How To Use Wire Cup Brushes For Angle Grinder

Angle grinders are a type of power tool that can be used to remove scratches, paint, smooth surfaces, and polish metal. Angle grinders work with attachments specifically designed for every task. One of the attachments is a wire cup brush. In this article, we will discuss how to install or use wire cup brushes for angle grinders.

Wire Cup Brushes For Angle Grinders

Wire bristles or filaments fastened to a cup-shaped base make form wire cup brushes, which are wire abrasive tools. Brass, carbon steel, and stainless steel are some of the materials used to make these brushes. They're also available in a variety of styles, including crimped and (twist) knotted. On both flat and curved surfaces, wire cup brushes can be used for a number of tasks, such as edge blending, cleaning, deburring, rust, paint, scale removal, and surface preparation.

There are cup brushes for a variety of tools, including grinders.  While a cup brush for die grinders and impact drivers normally has a hex shank attachment, a wire cup brush for angle grinders usually has a threaded arbor hole in the middle, though you should always check the product specs and recommendations.

Crimped Vs. Knotted Wire Cup Brush

Choose from crimped or twisted wire cup brushes. Crimped brushes seem very different from knotted brushes. Instead of joining the filaments, they are separated and crimped to keep the wires from tangling. Compared to their knotted counterparts, the brushes are more flexible and have more give. This style of cup brush is excellent for cleaning and polishing small areas.

Knotted cup brushes, often called twisted knot cup brushes, are made by finely twisting metal filament. This process creates strong and stiff, cable-like strands that enhance their strength and effectiveness. Because of the more solid structure created by joining the wires in this manner, the twisted wire cup brushes can be utilized for more aggressive applications.

How To Install Wire Cup Brushes For An Angle Grinder

Installation is a simple process. The following are the steps for installing wire cup brushes:

Step 1: Unplug or remove the battery from the angle grinder to disconnect it from the power source.

Step 2: Lock the angle grinder wheel. A wheel lock or spindle lock button is available on some models. It's typically found on the gearbox. The spindle is immobilized when you hit this button. You'll need a special flat wrench to keep the spindle in place while you remove the locking nut if your angle grinder doesn't have one.

Step 3: Remove the nut that holds the lock in place. Unlike wire wheels, wire cup brushes are connected directly to the angle grinder spindle. Place the locking nut in a secure location and take a photo of it. It's helpful to have photographic confirmation of where you put the locking nut when you're ready to go back to discs.

Step 4: Hold the headlock and tighten the anti-wire cover with a wrench

Step 5: Connect the grinder to the power source and turn it on. Look for unusual vibrations or wobbles in the wire cup brush for a minute. 

How To Use Wire Cup Brushes For An Angle Grinder

Step 1: Wear proper safety gear before working with grinders

Step 2: Use a vise or clamps to hold the workpiece you wish to wire brush and clean it properly.

Step 3: Move the brush against the item after pressing the "start" or "on" button on your tool. Concentrate your efforts on small parts of the surface. Begin with a lower speed and progressively increase the wire brush rotation speed. Brushing with a high-speed rotation is more effective than brushing with a low-speed rotation.

Step 4: If your tool is immobile and your object is small, move it toward the brush. Brush the object with the highest speed that is safe.

Do's and Don'ts of Using a Wire Cup Brush on an Angle Grinder

DO’S:

• Set the grinder application watch before each angle.
• Allow one minute for the grinder and wheel to warm up before using them.
• Continue to move the wire wheel across the material's surface.

DON’T’S:

• Keep in mind that you should not use carbon steel brushes, especially on stainless steel surfaces.
• Do not use an angle grinder with a missing or damaged guard.
• Apply no pressure to the angle grinder's wire cup brush.
• The angle grinder should not be held stationary.

ADDITIONAL POINTS TO REMEMBER

The following are some additional points to remember when using wire cup brushes with angle grinders:

• Wire Type

When choosing a wire cup brush, consider the material you are dealing with. While stainless steel brushes work best with aluminum and stainless steel, steel brushes work well with steel and iron. Also, crimped wires are flexible and perfectly suitable for light cleaning, whereas knotted wires are rigid and suitable for aggressive material removal.

• Brush size and Shape

Selecting the right brush size and shape for a project is also a crucial point to remember when working with wire cup brushes. Although wheel brushes are mainly used for curves or edges, cup brushes are highly suitable for working with flat surfaces.  

PRECAUTIONARY NOTE:

• Before removing and tightening the anti-wire cover, always hold the headlock.
•  When installing the wire cup brush, be sure to press the wire brush's inner hole firmly.

CONCLUSION

Angle grinders with wire cup brushes quickly remove rust and oxidation, as well as paint and glitter. It is critical to select a wire brush that is appropriate for your material because wire bristles can loosen and cause damage while in use. Proper protective apparel is required to test the wheel before use.