufacturers. Flexovit Razorblades are made without compromise in the USA.

Flexovit is committed to following strict manufacturing standards and safe product use, and these standards are carried into each and every one of our production processes. Flexovit’s Quality System is ISO certified, so you can count on every item being produced in exactly the same way, with the same results.
The Longest Lasting, Hardest Working Cutoff Wheel You Can Buy
Razorblade wheels offer the longest life in the toughest applications. They’re an essential tool in any metalworking facility that consistently outlast, out-cut, and outperform other wheels on the market.