A common method used in cut to length metal fabrication is to use extrusion. A fine diameter steel wire can be wrapped around a large steel core and the two materials are passed through a series of metal rollers that press them into the desired shape.
This is then subjected to surface deformation, which can be done by pushing against the rollers, either side of the steel wire. The wire is cut on the floor and the cutting head on the rolling cutter goes to the required length and edges are not formed. This allows for additional pressure to pull the wire towards the end of the rollers.
This process may cause a stress that will cause the surface of the rollers to deform. This will create a center of distortion between the rollers. The materials will also require continual pressure to create a smooth surface on the rollers, so that the finished product remains flat, even after the edge of the rollers have been cut.
The machined steel is then placed on an abrasive surface and is run down the roller to expose the next part of the process. This will continue until all the steel has been cut to length and the entire process should take no longer than one hour.
This method may be used to produce many more products if there is sufficient demand for them, however the low cost means that they are less expensive. This is a useful alternative to the more elaborate and costly production process used to make the final products.
It is however essential that there is enough material to ensure that the final product is accurately cut and there should be no blank spaces left. If there is excess material then it will cause the actual product to become sharpened and has little opportunity to properly bond with the surface of the metal.
If this is to happen then this process will not be suitable for the industry. In addition, machining the surface of the steel rollers may introduce problems of its own, in particular that it may also cause metal fractures and increases the possibility of surface breakage.
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