Wire wheels vs cups......and more.

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I've used wire cups for clean up and painting prep, but haven't used wire wheels on a grinder.Can someone explain what one would use a wheel for in favor of a cup brush?Also, on a slight tangent......What are the advantages of using a knotted cup/brush over a crimped wire brush?    All I've used thus far are crimped wire.   I'm assuming the knotted brushes are for heavier removal.  Is that correct?
Reply:The knotted brushes will hold up better since they don't lose wires like the crimped ones.  The wheel cup is a little more subjective.  either will work for most things but their are times when one might be prefered over the other do to access or some other reason I don't know.DennisThermal Arc 185-TSWMillermatic Challenger 172VictorO/AAtlas Craftsman 12 by 24 LatheEsab PCM-875Wholesalem Tool Mill-Drill
Reply:Wheels seem to last a little longer.  They can fit in areas the cups can't.  The cups seem to clean faster and can fit in some areas wheels can't.
Reply:It is my understanding that it is ONLY the tips of the wires that do the work. A cup brush will allow for better contact on flat type work, and a wheel is better for "nooks and crannies" and other areas not accessed by the cup. I build a lot of handrails, and go over everything with a power wire brush. I only use knot type, 90% is done with a cup, the rest with a stringer or wheel style. They work well to be-bur edges, remove little spatter deposits, etc. Crimped wire bushes tend to be "softer" and less aggressive, and like stated above, loose there wires at a faster rate.Just my  opinion, not from a book, just from the road.Howes Welding Inc.www.howesweldinginc.com
Reply:Thanks guys.   I guess I haven't had enough time with the brushing to see the advantages of each.  I've now got some knotted cups on order, as well as my 4th grinder which will be dedicated specifically to the brushes.
Reply:I wont use crimped brushes anymore because I got tired of the wires imbedding in my forehead.
Reply:Originally Posted by 76GMC1500I wont use crimped brushes anymore because I got tired of the wires imbedding in my forehead.
Reply:I noticed you said you ordered a new grinder also. I find a wire brush, any style, takes more power to drive than the average grinding wheel. I have seen people use their worst grinder for wire brushing, saving the best for grinding. I use a good grinder for wire brushing, and if all tools are not the same, a marginal one for grinding. All this is of course dependent on how aggressive you are with your tools.Just my  opinion, not from a book, just from the road.Howes Welding Inc.www.howesweldinginc.com
Reply:Originally Posted by tessdadI noticed you said you ordered a new grinder also. I find a wire brush, any style, takes more power to drive than the average grinding wheel. I have seen people use their worst grinder for wire brushing, saving the best for grinding. I use a good grinder for wire brushing, and if all tools are not the same, a marginal one for grinding. All this is of course dependent on how aggressive you are with your tools.
Reply:A few more things to think about with wire wheels:Surface speed increases with wheel diameter.  Usually the cups are smaller and therefore won't have the surface speed of a wheel which is generally larger.  Along with increased suface speed comes a greater chance of "throw-out" of the wires.  You should ensure that you are using the properly rated ginder for the wheel RPM rating.Which leads to point #2 ALWAYS wear safety goggles, not just a face shield that they can get by.  Sometimes both are in order depending on the position you are using them and your tolerance for wires in the forehead  !  I usually wear long sleeves too.Hobart 140 Handler w/ gasHyperTherm Powermax 380 Plasmaoxy/acetylene
Reply:I used a crimped wire cup to do a ton of clean up on some old scrap steel I picked up this weekend.    I was using HF cup and after about 1 hour of solid grinding the bristles were 1/2 gone and all over the garage!   Luckily, I was wearing a canvas jacket.  When I looked down, there were at LEAST two dozen wire bristle lodged in my jacket!!
Reply:I've had a couple stick in my inner thigh.  I really worry about the day when one will stick a few inches higher.
Reply:hhhhmmm iv only used the knotted cups and they dont loose bristles very often...wearing safety goggles only...i think the canvas jacket idea is a good one but a bit over kill for me...all i was wearing was coveralls with t-shirt underneath...the forehead factor sucked without a full shield though
Reply:I always use the twisted wire. A little more expensive but last a lot longer. They will also stick wires where you don't want them just not as often. I use a wheel on the bench grinder and cups on the angle grinders. I restore old tractors and farm machinery so use a lot of them. Both have their place and I find that small stuff is best on the bench grinder and larger with the angle grinders.He who dies with the most tools wins