Used Sheet Metal Brake

Image-Based Perforated Pattern For Architectural Sheet Metal Design

There are countless numbers of perforating patterns possible with many types of hole, including round, square, hexagonal, rectangular, triangular and oblong. The most common patterns used in conventional perforated sheet metal are straight line and staggered patterns. In a straight line pattern, the hole arrangement can be determined by two parameters: Vertical and horizontal direction. To create a square pattern, both directions should have equal distances. If the distance in the vertical direction is not the same as in the horizontal direction, the perforated pattern will be called a rectangular pattern. Unfortunately, compared to a staggered pattern, this straight line pattern is not as strong as the staggered pattern due to the nature of the layout.

Besides all those uniform and conventional perforated metal patterns a new perforated pattern based on an image has also become available widely. This opens a new and exciting market opportunity for any perforated sheet metal project which can benefit both the supplier and the customer. Basically, the perforated pattern is generated by capturing the image's colour by using a specific calculation / algorithm, and then all information is translated in a sophisticated way to create a pleasant perforated pattern design which reflects the original image in some way.

There are several considerations when designing a perforated sheetmetal pattern based on an image. These considerations are recommended to make the perforated pattern design reflect the original image as closely as possible and to reflect the pattern that the designer wants to have.

More hole types is better

More holes variation is likely to give a better result. In most cases, this is simply because the more holes that are used, the greater is the information that will be captured during the conversion process to generate the perforated pattern.

The proportions of Image and Perforated Sheet A good perforated sheet pattern design should have a size in proportion to the original image.

If the original image size and the designed perforated sheet are not in proportion, the designer will be forced to stretch the perforated pattern. In some cases this could be done on purpose, but in general this should be avoided if you wish to create a natural looking perforated pattern design that reflects the original source.

Original Image Composition

Although virtually any image can be converted into a perforated metal pattern design, the color composition of the image plays an important role in getting the best results. In most cases, an image that has strong contrast and vivid colour separation seems to capture better in perforated sheet pattern conversion. For example, a cartoon image or an Andy Warhol style painting are best suited to perforation conversion. The most difficult kind is an image photo that has smooth colour transition, light contrast or too-bright colour.

Viewing Distance to get an optimal representation of the pattern perforation

To design a better perforated pattern and to make the pattern reflect the original image optimally, a designer should consider the viewing distance between the perforated sheet project and the people who will see it. The viewing distance has a relation to the average hole size and the centre-to-centre distance between holes as well as the open area. Thus, if a perforated pattern is supposed to be seen at a distance of about 10 meters (eg: a car park building fascia), at this optimal viewing distance they will automatically recognise the image that appears on the perforated sheet. However when people see it at around 3 or 4 meters distance, they will just see the perforated pattern as a scattered, meaningless, hole pattern on the sheet.. On the other hand, if people see it from 20 or 25 meters away, they will see it as a dot image or a plain picture without automatically knowing that it is an art work created from a perforated pattern. The pictures below illustrate what people see when the perforated pattern design is too close or too far away.

Light arrangement to give better result

To make the image-based perforated metal outstanding, we should consider the use of back light to give a better representation of the original image. Lighting sourced either from natural light (eg. sunlight) or artificial light ( eg. a spotlight) plays an important role in creating a better composition to improve the visual effect of the perforated pattern. Placing a bright light behind the perforated sheet will create a perforated shadow which can be even more sophisticated for the perforated pattern.

Creating a 3D perforated pattern project before manufacturing

It is a recommended, based on my last perforated project, that all perforated pattern designs are visualized into 3D design by using a third party 3D CAD software before they are manufactured. By doing this, the designer and the project owner can deliberately check to see whether all the design considerations, including material colour, texture, light arrangement, and perforated sheet pattern design, are already suitable to their specifications. All in all, product alterations in the design stage are much cheaper than after manufacturing the real product.

Fransiscus Herry is a CNC programmer / operator as well as CAD Draftsman for a sheet metal company in Auckland - New Zealand. He studied Mechanical Engineering in Indonesia and completed Master of Engineering studies(hons) in 2003 from the University of Auckland. In 2007 he found Aucad Drafting Limited to accommodate his passions in software engineering for sheet metal industry. His first application, called Image2Punch, is used to convert virtually any image into perforated metal pattern design by using his own algorithm.

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Metal Fabrication Types - Press Brake Forming, Sheet Metal Fabrication and Bar Milling

Metal production experts use a variety of different techniques to produce customized parts, fittings, and other industrial and commercial solutions. Each technique produces a completely different product with different characteristics. Whether it is bar milling, sheet metal fabrication, or press brake forming, each has its own purpose and set of benefits.

Press Brake Forming

Using a computer operated press brake forming machine, which runs at extreme pressures of approximately 350 tons, this machine literally squeezes metal into shape. Many machines can work with up to a 3/8" thick material that is upwards of twelve feet in length. Press brake forming also works with a variety of different metals including brass, stainless steel, aluminum, and carbon steel. So what is it used for? If you need a metal housing for a particular part, brackets for machines and equipment, metal framing, and even decorative touches, this method will likely be the one used. This is an ideal solution for anyone needing replacement parts, large numbers of brackets, and fastening solutions as well as prototypes for almost any type of machinery.

Bar Milling

Bar milling is reforming an existing bar into a particular shape, form, and length to make it fit various jobs and specifications similar to running a router or shaper down a narrow length of wood. This could be by taking traditional round or square bars and making them into hexagonal or angled bars, adding grooves or other features down the entire length. It can also be made from various materials including brass and stainless steel. To create each shape, the specialist puts together a series of cutters that could be bevels, round overs, slots, and much more. Finally, it is milled down to a smooth surface and made into the proper dimensions.

Sheet Metal Fabrication

Sheet metal fabrication is ideal for detailing and precision cutting. With this method, specialists can use laser cutting, punching, press brake forming, shearing, and welding to create virtually anything from this super-thin and flexible metal product. It is used for everything from cultivator shovels and hopper bottoms for the agriculture industry to conveyor parts, guards, frames, decorative metal forms, and many other items for a variety of other industries.

Sheet metal fabrication works to build all sorts of covers and frames. It also works as a column cover or for ventilation purposes. Fasteners and other components are also made using this method. This includes many different parts involved in the transportation, refrigeration, and conveying sectors as well as amusement park rides and other recreational activities.

Depending on the task at hand, any one project could be subjected to one or a combination of these techniques. Then, welding is used to piece everything together to finish the completed project. Once that is complete, a quality provider will check the entire piece for quality, durability, and accuracy before handing it over for installation. Whether it is sheet metal fabrication, press brake forming, or some other technique, there is a process and the corresponding technology to produce the exact item you need.

Christine O'Kelly is the author for the sheet metal fabrication experts at National Metal Fabricators. They provide press brake forming, bar milling, angle rings, and custom metal fabrication to meet all of your business' needs.

Article Source: http://EzineArticles.com/?expert=Chris_A._Harmen

Methods for Forming Sheet Metal

Since the dawning of ancient civilizations, people have sought out ways to make life easier. Even humans today attempt to find ways to complete more work in a shorter amount of time. Ancient people had the same desire and thus tools were developed to aide in the completion of daily tasks. With the discovery of metal ore, and the process of applying heat to extract the metal from the ore, the complexity of tools significantly increased. Even today tools constantly become increasingly complex with new advances in engineering. Throughout the years of progress, increasing demand prompted the development of more efficient and precise ways of manipulating metal. Modern metalworkers use a variety of different metal forming machinery to reshape metal into varies parts and components.

Different shapes and forms of metals may require the application of different methods in order to shape the metal into something intended and useful. For example, specific processes are typically used to form sheet metal. Rollforming is an example of one such process that is typically used to shape sheet metal.

The art of sheet metal forming refers to the variety of ways used to shape sheet metal into a variety of forms. For example, sheet metal is used to make automobile panels and aluminum cans. Machinery has been developed to bend the sheet metal into new forms. An important word to know when discussing the forming of sheet metal is the word ductility. Ductility refers to the ability of the sheet metal to allow itself to be manipulated without fracturing. In other words, the level of ductility of the metal is the level to which pressure can be applied to reshape the metal without the metal breaking. Examples of highly ductile metals include silver, gold, copper and aluminum. These metals can be easily shaped without cracking or breaking.

Once the level of the metals ductility has been determined, its use can also be decided. Once a person decides what to use the metal for, the forming process can begin. Bending, drawing and the roll form process are all examples of methods for shaping sheet metal.

Roll forming refers to the process of continually bending a piece of sheet metal until the desired cross-section profile is obtained. Basically, each roll forming stand is developed to bend a small section of the metal. This allows each stand to be responsible for an incremental part of the bend. A roll forming machine consists of several stands. The metal is fed through the roll forming machine and gradually bent consecutively by each stand. Roll form is an ideal method to apply when shaping sheet metal because it is long and can be easily formed by passing through the stands.

The art of metal forming has come a long way since discovered in ancient times. The roll form method is an example of the type of complexity involved with shaping sheet metal. As technology continues to advance, one can also expect to see advances in rollforming techniques.

Article Source: http://EzineArticles.com/?expert=Alice_Lane

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