Description of the technological process of sheet metal beading

Short description

Applying a kind of relief pattern to the surface of thin sheet metal is carried out using special equipment called a zig machine. It is equipped with a pair of rollers, which during operation make corresponding ridges (grooves), which can be not only flat, but also three-dimensional types of workpieces.

In addition, with the help of this mechanism, corrugation, cutting, and flanging of sheet metal are carried out. This type of zigging machines is presented in several varieties, these are manual and electric zigging machines. But there is also a hydraulic one, but it is mainly used in large industrial enterprises.

According to the principle of application, they are no different, except that manual machines produce corrugation of a metal sheet with a thickness of 0.3 to 1.0 mm. But electric ones have a lot of power, so they can apply reliefs on a metal surface of more than 2.0 mm.

In principle, all types of beading machines are not very different from each other, but they have different capacities. In addition, these shafts can have different locations, for example, horizontal, vertical and inclined positions. Rollers with the required relief are put on them directly.

Extracting precious metals at home

Gold (Au)

Gold is obtained by amalgation or leaching.

During amalgamation, gold dissolves in mercury (Hg), forming an amalgam, which becomes solid if the Au content is more than 15%. From the resulting amalgam, mercury is distilled off in condensing devices, leaving Au and Ag (silver) nodules. Purification of Au from silver is discussed below. For leaching , a solution of sodium or potassium cyanide is used - NaCN or KCN (concentrated solution in distilled water), in which Au dissolves in the presence of oxygen (by blowing with air) to form complex anions [Au(CN)2] - - potassium dicionate:

4Au + 8CN - + O2 + 2H2O = 4[Au(CN)2]- + 4OH-

From the resulting solution, gold is isolated with metallic zinc (Zn filings) into a colloidal precipitate:

2[Au(CN)2]- + Zn = [Zn(CN)4]2 — +2Au

The precipitated gold is treated to separate the zinc from it with dilute sulfuric acid; washed and dried.

Further purification of Au from impurities (mainly silver) is carried out by treating it with hot concentrated sulfuric acid H2SO4 or electrolysis is required.

Au also easily dissolves in “aqua regia” (a 1:4 mixture of hydrochloric HCl and nitric acids HNO3), forming complex chloroauric acid H[AuCl4], which crystallizes upon evaporation in the form of light yellow needles of the composition H[AuCl4]•4H2O.

Au also easily dissolves in “chlorine water” and in aerated, i.e. purged with air, solutions of alkali metal cyanides.

All Au compounds readily decompose when heated, releasing metallic Au.

Due to its softness, Au is used in alloys, usually with silver or copper. These alloys are also used for electrical contacts.

Working with these reagents requires GREAT CAUTION, as they are all deadly poisonous.

The presence of Au in radio components is determined by the part's passport and the characteristic color of the coatings.

Silver (Ag)

Silver is obtained by amalgation or leaching. In leaching, silver is dissolved by the action of a concentrated solution of potassium cyanide KCN or NaCN in distilled water. From the resulting complex cyanide compound K[Ag(CN)2], Na[Ag(CN)2], metallic silver is deposited by passing electric current through the solution ([Ag(CN)2]- ? Ag+ 2CN-), a dense metal-ceramic crystalline layer at the cathode.

Hydrochloric and dilute sulfuric acid have no effect on Ag. Silver dissolves well in nitric acid HNO3, so nitric acid is used to separate Ag from gold Au, which does not dissolve in HNO3:

Ag + 2HNO3 = AgNO3 + NO3? + H2O.

All Ag compounds are easily reduced under the action of reducing agents (for example, formalin, hydrazine) with the release of metallic Ag. The amalgamation process is similar to Au. Large amounts of Ag are used for electrical contacts and in silver-zinc batteries.

Platinum (Pt)

The release of platinum is similar to that of gold. When platinum is dissolved in aqua regia, hexochloroplatinic acid H2[PtCl6] is obtained, which, when the solution is evaporated, is released in the form of red-brown crystals of the composition H2[PtCl6]•6H2O, which upon further heating decompose to release Pt.

Brief characteristics of the zigging mechanism

Depending on the type of production, such equipment has a wide range of actions, which makes it possible to crimp sheet metal with the appropriate relief.

Specifications:

Selection principles

When purchasing a crimping machine you need to consider:

• dimensions of equipment, premises;
• type of drive;
• roller material;
• control system;
• number of rollers;
• thickness of metal for the manufacture of housings and moving elements.

We must not forget that there are different types of videos. They vary in shape. You need to think in advance about the purpose of using the installation and purchase a set of consumables.

Compact machine (Photo: Instagram / metalmaster_stanki)

Advantages and disadvantages

Advantages:

Main purposes of serging equipment

Such machines, according to their intended purpose, are used for work related to tin materials that have a cylindrical shape. Therefore, it is very often used to increase the strength of a metal product, as a connecting profile, and is also used in the form of processing the edges of sheet metal. In addition, it is used:

1. In the production of cylindrical products in the form of ventilation and water pipes.
2. With its help, special locks are made on metal products made of thin iron, which makes it easy to connect various iron parts without the use of welding equipment.
3. In the production of thermal insulation of pipelines.
4. Often used in the processing of shells.
5. In roofing work for cutting and flaring drainpipes.
6. In the production of ventilation shaped parts.
7. It is also used in the production of components for drainage systems.

But the most common application of zig machines is the process of corrugating thin-sheet material that has a cylindrical shape.

Application area of ​​zig machines

The serging machine connects metal elements with a thickness of 0.5 to 4 mm. First, the lock is rolled, then the parts are connected. If required, the lock is reset manually.

A crimping machine is used to process sheet metal products. They allow:

• manufacture pipes, sills and other industrial elements in the shape of a cylinder;
• process shells;
• carry out thermal insulation of pipelines;
• create corrugated products.

Zig machines are used for metal roofing work.

The main advantage of crimping is that the metal is not heated, which means there is less risk of product deformation. In addition, energy and consumables are saved.

Features of the technological process

Metal beading is an easy operation to perform, but it requires some skills and knowledge of the technological process. Since, thanks to heaving, softer material acquires greater strength, it is necessary that the elements are made with high quality. To do this, you need to know how the process of applying relief occurs. It is as follows:

• The upper roller is raised onto the lower one to place the part for processing and then the raised upper roller is lowered onto it.
• It is very important that during the zigging process uniform corrugations are applied and the distance is taken into account, so it is imperative to use a stop.
• The degree of fixation of the workpiece is adjusted using the existing screws.
• Another feature is that if you use a more durable material, you need to take into account that for creasing in this case it is necessary to use a hydraulic or electric drive on the equipment.
• For example, if corrugation is used on aluminum or zinc materials, then it is necessary to increase the distance between the ridges, as well as increase the radius of the ridge itself.
• The shafts with corresponding rollers have the opposite effect during operation, that is, they rotate in the opposite direction, which as a result creates the necessary depressions on the sheet metal.

If the first time applying relief to thin-sheet metal was not done enough, then you can carry out several more cycles along the already completed zigs. Only after achieving the desired result can the workpiece be removed.

Advantages

Regardless of the type of creasing equipment, they all have their own advantages, which allow the necessary work to be carried out with a high level of quality. These include:

1. If you take a manual zig machine, then it is economical, since it does not require any financial costs other than physical strength. Also, its mobility allows you to carry out work in a convenient place without using electricity.
2. In addition, the small dimensions of the mechanism allow the use of a minimum amount of space for its placement.
3. With its help, it is possible to produce various corrugations on the surface of sheet metal with high quality, thereby increasing its strength.
4. As for stationary zig machines, they also do not take up much space, but the mobility of such equipment is lacking.
5. Directly one of the advantages is the fact that with the help of crimping you can connect parts of products without the use of welding or other similar methods.
6. The quality of the products produced is correspondingly higher, and, importantly, it is possible to use a material with a more solid structure, but with sufficiently high ductility, which, in turn, allows work to be carried out without damaging the sheet material.
7. In addition, the aesthetic appearance of the product increases.

In any case, such equipment makes it possible to produce parts with the necessary corrugation, especially if you consider that today there are a large number of varieties of ridge application of relief on sheet material.

As for the disadvantages, the only one is that when manually beveling sheet metal, you will need to put in quite a lot of physical labor, but this in no way affects the quality of the work performed.

Questions and answers

What products can be made on crimping machines?

Buckets, deflectors, and funnels can be produced using crimping equipment. The machines allow you to roll thrust ridges, corrugate metal blanks, make drainage elbows, etc.

Are there any differences in the operating principle of manual and electric seaming machines?

There are no fundamental differences in the operation of manual and electrical equipment.

What machines can handle metal with a thickness of 3-4 mm?

Metal of this thickness can only be processed on electric or hydraulic industrial crimping machines.

What does roller overhang affect?

Regardless of the type of equipment drive, roller overhang affects its technical capabilities.

What type of crimping machines is best to use for roofing work?

In roofing work, it is better to use manual zig machines. They can be lifted directly onto the roof.

How to make a crimping machine with your own hands?

First of all, you need to determine for yourself for what purpose this mechanism will be used, and how often it will need to be used. This is due to the fact that the zig machine is not a popular tool for daily use at home. But, if it is the object of professional activity, then you can do it yourself.

To create such a machine you will need to collect all the necessary parts. And, most importantly, every man who has even the slightest connection to technology can have them. The main parts that will be needed to make a zig machine:

• bracket;
• two working shafts;
• cylinder shank;
• device body;
• protective casing;
• spring device;
• locking pin;
• gear parts;
• rollers.

It is necessary to secure the beading machine using a special screw, but this must be done so that the shank of the main mechanism fits into the bracket. As for the body of the device, it needs to be secured well using a locking pin. To adjust the movement of the shafts, there must be a handle.

The rollers themselves on a homemade zig machine are driven by another handle and a toothed belt mechanism. A very important point in creating such equipment at home is that it is necessary that all parts of the gear mechanism be covered with a special protective casing.

Video: zigovka – electromechanical zigovka machine.

What do you need to know when working with a homemade zig machine?

A zig machine made independently is no different in operating principle from a factory machine, but still has some nuances that must be taken into account. These are such as:

1. The part to be processed must be very securely fixed.
2. The prepared workpiece must be placed between the rollers and secured with a special stop.
3. The process involves adjusting the upper roller, which is operated by a handle.

To avoid injury, be sure to cover all parts of the rotating mechanism with a protective cover. One of the most important advantages of this equipment is that when used, the material used is not exposed to high temperatures.

And also no additional financial costs are required, for example, there is no need to use fuel or large amounts of electricity. And if you use a manual zig machine, then only physical strength is required.

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