Roman Fursa, CC BY-SA 4.0, via Wikimedia Commons

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The history of wire mesh and wire mesh manufacturing

The manufacture of wire meshes has its roots in the most traditional textile production technologies, such as weaving and knitting. Wire weaving on looms for industrial purposes appeared in the early part of the 18th Century. In those years, the steam-driven loom for textile weaving was invented: this new technology rapidly transferred to the wire industry, in particular for automated wire weaving processes.

A driving force behind the development of wire meshes was the growing paper industry, as an endless wire mesh belt allowed the processing of pulp much faster than before. The result was that paper needed for newspapers, journals, and books could be produced at higher speeds and in larger quantities than ever.
Wire mesh also plays an important role in the &#;Davy lamp&#;, which was invented by the chemist Humphry Davy in . It was designed to reduce the danger of flammable gas explosions and to warn about carbon monoxide presence in mines. This safety lamp was crucial for the development of the coal and iron ore mining industry, and thus for the progress in steel making in the 19th century. Woven wire mesh, therefore, was key to the development of the industrial revolution.
In the early 20th century, with the widespread availability of electricity, modern welding methods &#; such as resistance welding &#; arose and opened the way to welded wire mesh manufacturing.
In the first decades of the 20th century, increasing military demand for military aircraft, tanks, vehicles, and gas mask filters caused an economic increase in the wire mesh industry.

Manufacture of wire mesh, wire cloth and packaging types

Different methods &#; such as welding, weaving, netting, or knitting &#; are used to process metallic wires into wire mesh. Flat mesh products arrive on the market in the form of coils or stacks.

Welded wire mesh is produced via automated CNC welding machines. Horizontal wires are continuously fed in parallel rows into the machine directly from the coil. Vertical wires are straightened, cut, and laid onto the horizontal wires for spot welding operations. In this way, a flat and rigid panel with square, rectangular, or diamond-shaped meshes is manufactured. A shear cuts the mesh panel once it reaches its specified length. Then, a transporting device extracts the final products from the welding line and stacks them for the following transportations.
Different diameter and wire spacing configurations allow great panel customization to accommodate any need.

Wire cloth is made on weaving machines. The longitudinal wires, known as warp wires, run continuously from the back of the machine to the front side. A device holds the warp wires in place. Some of these wires are alternatively raised or lowered by a mechanism, creating an opening in the transverse direction. A shuttle &#; with another wire, called weft wire &#; is &#;shot&#; through one opening, returned through the subsequent one, and so on. In this way, the weft wire is woven through the warp wires. Both types of wires interlace with each other at specific angles to form the wire cloth.

Wire nettings are manufactured via chain link machines, which loop different wires into one another according to a regular pattern.

Literature

About textile weaving:

Valeriy Choogin, Palitha Bandara, Elena Chepelyuk: Mechanisms of Flat Weaving Technology. 1st Edition. Woodhead Publishing,
ISBN:
eBook ISBN:

Introduction To Weaving Technology.
https://textilelibrary.wordpress.com//04/09/introduction-to-weaving-technology/

Emel Önder, Ömer Berk Berkalp: Weaving Technology II
https://web.itu.edu.tr/~berkalpo/Weaving_Lecture/Weaving_Chapter1a_06S.pdf

About resistance welding:

Hongyan Zhang, Jacek Senkara: Resistance Welding. Fundamentals and Applications. Taylor & Francis Inc; New edition, .
ISBN-10:
ISBN-13: 978-

Nigel Scotchmer: The Other Resistance Process: Cross Wire Welding. In: Welding Journal, December , pages 36-39.
https://www.researchgate.net/publication/_The_other_resistance_process_Cross_wire_welding

For helping us compile the information, we thank -Ing. Konrad Dengler, technical journalist and translator specialized in industrial topics.

Welded wire mesh manufacturing process, include galvanize welded wire mesh and vinyl coated welded wire mesh production processing.

Wire rod

The raw material used for product material is of low carbon steel from various steel manufacturers, commonly known as wire rods. The raw material grades are SAE , SAE , and SAE which has a percentage of carbon in the range of 0.08 to 0.12. Stainless steel wire, iron wire, galvanized wire is the ideal raw materials.

Cold rolling

Cold rolling is a metal working process in which metal is deformed by passing it through rollers at a temperature below Recrystallisation temperature. Cold rolling increases the yield strength and hardness of a metal by introducing defects into the metals crystal structure. These defects prevent further slip and can reduce the grain size of the metal.

Straightening & cutting

Specialized machinery from Italy is used for straightening and cutting process. The cold rolled wire rods in the coil form is passed through pre set die and cartridge units (special sets for different diameter wire rods) present in the straightening and cutting machine, where the wire rods are first straightened and then cut to set length (precision up to 2 mm) automatically. The wire rods can be cut to any size ranging from 0.8 metre to 12 metre with a max tolerance of 2 mm.

Welding

Welded wire steel fabric is manufactured with automatic welding machines, where wires are welded together in square or rectangular grids. The wires are welded by electric resistance in an automated state of the art machine which controls welding parameters precisely. All the settings for dimensions and welding are programmable. The weld is formed by a controlled combination of pressure, intensity and duration of electric current to develop fusion of the wires. Welded steel fabric utilizes welded intersections for bond and anchorage.

Bending & cutting

Two separate machines from Schnell, Italy are available for cutting and bending operation. The cutting machine is used for cutting the finished meshes to desired dimension. It is a motorised unit, capable of cutting meshes at a speed of 2 to 3 cut per second. The bending machine available is used to bend the cut meshes to the required shape (as required by design). The machine is capable of bending sheet to any angle (Up to 180o). Depending upon the design requirements, the sheets requiring cutting and bending will be taken for this operation else the meshes will be directly taken for despatch from the third process.

Finished mesh

After the bending and cutting process comes the final stage in manufacturing process, galvanizing or PVC coating.

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