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Wire Brush Recommendations and Guides

Recommended Brushing Speeds

Performance is improved when the recommended operating speeds are used. Below is a recommended guide to improving brushing efficiency by application.

Application Surface Feet Per Minute (SFPM)
Removing Burrs 5500 to 7500
Removing Scale 7500 to 10000
Cleaning Welds 7200 to 9400
Edge Blending 4700 to 7500
Cleaning (Dry) 4000 to 5500
Cleaning (Wet) 1900 to 4000
Surface Polishing 6400 to 8000
Surface Buffing 8000 to 10000

Horsepower Guide

Several factors affect the horsepower required to drive an industrial power brush for each given application: First, the brush pressure required to perform the job. Second, the resistance that exists between the brush and the workpiece and third, the speed of the brush itself.

Below is a recommended guide for the horsepower requirements for light to medium surface preparation.

Brush Diameter (BD) Recommended Motor Size RPM
4 1/4 H.P. 3450
6 1/2 H.P. 3450
8 3/4 H.P. 3450
10 1 H.P. 1750
12 1 H.P. 1750

Minimum Shaft Diameter For Wheel Brushes

It is important that the wheel brush is mounted properly. The shank/shaft should be held next to the supported end minimizing overhang of the shank. See illustration below.

Brush Diameter (BD) Face Width (FW) Shank Diameter (SD)
2 1/4 1/4
3 3/4 1/4
4 1 3/8
6 1-1/4 1/2
8 1-1/4 5/8
10 2 3/4
12 3 1
14 3 1-1/4
15 3 2

Recommendations for Using Tube Brushes

Stems on Tube Brushes are not as strong as shanks on Piloted Bonding Brushes or other single construction shanks. It is important to run Tube Brushes at speeds below 2000 RPM and limit the overhang. Excessive overhang when fixtured could lead to bending of the brush. See illustration for better fixturing.

Applied Pressure While Wheel Brushing

Properly applying pressure to the brush while brushing is critical to performance. The brush life and the quality of the job are impacted when too much pressure is applied. It is important to run the power brush at the highest speed recommended and limit the pressure that is used on the workpiece. The wire fill material will do the work. Excessive pressure will breakdown the brush sooner and provide less than satisfactory results. Below is an illustration of proper pressure and too much pressure.

Exhaust Recommendations

The operator of power brushes should determine for proper exhaust requirements. Below is a guide for dry brushing and the recommended minimum exhaust volume that should be used according to OSHA Safety Code 1910.94, Section 2.

Brush Diameter (Inches) Minimum Width (Inches) Exhaust Volume (ft /min.)
Up to 9 2 300
9-16 3 500

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