Brushing Guide and Information
Applications Advantages Power Brush Types Mounting Power Brushes
Typical Power Brush Applications
Deburring Power brushes are widely used to remove burrs
created by other machining operations. Power brushes can completely
remove burrs without creating secondary burrs or leaving two sharp
edges. Unlike grinding tools, brushes are selective to an edge;
they will remove the burr but none of the base material.
Surface Finishing Power brushes are excellent tools for
improving surface finishes to gain a desired appearance. Brushes
do not remove the base metal. They remove only the metal particles
left on surfaces which have been ground or abrasive polished.
Power brushing also tends to relieve stress created by other machining
operations. Many different surface finishes can be obtained by
using power brushes.
Edge Blending Power brushes are ideal for developing a
rounded corner at the juncture of two surfaces. Power brushes
perform this application without removing material on the surface
adjacent to the edge or changing the part tolerance. This reduces
stress concentration and part fatigue, increases part life and
improves the surface finish.
Roughening Power brushes are uniquely suited for creating
better bonds on surfaces such as rubber, leather plastics and
nonferrous metals. Surfaces can be roughened prior to painting
or bonding to achieve better adhesion.
Cleaning Power brushes are distinctly suited for removal
of surface film, dirt, rust, heat treat scale, weld slag, corrosion
and paint. Power brushes also remove varnish and insulation from
electrical wire, motor stators, etc. fiber, synthetic and fine
stainless steel brushes can be used for wet-cleaning operations.
Advantages of Power Brushes
Rugged Construction The only surface cleaning and conditioning
tool tough enough to stand up under prolonged, heavy use.
Easy on Equipment Brushes are non-abrasive so they do not
produce equipment-destroying abrasive dust.
True Selective Cutting Brushes act as an impact tool removing
surface contamination with millions of tiny hammer blows without
cutting away any base material as abrasives will.
Stress Relieving
and Surface Conditioning Brushing action produces the same
effect as shot peening (a method used to increase the life of
highly stressed parts in aircraft and race cars) without adding
extra operations Brushing will not change part tolerances.
Brushes Are Non-loading Unlike non woven, bonded and coated
abrasives, brushes will not load when brushing soft materials.
Use Brushes Instead of:
- Abrasive Belts
- Non-Woven Nylon Products which wear rapidly
- Sand Blasting
- Steel Wool
- Buffing Wheels
- Harsh Chemicals
- Hand Filing
- Hand Sanding
- Tumbling or Vibratory Finishing
- Grinding Wheels
Power Brush Types
Wheel Brushes 
Are circular in shape and generally no wider than 2". Standard
wheel brushes range from 5/8'' to 15'' in diameter and may be
filled with material such as: Steel, Stainless Steel, Brass, Bronze
and Nickel Silver Wires; Natural Fibers such as Tampico and Animal
Hair, and Synthetics such as Nylon, Abrasive Filled Nylon and
Polypropylene. There are two basic forms of wire used in wheel
brushes - Crimped Wire for flexibility and Straight Wire for knot
type for more aggressive brushing action.
Wide Face Brushes Are
identified as brushes where the face is greater than the diameter.
This type of brush can be created by stacking a number of wheel
brushes on a common arbor. Wide face unit brushes are generally
specially designed for a specific customer application.
Cup Brushes Are available in three basic types: Miniature
3/8" - 1" diameter (stem-mounted), Crimped Wire Types
1 3/4" - 6" diameter for lighter jobs and Knot Type
2 1/2" - 6" diameter for heavy duty jobs requiring aggressive
brushing action. These brushes are generally filled with wire
or abrasive filled nylon and used on portable power tools.
Tube Brushes Are generally
twisted-in-wire types for use on portable tools and drill presses
to clean and finish holes and internal threads. Series 84 Diameters range
from 1/8" - 3" . Series 81,82 diameters range from .024" to 1/2".
Stem Mounted Brushes
Are generally used in portable air and electric tools for light
to heavy duty work where space is limited. Diameters range from
1/2" - 4". End, Wheel and Cup brushes, crimped wire
and knot type, are permanently mounted on a 1/4" steel shank.
Special/Custom Designed Brushes
Our Engineering department takes pride in solving customers' special application problems. If one of our hundreds of standard stock brushes does not completely satisfy a customer's application, special brushes can be designed to meet the required specifications. Brush types and size ranges are virtually infinite to meet the challenges of industry
Mounting Power Brushes
- Select a brush which is compatible with the horsepower of
the machine.
- Select the largest diameter brush which will fit on the machine
with all guards in place.
- Make sure all guards are in place before starting the machine.
1. Largest diameter brush which equipment will handle is generally most efficient.
2. At a given spindle speed (R.P.M.) a larger brush has a higher surface speed (S.F.P.M.).
3. 8" diameter is maximum generally recommended for use on portable tools.
4. The larger the center plate, the more wire ends that can be made available on the cutting perimeter.
5. Short trim and dense fill is very fast cutting.
6. Long trim is more flexible and best for contacting irregular surfaces or removing surface particles.