Archive for the ‘Metal Forming’ Category

Roll forming is a metal forming process that is used to create shapes of uniform cross section. During this process, metal is fitted between successive pairs of rolls in a sheet, strip, or coiled form until the desired shape and cross section is obtained. The process of roll forming adds strength and rigidity to lightweight materials (such as aluminium brass, copper and zinc), composites, some heavier ferrous metals, and specialized alloys and other exotic metals. 

Stock can be roll formed into various standard shapes including angles, struts, C-channel, U-channel, T-shapes, hat sections, round Z-shapes and many others. 

Here are few benefits of roll forming: 

Closer Tolerances: Roll forming processes provides closer tolerances in comparison to other competing sheet metal processes (brake forming and stamping).

Thinner when needed: Roll formed shapes can be developed with thinner walls compared to other competing processes (extrusion).

Superior surface finish: Roll forming technique is ideal for decorative stainless steel parts, or for parts requiring a finish such as anodizing, pre-painted and galvanized.

High speed: Because of its high speed (100 fpm), the roll forming process is highly preferred for high volume production. 

Efficient: The process can utilize any bendable material, and do so efficiently. For example, up to 98% of strip/sheet material can be used in the final product, verses 67% in stamping, thus significantly reducing scrap.

Apart from above mentioned benefits, Roll Forming is the most economical choice for companies looking forward to streamline their production and reduce overall cost. Because of its high-speed continuous nature, roll forming is especially beneficial for large volumes. 

Located in every corner of the car, Struts have the suspension components namely the spring and the damper. The geometry of struts changes with time and require camber and toe adjustments to maintain wheel alignment. Generally manufactured from aluminium or steel, strut braces are used to connect two strut towers at the top and give extra rigidity between the two. 

Best feature of strut braces is that they can adjust as per your convenience allowing you to fine tune the setup. These will typically have a nut and screw at one or both ends of the brace. Fitting struts is an easy job. Most of the strut brace kits available in market come with complete instructions and all the required components. 

If your car has a set of screw and nuts at the top of the strut, these will typically be used to connect the strut brace to your car. But some vehicles have only one nut which is located directly at the top of the damper and this will not be suitable for connecting a strut brace. In such circumstances, it is necessary to create your own mounting points.

After fitting the strut brace, you will notice that the car has become more responsive and you get better feedback from the front wheels whilst steering, and the car is able to corner at greater speeds. Many people confuse strut brace with an anti roller bar. But an anti roller bar  is fitted to the bottom of the suspension at the rear and prevents the rolling motion of the car which has a tendency to lift the inside wheel when cornering quickly.

Learn more about roll forming  strut lines and the machines sued to manufacture them.

Technically speaking, angle beads are employed to provide corner support to traditional plaster applications. In other words, they provide the much-needed reinforcement for such conventional applications. Incidentally, the angle bead's firm metal nose prepares the perfect ground for screeding. The straight and rigid ground serves as a perfect platform for the beads. These angle beads can easily bend over uneven surfaces. However, this credit of manufacturing such beads goes to the latest angle beads machine.

These days, angle beads machines are known to manufacture beads made up of galvanized steel, stainless steel, alloy and even of Zinc (and that too 99 percent pure zinc). Available in all shapes and sizes, these beads act as a plastering stop that guarantees proper finish. Moreover, they cater to all kinds of needs (which is chiefly because of the expanded flange grounds). The bead plate thickness usually varies between 0.3mm – 0.5mm. However, with the help of angle beads machines, customized beads can be manufactured. 

Apart from metal corner beads, modern-day angle beads machines are also rolling out plastic corner beads. That's not all, one can easily spot PVC corner beads in the market. These plaster beads are extensively used to eliminate plaster edge situations in doors, windows and various other kind of openings. 

Meanwhile, perforated metal angle beads are also available in market. The complex pattern of  holes allows the cement and mud to seep through the bead and pass on to the drywall, finally becoming the part of the wall. 

Interestingly, the perforated corner beads manufactured by machines easily deal with inconsistencies and adjust with appropriate screed heights. 

Thanks to angle beads machines, one can now choose from a wide range of angle beads available in the market. But first things first. Angle beads are used to extend strong corner  support for conventional plaster applications. Generally, it is the solid metal nose of the angle bead that provides a sound platform for screeding. The ground which is chiefly straight and rigid in shape, allows for bending of angle beads to overcome problems posed by irregular and uneven surfaces. But remember, the plaster keys located near the solid nose provide additional support and ensures straight corners all the way. 

Speaking of variants available in angle beads category, they are as under:

Standard Angle Beads: Like the normal beads, standard angle beads straightens the irregular corners of the walls. Also known as plaster beads, it gets rid of edges in doors, windows and other openings. 

Perforated metal beads: Metal beads (also known as metal corner beads) contain holes that allow cement, mud to go through and become part of drywall. 

Stop bead: Another popular variant, stop beads provides additional surface area thus, making space to receive sealants. That's not all, it even prevents insulation boards from getting affected while applying primer or sealant. It even improves the overall appearance of straight edges. Due to rising demand, angle beads machines can be seen manufacturing huge volumes of stop beads these days. 

Apart from the above-mentioned categories, one can easily locate PVC corner beads and different other types of plastic corner beads in the market. Not just these alone, angle beads machines are also being employed to manufacture customize angle beads.

Expanded metal mesh machines are used to manufacture all kinds of expanded metals including aluminum expanded metal, titanium expanded metal, copper expanded metal, aluminum foil metal and expanded metal of other materials. Expanded metal mesh are the key ingredient of furnishing materials such as  plasters / renders on masonry, ceilings, suspended ceilings and timber framed buildings.

Manufactured in galvanized and stainless steel, metal mesh are used for both internal and external applications. Metal mesh are not only used on flat surfaces, but can also be used on projects where curved or domed shapes are required. 

Here are few benefits of Expanded Metal Mesh: 

1. Expanded metal wire mesh offer quality and value to any of the projects. 
2. Expanded metal mesh can easily be used to form curved surfaces.
3. They improve the appearances of cracking plaster / render.

Compared with perforated sheet, here are few advantages of expanded metal mesh:

1. Expanded metal mesh are low price. 
2. They can be formed to make two-dimensional or three-dimensional designs.
3. As expanded metal is manufactured without loss of material, hence they offer maximum utilization of the pre material.

Compared with woven wire mesh, advantages of expanded metal mesh are:

1. Expanded wire mesh offer greater stability than woven wire mesh.
2. Expanded wire mesh have homogeneous surface. 
3. Expanded metal mesh do not have any loose wire ends. 
4. Expanded wire mesh are cheaper as compared to the wire cloth. 

With so many features and advantages, expanded metal mesh are definitely a good deal. 

Strut bars or stabilizer bars evenly distribute the tension between the left and the right struts of the car. They are more often called as anti-sway or anti-roll bars. While turning your car, you feel a push or throw to the outside of the turn and tend to compensate by leaning into the turn to remain upright. Strut bars work in the similar manner i.e, they stabilize or share the roll tension between the left and right strut.

Some of the advantages of strut bars are: 

• Struts minimize the amount of sway a car has and distribute the weight evenly between the left and the right. As a result of this, tires remain solidly on the road thus providing better traction and handling. 
• Some vehicles roll over more easily than the others. Like the higher the car is, the higher is its center of gravity. So, while turning a high-stepping car at high speed, the chances of it rolling are greater than the car that sits lower to the road and has lower centers of gravity. Here comes the role of a strut bar that evenly distributes the roll force and helps keep the vehicle upright.
• Without a stabilizer bar, an unequal amount of stress is placed on different vehicle components, including the struts and suspension. When the tensions caused by turning routinely are shared, various car parts wear more evenly. And there isn't undue stress placed on one strut more than the other, which can cause premature failure and the need for replacement.

Many home owners are looking for new cost effective ways to increase the value of their homes.  Typically asphalt roofing offers limited options for improving the look and value of your home.  Today steel roofing systems offer superior value and longevity for home, office and commercial roofing.

Innovative roll forming companies now offer a unique ‘tile effect’ roofing system that looks just like traditional clay roofs.  These systems “tile effect roofing systems” create a realistic look and feel to the traditional look of clay tile.  Now home owners have options as to what roofing material they use and what metal roof tile panel’s they pick from.  Corrugated roofing materials are now more affordable, attractive and easier to install.

Having a corrugated tin roof was once either not an option or an option not well sought after.  Today’s rollformers offer superior technologies for the tile effect roof cladding industries.

The biggest advantage of trapezoidal profile forming machine is the fact that it is a very effective solution when the question is – how to install  galvanized roofing. They are very useful in fabricating steel roofing and prove to be useful with all sorts of roofs like snap lock metal roof, corrugated roof, galvanized roof, insulated roof panels, color steel roofing, steel rite construction etc. These are also useful in installing steel roofing. 

Amongst other important advantages of trapezoidal profile forming machine is the fact that it can roll form two different types of meta roofing sheets with the need to change any rollers. One of these sheets is a normal rectangular roofing sheet and the other is an extraordinarily tapered roofing sheet. What is important here is the fact that the tapered sheet is produced in the same process as the normal roofing sheet. What however, remains to be the most important feature of trapezoidal profile forming machine is the fact that it makes the surface of the steel roof very smooth and attractive. So, it can work wonders with all types of steel roofs and panels like snap lock metal roof, corragated roof, galvanized roof, insulated roof panels, colour steel roofing and so on.

There are many other interesting features of a trapezoidal profile forming machine. It is fully automatic and extremely easy to handle. You just need to key in the desired length and the quantity in the control panel. The machine is equipped with a hydraulic single head uncoiler and a hydraulic cutting system with automatic cut-to-length. It can also be designed as per the specifications and profile drawing to offer customized solution to the client. Most leading manufacturers of trapezoidal profile forming machines offer one year warranty period.  

The value of trapezoidal profile forming machine can be gauged from the fact that they are used in fabricating steel roofing and are used for making all types of roofs, including like snap lock metal roof, corrugated roof, galvanized roof, insulated roof panels, color steel roofing, steel rite construction etc. There are many other advantages of trapezoidal profile forming machines. Most important of which however, is the fact that they can roll form two different types of meta roofing sheets without changing any rollers.  

One of the meta roofing sheets is a normal rectangular roofing sheet and the other an extraordinarily tapered roofing sheet. What is interesting to note here is the fact that the tapered sheet is produced in the same process as the normal roofing sheet. No extra complicated process is required for producing it. Another advantage of trapezoidal profile forming machine is the fact that it makes the surface consistently smooth and scratch-free.   

There are several other advantages of trapezoidal profile forming machine as well. For instance these machines are fully automatic and extremely simple to operate or handle. Furthermore, these can be designed as per specifications and profile drawing. What however is the biggest attraction of Trapezoidal Profile Forming Machine is the fact that most of them come with one year warranty.   

These trapezoidal profile forming machines also pose a very effective answer to the question “how to install galvanized roofing?”. They prove their relevance with all sorts of roofs like snap lock metal roof, corrugated roof, galvanized roof, insulated roof panels, color steel roofing, steel rite construction etc. They also play an effective role in installing steel roofing.  

No wonder their popularity is growing with every passing day. 

Door frame forming machines play an instrumental role in fabricating steel door frames which are commonly used in many commercial buildings. The biggest advantage that this metal processing machinery brings to any building is that the door frames formed by them are usually very smooth and consistently beautiful. They don't have any mark of scratch which otherwise may ruin the appearance of any building.  

No wonder these machines are extremely popular. This becomes apparent from the fact that there are several varieties of door frame forming machines like vacuum forming machines, thermoforming machines etc. available in the market. All these are a type of metal processing machinery and play an important role in dishing out such varieties of door frames used in rolling doors, insulated garage door, insulated steel doors, custom garage doors, commercial garage doors etc.  

The advantages of door frame forming machines are many. For instance, they can competently roll form metal doors. The speed of roll forming is usually between 12 ~ 20 m / per minute with a sheet thickness between 1.2 ~ 1.8 mm. This makes them popular in commercial applications. Door frame forming machines can also carry out punching as per instructions. Furthermore, they have fully automatic and very effective control system which makes them very easy to handle and operate. The machines can also be designed as per specifications and profile drawing. However, it should be noted that one roll forming machine can produce only one profile. Last, what makes these machines so attractive is the fact that most of them come with one year warranty.