Round Perforated Metal Pipe , Spiral Perforated Tube Varnished With
Subsequent Baking
Machinery Used
Wide Punching Press
Wide punching presses offer quick and inexpensive perforation. They
feature a die and one or more punch rows that strike the metal
plate as it moves through the machine. With each strike, it punches
the entire width of the plate. Manufacturers can modify die and
punch row patterns in order to create custom perforated metal
products. Because the machine works so quickly, it is easy to find
stress faults in the perforated part. To rectify this, metal
perforators often use a leveler. This removes stress errors by
flattening the plates. The main drawback of this perforation method
is that is has a high tooling cost.
Sectional XY Axis Punching Press
To perforate using the XY press, sheet metal is secured to the
machine and slowly moved around underneath one to several
stationary single-shaped punching rams, which create a detailed
perforated pattern on the metal as it moves in the direction of the
hole design. This process is long, but patience rewards the metal
worker with complex, precise, decorative perforated sheets and
perforated metal panels. Though both manual and CNC punching
methods have their merits, CNC punching tends to be preferred due
to lower labor costs, higher production speeds and greater process
repeatability. In addition, using CNC equipment, it’s easy to
create custom programming.
Automatic Nibbling Machine
Automatic nibbling machines are quite similar to sectional presses,
in that they work on just one section of plate at a time. Unlike
sectional presses, though, their production, including perforation
tool changes, is automated. They create perforations by nibbling
contours. Automatic nibbling machines offer affordable perforating
and good outer plate finishing. Like all perforating equipment,
they can create custom features related to: strength-to-weight
ratio, open area, hole diameter (measured in mm) and hole size
(measured in mm).
Variations and Similar Processes
Metal Expansion
Metal expansion is a process that creates metal with hole patterns
by cutting or stretching them into a shaped framework. Expanded
metals are desirable because they create little to no waste and
they are inexpensive. In other words, they’re all around
sustainable. They can be used for many of the same applications as
perforated metals, including: filtration, enclosing, structural
support, decoration and reinforcement. However, metal expansion
cannot create holes as fine or as intricate as metal perforation.
Laser Perforation
Laser perforation is a modern perforation technique. As its name
implies, it involves the use of lasers. Laser technology offers
extreme precision without stress, high consistency and virtually
endless possibilities. However, the process is rather expensive.
So, it’s best reserved for the most important and precision-reliant
applications.
Rotary Pinned Perforation Rolling
This alternative perforation process is known for its efficiency
and cost-effectiveness. It employs a rotary pinned perforation
roller, which is a large cylinder lined with sharp, pointed needed.
As metal sheets move across the roller, the needles punch holes of
varying diameters into them. Sometimes, to reinforce the
perforations, manufacturers heat the needles. This causes the metal
to melt and form a hollow ring around the needle hole. To customize
hole sizes and patterns, manufacturers swap out needles.
Die and Punch Perforation
A final variation is die and punch perforation. During this
procedure, manufacturers put sheet metal in between a die and a
press. The latter pushes the sheet into the die, which punches it.
The press may be hydraulically or mechanically driven. This process
requires shearing to remove leftover material and smooth the
surface after punching.
