Wire Forming and Fabricating
The versatile wire forming and fabricating shop works with low-and-medium carbon steel, Type 300 stainless steel, Inconel, Monel, titanium, and aluminum, coupled with CNC sheet metal stamping and forming capabilities.
Wire in 0.050" to 0.500" diameters is used to make fan and machine guards, baskets, frame handles, clutch rods, paper guides, and rack, chassis, and monitor frames, cable brackets and troughs, masks, and wire grids. Tubes to 2" diameters or 1-1/2" square and sheet metal to 1/8" thick can be used in conjunction with wire.
The use of wire in these and other applications improves air flow, reduces component weight, improves accessibility and reduces tool costs. Painted, plated or electropolished finishes are available to broaden the use of wire.
The types of tooling required to produce wire components are templates, go/no-go gages, machining fixtures, forming dies, welding fixtures, assembly fixtures and inspection/checking fixtures. It has been noted that tooling for wire fabrication is less expensive than plastic molds, die castings or four-slide tooling. Swages and flattened wire with pierced or tapped holes can also be generated with tooling.
Conventional bending methods yield the 0.010"/bend tolerances. With special tooling 0.005" can be achieved. Tighter tolerances can often be held by die forming parts. Parts can also be formed in multiples instead of being bent one at a time. CNC forming equipment will not have as tight tolerances as bent or die formed. Bend tolerances of 0.015" and angularity of 2% are achievable with CNC equipment.
Various types of welding are applied in wire fabrication: butt welds, T-welds, line welds, crosswire resistance welds, projection welds and TIG or MIG welds. The welding of dissimilar-diameter pieces with greater than 2:1 ratio should not be attempted. If a joint contains a T-weld, the T-wire and frame wire should be within one gage number of each other. When welding two wires of different diameters in crosswire applications, the smaller diameter is set down into the larger wire.
Riveting, component assembly, and special packaging should be offered with weld testing, certified products to allow direct ship-to-stock policy, and Just-In-Time delivery.
Today's wire forming and fabricating source learns customer needs, handles engineered and close-tolerance applications, and provides a high level of hands-on value added to prototypes through production runs of thousands.
Monel and Inconel are registered trademarks of the Inco family of companies.
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