How to Select Power Brushes

Power brushes are used to clean and polish parts, prepare surfaces, blend edges, remove burrs, and improve surface finish. Because these industrial brushes can be used with handheld power tools and production machinery, power brushes can help manufacturers make the most of existing equipment. The durability and flexibility of these versatile brush tools complements the repeatable, uniform results they provide.

Selecting power brushes requires an analysis of application requirements and product specifications. These deburring tools can be used to surface finish many different base materials, including aluminum, bronze, steel, and plastic. In general, filament type and brush type are the most important parameters to consider during cutting tool selection. Additional specifications may vary, and include trim length and maximum safe free speed (MSFS).  

Filament and Brush Types

Power brush filament types include wire, nylon, abrasive nylon, and natural fiber. Wire filaments are made of metals such as brass and steel. Filament hardness is important, but over-penetration of a part’s surface is problematic. Abrasive nylon brush filaments can differ in terms of aggressiveness, and may require the use of a liquid coolant. Natural fiber brushes aren’t inherently abrasive, so they’re sometimes used in conjunction with an abrasive compound.

With regard to brush type, power brushes can be divided into several major categories. Besides wheel, cup, and end brushes, many manufacturers use encapsulated brushes, pilot bonding brushes, and flare brushes. Miniature brushes and adapters for power brushes are also available. Although mounting hardware serves mainly to introduce the brush filaments, differences in product shape or configuration help to explain deburring tool types.

Wheel Brushes and End Brushes

For example, wheel brushes are wheel-shaped power brushes. Although these brushing tools can use either crimped wire or knotted wire, other filament choices are available. Abrasive nylon wheels offer a safe, non-reactive alternative to wire wheels, and can feature filaments impregnated with aluminum oxide or silicon carbide in a range of grit sizes. Tampico wheels use natural fibers instead of nylon, and offer good heat and oil resistance along with superior polishing performance, especially with chrome.      

Like wheel brushes, end brushes are available in different filament types. Applications include cleaning, polishing, deburring, and surface preparation. Used mainly with high-speed, hand-held power tools, end brushes have solid, knotted, or circular flared ends. Typically, these power brushes are recommended for applications where space is limited. For a fast, positive cutting that’s highly effective on flat surfaces, encapsulated solid end brushes are a good choice.

Cup, Pilot Bonding, and Flare Brushes

Cup brushes come in a variety of diameters and feature either metal wire or abrasive nylon filaments. For preparing and deburring large metal surfaces, wire cups with steel filaments are recommended. Crimped cups are designed for light-duty work, and knot cups have an arbor hole for attachment to grinding tools. Nylon abrasive cup brushes are a good choice for light deburring, edge blending, and general surface finishing.

Other power brush categories include pilot bonding brushes and flare brushes. Pilot bonding brushes are used for cleaning paint, dirt, rust, and varnish around bolt and rivet holes. The tip of the tool features a metal pin that’s placed in the hole to contain the cleaning action. Flare brushes remove contaminants and deposits from the insides of pipes and ports. These brushing tools are also used for rust, scale, and weld slag removal. 

To learn more about power brushes, please visit the Brush Research Manufacturing website. The BRM YouTube channel also provides power brush information, including this new video about BRM Wheel Brushes.