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.