Metal perforation is an important modern process that is achieved through various methods, the most efficient and useful is press and punch perforation forming. To fulfill various requirements, manufacturers have access to a number of techniques that fall under the press and punch perforation umbrella. Below, we will describe three of them at length: wide press, sectional press and automatic nibbling machines. Other methods that we will not describe include: plate shearing, folding, welding, leveling, rounding and surface polishing.
Wide Press The most common perforation technique is wide press perforation, popular because it is most cost-effective and efficient method available. In wide press, the entire width of the plate is punched with every strike of the die, and a punch row or rows work simultaneously as the plate traverses the machine.
Wide press is considered the best option for high volumes of metal because it is a rapid process that commonly produces stress faults. Its tooling cost is also high. A leveler is used to fix these faults or distortions. With it, stress errors are removed through flattening. Since leveling does not adhere to a standard procedure protocol, strategy depends on the location of the perforated and non-perforated areas.
Sectional Press To work on a small section or area, many choose the sectional press method, which, while carrying a lower production rate, is less expensive than wide pressing. Section pressing is also used for thick plates, up to 20 mm, because it takes fewer punches. Section presses may be connected to CNC equipment that pre-programs patterns and perforation areas. This allows for well-made, tailored products.
Automatic Nibbling Machines The final technique that this article will discuss at length is the automatic nibbling technique. Automatic nibbling machines share one major feature with sectional pressing, which is that they work only sectionally. This is where the similarities end. Automatic nibbling machines are automated, with tools that change out on their own. Also, they make economical perforations by nibbling the contours. If needed, they can also finish the outer plate of contours.
The other processes involved in manufacturing of metal plates are leveling, plate shearing, and folding, welding, surface polishing, and rounding. For shearing, a straight plate shearer is typically used, however, in some high-precision processing, lasers are used. For bending, a CNC machine is commonly used, which suits even complex profiles. For welding, either a metal inert gas (MIG) or a tungsten inert gas (TIG) is used.
To post process the surface of plate, grinding and brushing techniques are typically employed. Sometimes, for different applications, the plate is polished—either mechanically or with the use of electric methods—and then de-greased and blasted with beads and sand.
Perforated metals, or pierced metal sheets with different shapes and patterns, have been used for hundreds of years for both decorative and functional purposes. In the 19th century, they were manually perforated to serve as coal separating screens. Later, with further industrial and technological developments, custom presses appeared, using dies to perforate metals. Later still, we saw the emergence of rotary pinned perforation rollers, laser perforation and other game-changing technologies. Today, metal perforation is such an efficient and reliable practice that it’s used on a large scale for a wide range of applications, with readily available perforated metals, such as copper, stainless steel and aluminum.
The most common of these applications of include:
Perforated metals contribute to the food industry in a number of ways. First, beehives made from perforated metals support the modern beekeeper with less delicate frames. Additionally, perforated sheets are used liberally in food processing as grain dryers. They’re also used for silo ventilation, wine vats, cheese molds, juice presses and fish screens.
One of the most heavily engaged applications of perforated metals is architectural use. First, they are commonly used for fencing, signage, column covers, access control and aesthetic fittings. In addition, they are used for eco-friendly building, with design components like sunshade, cladding and panels. These, according to environmental studies, offer energy savings of up to 25 percent.
Chemical & Energy Industries
Another heavily engaged area of application for perforated sheets is the filter mechanism, used extensively in the chemical and energy industries. This broad category includes laboratory centrifuges, battery separator plates, washing machine drying baskets, water, gas and air purifying screens and traditional mine and coal washing cages.
Aside from building facades, the most common use of perforated metals is found in the automobile industry. Auto parts that utilize perforated sheets include silencers, running boards and grills. Furthermore, nearly all filters, from air filters, to oil filters, to ventilation grids, are made with perforated sheets.
Supplanting Material Development
Finally, the last common application of perforated metal sheets that we will mention is a utilization in material strength and support. Perforated metal is, for example, used for strengthening glasses subjected to extreme environments, and in the manufacturing of screens of textile printers, cement slurry, dyeing machines, felt mills and blast furnace screens.
Woven wire is used to make grates, metal walkways, stairs for fire escapes, and other lightweight platforms. The woven pattern makes the wire frame strong without making it too heavy to lift or install. Here are Remaly, we can manufacture woven wire in aluminum, steel, stainless steel, or other coated alloys of your choice. Based on your intended use, we will manufacture wire with a particular size and thickness so that you have material with the necessary strength for your application. As with our other products, our woven wire sheets are fully customizable. There is no minimum order size either, so you can order as little as one sheet or a large quantity. We can even keep your specifications on records in case you need to order more later on.
For added performance and durability, many of our customers choose to have one or several of our secondary operations performed on their woven wire sheets. We can paint the wire in a color of your choice, add a powder coating, anodizing and more. Any one of these steps will help to improve the quality of your woven wire and add further protection during use. If you have a design in mind, we can fabricate a product based on your concept. If not, you can give our design team your specifications and let us design something for you.
Woven wire from Remaly has been used by clients in industries like mining, healthcare, military and transportation. Applications include vibrating screens, decking, catwalks and metal safety cages. You can be sure that whatever application you need woven wire for, Remaly has the ability to manufacture the perfect solution. We even have several different weave patterns to choose from, making customization just that much easier.
Looking for a trusted manufacturer who can provide you with superior metal products for your industry? That’s exactly what Remaly is here for! With over 100 years of experience, our expertise and knowledge of metal can’t be beat. Contact Remaly today for excellent customer service and a rapid response to your metal fabrication needs. We’re ready for your business!
It’s quite likely that at some point your business is going to need custom metal fabrication for a particular project or application. It’s also quite likely that when this need arises, it will need to be done quickly.Here at Remaly, we do rapid response custom metal fabrication, so you get speed and quality! Our specialities in this area include applications with unique acoustic, architectural or artistic requirements. This is often detailed and extremely precise work that needs to be done by a team of experts like our who have access to state of the art metal fabrication equipment. We can even respond to low volume orders and create prototypes for you to review before we fabricate a complete part.
Some of the value-added fabrication capabilities that we offer at Remaly include rolling, bending, shearing, welding and notching on all types of metals. We’ll work with you to select the best material for your project before we get started. We have access to a wide variety of metals, including carbon steel, brass, bronze and aluminum. We want to make sure that before we do any custom fabrication, you have the metal that will function best in your application.
With our custom metal fabrications services, we’ve served a long list of industries. To name just a few, they range from mining to military to transportation and OEM. We’re able to manufacture products for so many different applications in such a diverse array of industries because of our highly advanced machining capabilities and our skilled workforce. After we have completed your custom metal fabrication product, we can even treat is with our secondary operations like powder coating and painting.
Now you know all about what makes our custom metal fabrication services so great! If you’d like to request a quote, just give us a call and we can work with you to design a solution for your application. Believe it or not, we’ve been in business since way back in 1865! All of that time has given us the experience and knowledge to be true experts in the field of custom metal fabrication, so you can trust us to provide you with a quality product.
You may have heard that one of the services we offer at Remaly is high definition plasma cutting for sheet metal projects. We are able to cut through metal plates that are up to 1” thick, and we offer related services like powder coating, painting, cleaning and degreasing. Plasma cutting is a great way to precisely cut sheet metal and prepare it for use in a wide variety of applications. We have all the equipment and expertise onsite to perform professional plasma cutting, and we’ve done so for clients in many different industries; from pharmaceutical to petrochemical to mining and beyond. Those of you who aren’t familiar with plasma cutting might be wondering, “What exactly is it and how does it work?” We’ll look briefly at how plasma cutting technology works and what it’s advantages are in manufacturing and metal fabrication.
To start off, plasma cutting is performed using a piece of equipment called a plasma cutting machine. These units come in various sizes and strengths, but they technology that they use is basically the same across the board. This machine generates a heated and electrically charged gas (the plasma) that is thrown out of the nozzle on the gun connected to it at a high accelerated rate. The electrical charge flows through the plasma into the piece being cut and then back to the machine through the grounding attachment, completing the circuit. The heat from this electricity melts right through the metal, causing it to be cut.
Plasma cutting is quick, precise, and much cheaper than it used to be. Because of this, many metal shops use plasma cutter to create holes, separations or other divides in pieces of metal. More advanced plasma cutting machines are very useful when cutting angled or curved metal. In large manufacturing facilities, plasma cutters are often built with CNC (computer numerical control) technology to allow for more efficient operation and a higher degree of accuracy when cutting complex shapes.
Contact Remaly today to learn more about our plasma cutting capabilities and request a quote for your project. Our toll free number is (888) 2182260.
Remaly Manufacturing Company is a rapid response manufacturer of high quality perforated metals and custom fabrications, specializing in design and delivery of low volume orders or prototypes. Our capabilities include value added operations such as rolling, bending, shearing, welding and notching on both ferrous and non ferrous metals. Design and drafting assistance are available. We also specialize in the unique requirements of acoustical applications, architectural concepts and artistic displays.