The Most widely used designs , the WHEEL BRUSH can be mounted either horizontally

Or vertically , with the tips of the wires doing the actual work as they contact the work piece.

Manjul Industrial Corporation is a brush manufacturer offering ,a broad line of both standard industrial power brushes and custom brushes. We design and manufacture custom brushes in Following category:

Wide-face cylinder brushes for conveyor cleaning, surface preparation, surface finishing, scrubbing, dusting, applying, and polishing.
Wheel brushes provide straight line brushing action, for surface finishing, cleaning and polishing, weld blending, Deburring, and removal of paint, rust, scale, or other contamination. Wheel brushes are appropriate for use with various types of hand-held grinders, bench grinders, robotic finishing equipment, or for mounting onto a driven arbor in a production process. Manjul Industrial Corporation manufactures a broad line of wheel brushes, ranging from small diameter copper center wheel brushes to large wide face brushes that are capable of being gang-mounted on a common drive shaft. Most wheel brush styles may be filled with crimped wire or a variety of synthetic or natural fibers. to provide progressively higher levels of brushing action control and aggressiveness of cutting action.

Wheel brushes are available in the following sizes and formats:
 

WHEEL BRUSH

Fixed Arbor Hole Wheel Brushes:
Wheel brushes are available with crimped wire sizes from .003" (very fine) to .020" (aggressive), synthetic materials from .006" to .028", Wheel brush sizes range from 3" to 15" outer diameter. Brush face widths of Narrow (3/8" to ½" between face plates) and Wide (1" between face plates) are available for most material types. Short, medium and long trim options are available for most sizes and material types. A full range of arbor holes from ¼" to 2" or larger are available, depending on the size of the brush. Threaded arbor holes are available at an extra charge. Other features that are available by special order include single or double keyways,  square or hexagonal arbor holes, non-standard size arbor holes or brush diameters, and close-tolerance ground finishes. Brushes can be used separately or gang mounted to accomplish a wide face.
 

Fixed Arbor Hole Wheel Brushes

Adapter Style 2" Arbor Hole Wheel Brushes:
Our brushes are supplied with a standard 2" arbor hole. Adapters are sold separately for arbors less than 2" in size. Brush diameters from 4 ¼" up to 15" are standard. Face width options include narrow (up to 1 3/8"), medium (to 1 ¾"), wide (to 2"), and extra-wide (up to 2 ¼"). Brushes are densely filled with high fatigue tempered steel wire, type 304 stainless steel wire, brass wire ,Brass Coated Wire or bronze wire. Crimped wire sizes from .006" to .020" are standard; other sizes are available upon request. Other fill material options include abrasive nylon, Nylon Filaments 6-6, nylon 6-12,  and polypropylene.
 

Adapter Style 2" Arbor Hole Wheel Brushes

Copper Center Small Diameter Wheel Brushes:
Rivet-Ring brushes are the best solution for removing scale, burrs, and corrosion in hard to reach areas and internal surfaces. High speed operation is necessary for most effective use. Brush diameters as small as ¾" are possible with .003" to .005" wire or synthetic filament. Diameter tolerances of .001" can be attained with a ground finish. Standard sizes are available from ¾" to 4" brush diameter, 3/16" to 1" arbor holes, and brush face widths from 1/8" inch to ½". Maximum size of wire or synthetic fill is dependent on overall brush size. The full range of fill materials is available: carbon steel, stainless steel, brass, Brass Coated Wire , bronze, abrasive nylon, 6-6 and 6-12 nylon,  polypropylene,  Rivet Ring brushes also can be tubed together to create a small diameter, densely filled, wide-face brush. Wire stripping devices employ two brushes rotating in opposite directions in close proximity.
 

Copper Center Small Diameter Wheel Brushes

Stem-Mounted Wheel brushes:
Small Diameter brushes (1 ½" to 3" dia.) are available factory-mounted onto a ¼" wide by 7/8" long stem in single or double brush face width configurations. In addition, small stem-mounted  (3" and 4" dia.) are available with steel or stainless steel wire in 0.014" and 0.020". Alternatively, shank adapters can be purchased separately for mounting Small Diameter Wheel brushes. Threaded safety style shank adapters can fit up to 5 small brush sections and will accommodate arbor holes from ¼" up to 5/8". Non-threaded press-fit shank adapters are available for single brush sections with arbor holes of ¼", 3/8" and ½".
 

Stem-Mounted Wheel brushes

Center less Grinder Brushes:
For use with through-feed center less grinders , in place of a grinding wheel. Typical applications include removal of sharp edges, feather burrs, surface finishing, surface preparation for plating, and removal of rust stains and discoloration from heat treating. Standard outer diameter is 20". Brush face widths range from 3 ½" to 10" wide. Inside diameter is 12". A choice is offered between the standard core or a closer tolerance machined core. Available fill materials include carbon steel wire, stainless steel wire, Brass wires, Brass Coated wires and abrasive nylon. Brushes can be filled with a combination of coarse and fine abrasive filament to perform two stages of finishing in one pass. Other sizes are available on special order to meet the requirements of a specific center less grinder.

Our wheel brushes feature durable carbon , stainless steel wire, Brass , Brass Coated Wires with permanent or flexible mountings ready for electric or air power. Copper centers hold wire securely, and stiffness is optimized to reduce operator fatigue.
 

Center less Grinder Brushes

• Carbon steel Wires
• Stainless steel Wires
• Brass Coated Wires
• Brass Wires
• Bronze Wires
• Nylon Filaments
• Abrasive Nylon Filaments

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Carbon steel wires:
Wire brushes made from steel wire are suitable for a wide variety of applications and are generally the most economical and most widely available of the different wire brush options. Steel wire is the hardest of the commonly offered brush wires, providing a high fatigue life and durable cutting action. Steel wire is most appropriate for work on steel and iron workpieces, but may also be used on wood, aluminum, brass and copper; however the softer the material to be brushed, the more likely that a steel wire brush will cut into the material and remove base material in addition to the targeted coating or contamination.
 

Steel wire is appropriate for constant operating temperatures up to 275° F, but can be used where the brush will come in contact with higher temperatures for shorter periods of time. When ambient temperatures will exceed 275°F, stainless steel wire should be considered.
 

Stainless steel wires:
Wire brushes made from stainless steel wire are suitable for work on stainless steel and aluminum fabricated products, and for use in direct food-contact applications, in higher heat situations, and in environments where the brush wire may be exposed to moisture or high humidity on a repeated basis. We feature 304 Stainless Steel wire to offer a higher analysis wire to customers working on either 302 0r 304 stainless workpieces. Stainless steel wire is generally recommended for continuous operating temperatures up to 600°F
 

stainless steel wires
 

Brass Wires:
Brass wire is softer than steel wire or stainless steel wire, and offers a brushing action that will not scratch harder metals. Our brass wire is Alloy 260, composed of 70% Copper and 30% Zinc. If your work-piece is either brass or copper, then brass wire is the most suitable choice. Brass wire (as well as bronze wire) will not generate sparks when struck against other metallic surfaces, and is suitable for hazardous environments (1) . Brass wire is also an excellent conductor of electrical energy (28% IACS), and is suitable for static reduction applications . Brass is appropriate for operating environments up to 300°F constant temperature. Brass wire is also relatively corrosion resistant.

 

• Cleaning plastic extrusion parts, including molds, dies, and extruder barrels.
• Cleaning machine parts where sparks might pose a risk of fire or explosion.
• Cleaning metal parts without removing any of the base material.
• Satin finishing aluminum extrusions or sheet.
• Static reduction brushes for industrial environments.

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Bronze Wires:
Bronze wire is harder and stiffer than brass wire. We utilize a Phosphor Bronze wire, Alloy 510, consisting of 95% Copper and 5% Tin. The presence of Tin improves fatigue strength and tensile strength over the C-260 brass wire.

Bronze wire will not generate sparks when struck against other metallic surfaces, and is suitable for hazardous environments (1) . Bronze wire is a good conductor of electrical energy (15% IACS), and is suitable for static reduction applications when incorporated into a bronze wire strip brush with a brass channel backing. Bronze is appropriate for operating environments up to 400°F constant temperature. Bronze wire is also relatively corrosion resistant.

Popular Applications for Bronze Wire brushes: :

• Cleaning plastic extrusion parts, including molds, dies, and extruder barrels
• Wiping tenter frame rollers in synthetic fiber plants
• Cleaning machine parts where sparks might pose a risk of fire or explosion
• Cleaning metal parts without removing any of the base material.
• Satin finishing aluminum extrusions or sheet
• Static reduction brushes for industrial environments

Nylon Bristles:
Nylon filled industrial brushes are suitable for a range of applications from aggressive scrubbing to dusting, in both dry and wet environments. Brushes with Nylon fill offer the following characteristics in most applications: excellent fatigue life, good abrasion resistance, low to moderate absorption of water (3% to 9%) leading to only a temporary reduction in stiffness, an excellent bend recovery rate, resistance to most common solvents, and suitability for use in weak acids.

Nylon 6.6 is a medium grade suitable for most dry industrial applications and constitutes our regular duty filament for industrial applications. Nylon 6.6 has a higher moisture absorption rate at 9%, and therefore loses approximately half its stiffness when exposed to wet environments. Nylon 6.6 also has limited resistance to many common chemicals. Nylon 6.12 is a higher performance grade for industrial and food-contact applications with the following attributes: a significantly greater wet stiffness modulus than 6.6 nylon, resistance to petroleum distillates, benzene aromatic hydrocarbons, ethyl acetate esters, and trichloroethylene hydrocarbons. Nylon 6.12 is FDA approved for direct food contact.
 

Abrasive Bristles:
Abrasive grit encapsulated into the extruded nylon filament allows an abrasive nylon brush to perform deburring, edge blending, and surface finishing. Power brushes and Cylinder brushes made with abrasive nylon deliver features of a brush: flexibility of design and conformability to irregular surfaces, while also imparting the benefits of an abrasive: selection of grit sizes to control finish, and functionality for deburring, cleaning, surface finishing, and edge blending. Abrasive Nylon is suitable for use on a broad range of materials.

Wheel brushes: Deburring, surface preparation and removal of coatings without affecting the geometry of the underlying surface. Wheel brushes provide a linear brushing path.

For many dry industrial applications Nylon 6-6 is acceptable, while more demanding applications may require the additional heat resistance, lower water absorption and increased toughness of a Nylon 6.12. Both Silicon Carbide grit and Aluminum Oxide grit are available, and approximate a 30% loading by weight in the extruded nylon filament. Silicon Carbide is more commonly used because it is harder and sharper than aluminum oxide, and it is preferred for finishing ferrous metals. Aluminum oxide grit is less likely to fracture and is preferred for finishing softer metals including stainless steel and aluminum, wood and plastics. Aluminum Oxide also eliminates the small risk of contamination of the stainless steel or aluminum surface by free carbon deposits from the silicon carbide.

Different from a typical wire brush, where the operating guidance is to use the tips of the wires to do the work with light pressure and high brush face speed, abrasive nylon brushes abrade with the sides of the filament as well as the tips because the grit is spread randomly throughout the filament. As a result, lower brush speeds and greater engagement of the work-piece into the brush face may contribute to increased brush effectiveness. A work-piece requiring finishing of contoured or recessed surfaces can be accommodated with a longer trim brush, controlling the brush speed, and by engaging the work-piece.

 

Abrasive Bristles

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