To facilitate the centuries-old weaving process, wire mesh suppliers must employ specialized weaving looms designed to work with metallic wires. These looms consist of seven components: a warp beam, warp wires, heddle frames, weft wires, a rapier band, a reed, and a front take-up mechanism.
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The warp beam is a cylindrical beam that is used to wind the warp wire after the volume and length of the wires are calculated based on the specifications of the mesh.
Warp wires are the wires that run vertically and are threaded through the entire loom.
The heddle frames are holsters that are used to organize and separate the warp wires. Looms set up to produce a square mesh may have two sets of heddle frames, whereas more complex filter cloth weaves may have more.
Weft wires are the wires the run horizontally and are typically fed by a separate spool of wire.
The rapier band system is responsible for threading the weft wire through the sets of warp wires between heddle frame movements.
The reed is one of the most essential elements of a weaving loom as it is used to position the warp wires they will be woven in and drive the weft wires into their exact potion.
The front take-up mechanism rolls the woven mesh once it is fully woven.
The Weaving Process
To initiate the weaving process, a loom operator will attach and arrange the individual wires on the warp according to their position in the weave. To prevent entanglement, these wires are housed in a wire housing unit known as a creel.
Once attached, the warp beam is wound, allowing the proper length of wire to be wrapped around the beam.
Each wire wound on the warp beam is threaded through its own heddle in a specific heddle frame then carefully threaded through the reed openings based on their order in the weave. At this point, the warp beam, heddle frame assembly are transferred to the weaving hall, and the remainder of the loom is assembled.
NOTE: A great deal of attention to detail must be applied when threading the wire through the heddle frames and reed, as this process control how accurate the mesh specifications are.
Once the loom is fully assembled and the wires are properly threaded, the weaving process can begin.
When first initializing the weaving loom, the warp beam unwinds slightly to feed a small increment of wires. At the same time, the front take-up mechanism winds the same increment of wires to maintain the required tension to produce high-quality mesh.
Once these movements are made in conjunction, the heddle frames shift to separate the wires. In a two-heddle frame system, the first heddle frame lifts one half of the wires, and the second heddle frame drives the other half of wires down.
While the two sets of wires are separated, a weft wire, typically fed from a wire spool that is separated from the creel and placed next to the loom, is shot between the wires by the rapier band. The rapier band then moves back to its resting position.
It's at this point that the reed propels the weft wire to its final position, creating the precise cross-sections that wire mesh is known for. Once the weft wire is positioned, the reed returns to its resting position.
This marks the completion of the first interval.
To continue the weaving process, the warp beam and front take-up mechanism make the same slight, rotating movement to begin another interval. At the same time, the heddle frames will switch potion, wedging the previous weft wire as the two sets of wires are separated in the opposite direction.
These joint movements repeatedly continue until the desired length and mesh specification is woven.
Wire mesh is extremely versatile in its uses and can be manufactured to accommodate many different applications. Depending on your use, finding the right woven metal mesh or welded wire mesh for your project can be crucial. Check out this guide for tips on buying the best wire mesh the industry has to offer. Keep in mind, quality really does matter when it comes to working with wire mesh materials.
Contact us to discuss your requirements of stainless steel pre-crimp mesh. Our experienced sales team can help you identify the options that best suit your needs.
Explore more:Questions You Should Know about Welded Wire Mesh Supplier
Find Your Mesh Specification
Wire cloth fabrication can be molded to fit a variety of specifications. Knowing some specifics of the application you&#;re using it for can be very helpful in making sure you get the right mesh for your project. One of the largest deciding factors is the need for strength and durability in its application. For instance, if you are looking to invest in woven metal mesh to assist in allergy-proofing your home, a single-layer of wire cloth over windows will cleanse the air while ensuring proper airflow.
In addition to choosing between a single layer of wire mesh or multiple layers, you must also consider the size and shape you are working with. For instance, when working to create a filter product through wire cloth fabrication, choosing a very fine wire will allow for the optimal level of filtration to be achieved.
Understanding the mesh count, wire diameter and opening needed for your application is an important first step in making sure you find the wire mesh to fit your project. Additional tools can be used to help you find the right fit. For example, Lawrence Sintered Metals has a free wire mesh calculator that can help you determine what specifications you may need.
Choose Your Weave Type and Pattern
Once you have the basic specifications of the mesh you need, it may also prove beneficial to decide on your weave type and pattern. One of the main considerations in selecting a wire mesh is whether to select a woven or welded pattern. Woven mesh is more common overall because not all wires are suitable for welding.
Woven wire mesh&#;also sometimes referred to as woven wire cloth&#;is created by weaving wire strands in an over-under or under-over method to form different patterns with varying specifications. Some of the most common weave patterns for woven wire mesh are plain/square weave, rectangular weave, plain Dutch weave, twilled Dutch weave, and intercrimp weave. The weave pattern of mesh significantly influences what it can be used for. For example, plain square weaves are ideal for use in general-purpose applications, while Dutch weaves are more appropriate for use in air and liquid filtering applications.
Welded wire mesh is a sheet of metal wires arranged into a stable grid pattern, then welded at the intersections for durability. Welded wire mesh is cost-effective and highly customizable, with options for a range of materials, thicknesses, and grid patterns. Stainless steel is oftentimes the material used to create welded wire mesh, as it offers the highest performance, valued both for its strength and corrosion resistance. Applications that may call for stainless steel mesh for either functional or aesthetic purposes include filters for chemical and oil processing, air filtration, food service and medical filters and guards, and building facades.
Think About Your Application&#;s Conditions
When chosen correctly, wire mesh offers the strength and flexibility needed for its given application. It is important to select a material capable of withstanding the operating and environmental conditions. For example, in applications involving corrosive materials, stainless steel is a viable option. In general, stainless steel is one of the most&#;if not the most&#;commonly employed construction materials for wire mesh products. Typical alloys used include Type 304, 316, and 316L.
Do the Necessary Research
Just as you would with any other project, doing the research before you start is imperative. We encourage all users of wire mesh, especially those new to the industry, to familiarize themselves with the products, their terminology, and users. In addition, know where you can save money in the process. For example, to receive the best SQFT price, purchase a full roll of material. Standard rolls measure 100 feet in length, and when purchasing in this quantity, there is no extra labor cost and no cut to size waste.
Lawrence Sintered Metals Offers High Quality, Affordable Wire Mesh
Once you have all of your specifications laid out, all you need to do is find a wire mesh products provider. Lawrence Sintered Metals offers a variety of wire mesh products in woven and welded form, in different alloys including plain steel, stainless steel and galvanized steel, aluminum, copper, bronze, brass, Monel, Alloy 20, and many more.
At Lawrence Sintered Metals you can also send in your drawings, designs or descriptions to receive a quote. Contact Lawrence Sintered Metals today for more information on how to plan and purchase the highest quality, affordable wire mesh for your needs.
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