What Are The Recommended Rpms For Different Types Of Power Brushes

DRIVING BRUSHES NEEDS HORSEPOWER

Horsepower requirements for driving a power brush are often determined by four factors:

• The need for a strong brush.
• Resistance (trim length) between the work surface and the brush.
• The brush's speed.
• width of the brush face.

Estimated horsepower chart (based on a medium brushing action for a 1" brush face)

The amount of horsepower needed for wide-face brushes depends on the relative brush load. Short-trim brushes typically require more horsepower than long-trim brushes.

SURFACE SPEEDS THAT ARE RECOMMENDED FOR BRUSHING APPLICATIONS

SURFACE SPEEDS TABLE (PERIPHERAL SPEED IN FT/MIN)

Related Article: Understanding RPM Ratings on Abrasive Tools

BRUSHING ACTION

Power brushing conditions are subject to several variations. Many times, using one or more power brushes will yield the same results; nevertheless, if using only one brush does not yield the intended outcomes, consider the advice below:

RESULTS CHANGES AIM FOR

• Change in brush suggested.

QUICKER ACTION

• Speed up your brushing.
• Employ thicker filament or wire.
• Use a brush that has been trimmed short.
• Increase RPM or use a wider brush.

SUPERIOR FINISH

• Employ finer filament or wire.
• Try using a nylon filament brush or Tampico.

REACH UNUSUAL SURFACE AREA

• For increased versatility, use a brush with a longer trim length.

REDUCED LIFE

• Use longer trim and finer wire.

INSTEAD OF ROUGHING OR PREENING IT, REMOVE THE BURR

• Boost the brush's speed.
• Use a shorter brush.
• To check if the tips are cutting or wiping, check the brushing pressure.

Note: The brush's rotational speed is crucial. (See the Surface Speed Table).

TOOLS THAT ARE PORTABLE

Brushes with a maximum recommended diameter of 6" should be used with electric or air-powered portable tools.

FACTORS THAT INFLUENCE RECOMMENDED RPMS FOR POWER BRUSHES

Diameter and surface speed aren't the only factors to consider when choosing the right RPM for your power brush. There are several other real-world operating factors that an industrial user must consider when determining performance, finish quality, and brush life.

1. Type of Brush Construction

Different brush constructions react differently at higher speeds:

• Crimped Wire Brushes: They are more flexible, best used for light deburring and general cleaning at moderate to high RPMs.

• Twist Knot Wire Brushes: They are designed for aggressive cutting but call for controlled RPMs to avoid premature wire breakage.

• Abrasive Nylon Brushes: Generally can run at higher surface speeds; however, overheating can shorten filament life.

Knowing your construction helps avoid over-speeding and provides uniform results.

2. Material Being Processed

The workpiece hardness influences the optimal RPM (revolutions per minute).

• Soft metals (aluminum, brass): Lower RPMs prevent gouging. 

• Carbon steel or stainless steel: Medium to high RPMs improve cutting efficiency. 

• Non-metal surfaces include plastic, composites: Must use reduced RPMs to avoid melting or distortion.

3. Aggressiveness Required

Competitor references emphasize matching RPM with required brushing intensity:

• Low RPM → Light cleaning, rust removal, polishing

• Medium RPM → Blending, scaling, weld discoloration removal

• High RPM → Heavy deburring, burr removal, aggressive surface prep

Increasing RPM without adjusting brush pressure can lead to wire fatigue, so balance both factors.

4. Safety and Maximum Rated Speed

Every power brush has a maximum safe RPM stamped on the brush or packaging. Exceeding this rating can cause:

• Wire breakage

• Excessive vibration

• Brush failure

Always match the tool’s RPM range with the ANSI safety recommendations for power brushing.