Metawell Klimadecke 1 processing and design tips
Metawell Klimadecke 1
processing and design tips
contents
Contents
Edge forms 2
•Edgedesigns 2
•Borderfinishes 4
Riveting 5
•Specifications 5
•Sourceofsupply 5
Sawing 6
•Specifications 6
•Toolparameters 6
•Sourceofsupply 6
Milling and drilling 7
•Specifications 7
•Toolparameters 7
• Slitcutter 7
• Router 8
• Prismaticcutter 8
Bonding 9
•Specifications 9
•Sourceofsupply 9
Forming 10
•Metawell 10
•MetawellAluflex 11
Individual colouring 12
•Painting 12
•Coating 13
page
®
®
Modifications and errors reserved 2
EdgEfoRMS
Edge designs Metawell®offersotherpossibilitiesforedgefinishesthansheetmetal,whichisduetoitsspecificpanelstructure.Moresignificantcharacteristicscanbecreatedattheedgeofasandwichpanelbyuseofanapplication-matchingedgedesign:
•opticaladjustmentoftheedgetotheapplication•increaseoftheelement‘sstiffnessintheedgeareas•reductionoftheriskofinjuriescausedbysharpmetaledges•reductionofassemblyworkby„automatic“fittinge.g.byintegrateddrillholesforconnectors•concealedattachmentofprofilesandfittingsatthebackofanedgefinish
Inordertoobtainanattractiveedgethepanelhastobemechanicallyprocessed.Thereforethepanelismilledthroughbacksheetandcorrugationtothecoversheet.Themillinggeometryisdependendonthefinaledgeformandthemachiningtools.InviewoftherequestednarrowtolerancesfordoublefoldingsandfoldingsatthecornerstherelevantpanelsshouldbeprocessedwithCNC-workstationsonly.oncethepanelsaremilled,thefoldingitselfcanbedoneeitherbyhandorwithsimpleedgingaids.Likethisflat(milled)panels,thattakelessspaceduringtransport,canbesenttotheassemblysitewheretheyarefurtherprocessedandfolded.onlypa-nelswithacoversheetthicknessofmin.0.8mmcanbemilledandfolded.Themax.foldinganglewithsinglemillingis135°.
NoteItisstronglyrecommendedtomakeapreliminarytestoraskforprocessedsamplestojudgethetechnicalandopticalsuitabilityofthechosenedgedesign.Pleasecon-tacttheplantforanyfurthertechnicalquestions.
Edge design KR-90Use: ceilingelements,liningsTool: CNC-workstation,verticalsaw,hand-tool(limited)Particularity: foldingradiiof2.5and4mmcanalsoberealizedwith coil-coatedpanels
Edge design KR-120Use: ceilingelementsTool: CNC-workstation,verticalsaw,hand-tool(limited)Particularity: foldingradiiof2.5and4mmcanalsoberealizedwith coil-coatedpanels
designKR-120(120°-folding)Radii:2.5and4mm
designKR-90(90°folding)Radii:0.5-2.5and4mm
Edge forms
Modifications and errors reserved 3
Edge design BKUse: ceilingelements,linings,doors,coversTool: CNC-workstationParticularity: canalsoberealizedwithcoil-coatedpanelsdesignBK(sheetcoverededge)
Radius:approx.1mm
Edge design EP/SUse: ceilingelements,liningsTool: rotaryjarsParticularity: ideallysuitedforcoil-coatedpanels(nocuttings)
designEP/S(hammershearcutedge)
Edge design EP/DUse: gaplessceilings,bigjoint-lesssurfacesTool: CNC-workstationParticularity: perfectlysuitedforsubsequentsealing/jointing
Edge design KBUse: structuralpartsTool: edgingbankParticularity: foldingwithoutpreparatorymilling,nocuttingofcoversheets, onlyforapplicationswithnovisualdemandsNote: bendingonlypossibleright-angledtocorrugation
designEP/d(coversheetpressed)
designKB(edgingbank)
Edge forms
Modifications and errors reserved 4
BesidesfoldingsmanyotherborderfinishesarepossiblewithMetawell®panels.Whenchoosinganappropriatefinishthefollowingaspectsshouldbeconsidered:
•opticalrequirements(design,typeofsurface) •generalconstructionalconditions(flushconnectiontothepanelsurface, fixingofaccessoriesorconnectionwithotherelements) •Ambiantparameters(temperature,pressure,affectingmedia) •Loadonthebordersduringoperation(mechanicstress,thermalloads, typeofelement–mobileorfixedmounting) •Requirementswithregardtotightness •Productioneffortsandquantity(singleproduction,project-wise production,serialproduction,availabletoolsanddevices)
ThecombinationofMetawell®panelswithotherelementsormaterialsispossibleandhasbeendonesuccessfullyforyearsinconsiderationoftherelevantindividualconditions.forinteriorconstructions,forinstance,postformingedgeswithglued-inwood,plasticoraluminiumprofilesandHPL-surfacescanberealized.
Inordertohaveadefinedbaseitmaybenecessarytomachinethepanels,e.g.tomillthecorrugationoffalongtheedgesandtofillthemwithfoamorinsertedplasticribbonsbeforeapplyingthefinaledgeending.Thispreparationismainlynecessarywhenedgebandingsorinjection-moldedbordersarewanted.furthertechnicalquestionsregardingtheseborderfinishescanbediscussedwiththeplant.
Plasticbeading
Edgeprofile
gluedinsert
Postformingedge
Tongue-and-groovesystem
Edge-banding
Border finishes
Edgecap
Injection-moldededge
Edge forms
Modifications and errors reserved 5
Metawell®panelscanbeconnectedtoeachotherortoothermaterialsbyconventionalrivets.Therivets‘lengthanddiameterdependmainlyonthecombinationofthecomponentsinvolved.
ThecorestructureofMetawell®alsoallowsconcealedrivetingononeside.Theuseofblindrivetsenablesthevisiblesurfacestobemechanicallysecuredwithoutdetractingfromtheirvisualappearance.Suchmethodsareused,forinstance,ininteriorconstructionsandfaçadetechnology.
MountingblindrivetnutsandscrewsintoMetawell®ispossible.Whenpiercingthroughcompletelytheyprovideincreasedresistanceagainstbendingmomentssincethebacksheetholdstheblindrivetnutandwithstandsdeformation.Blindrivetnutsshouldhaveatleastfourturnsofthread.
Therivet‘sextractionstrengthdependsonthecombinationofmaterialsandadditionalfactors,thedeterminationofwhichmightmakeatestnecessary.Therivets‘mechanicalparameterscanbefoundintherelevantsupplier‘sproductiondescription.
•TitgemeyergmbH,d-49084osnabrueckhttp://www.titgemeyer.deBlindrivets,blindrivetnuts
•BoellhoffgmbH,d-33622Bielefeldhttp://www.boellhoff.deBlindrivets,blindrivetnuts
•gesipagmbH,d-64546Moerfelden-Walldorfhttp://www.gesipa.comBlindrivets,blindrivetnuts
Specifications
Blindrivet–concealedfixing
Blindrivet-throughgoing
Blindrivet–rivetingindoublepanel
Blindrivetnut-throughgoing
Blindrivetnut-concealed
Blindrivetscrew
Riveting
RIvETINg
Source of supply
Modifications and errors reserved 6
Specifications Metawell®canbeworkedwithcircular,jigandbandsawswithconventionalsawblades:dihedralsawbladesshouldnotbeused,however,sincetheteethmaybecomeentangledbetweenthecoversheetandthecorrugationproducinganuncleancut.flattrapezoidalteethwithanegativetoothpositionandhardmetalcuttingedgeshaveprovenidealwhenusingcircularsaws.
Aformat-cuttingslidingtableortheuseofverticalsawsisadvantageouswhenprocessinglargepanels.foroptimumresults,werecommendtheuseofendstops.Sawinginpackstorationalizeprocessingispossible.
Thefixationofthepanelsandthesuitabilityofthesuctiondevice(e.g.ATEXdirecti-ve,volumeflow,etc.)shouldbeconsideredparticullarly.
groovesthatallowsubsequentedgingwithoutthehelpofafoldingmachinecanalsobeintroducedintothepanelsbyusingcircularorverticalsaws.forthis,however,inadditiontotheuseofaprismaticmillcutter,arollermustalsobeusedtopressdownthepaneltoensureadefinedcuttingdepth.
Preliminarytestswithsuitablesamplesarerecommended.
verticalsaw(panelsaw)
NegativeflattrapezoidaltoothLeitz-circularsawblade
Sawtype Circularsaw Bandsaw CNC-sawblade
Sawblade 80teeth/d=250mm 14teeth/1“ d=160mm
feed 10m/min 20m/min 10m/min
speed 3500-6500U/min - 12.000U/min
Source of supply LeitzgmbH&Co.Kghttp://www.leitz.org
Sawing
SAWINg
Tool parameters
differentdimensionsatLeitz-circularsawbladeswithneg.fZ/TR.
Modifications and errors reserved 7
Specifications Metawell®panelscanbeprocessedwithhandtoolsandmachinetools.
Wood-workingtoolsareideal,especiallyifequippedwiththerelevantprotectiondeviceagainst
metalcuttings,sinceprocessingMetawell®ismorecloselyrelatedtoprocessingwoodthanto
processingmetal.Thisrefersparticularlyintermsofthelargesurfacearea,theclampingtech-
niques,thefeedspeedandthelackofrequirementforcoolantsandlubricants.Inaddition,the
usabilityoftheexistingsuctiondevicemustbecheckedinadvance.Inaddition,theusabilityof
theexistingsuctiondevice(e.g.ATEX,volumeflow,etc.)hastobecheckedinadvance.
generallywedistinguishbetweenthefollowingtypesofprocessing,forwhichdifferenttypes
ofmachinesortoolsarerequired:
•Millingcontours
(bothcoversheetsandthecorrugationareremoved)
-handtool -endmillwithrouter
-machine -CNC-workstationwithrouter
•Millinggrooves
(onecoversheetandthecorrugationareremoved)
-handtool -panelrouter(limitedapplications)
-machine-CNC-workstationwithprismaticcutter
-verticalsawwithprismaticcutter(limitedapplications)
•Millingoutthecorrugation
(thecorrugationisremovedonthepanelsidesonly)
-handtool -trimmerwithslitcutter
-machine -CNC-workstationwithslitcutter
•drilling
handtool -drillingmachineorrouter
machine -CNC-workstationwithdrillerorrouter
Thetoolparameterslistedbelowarebasedonlong-termexperience.Inviewofthemanydif-
ferenttoolsandmachinesavailableitishighlyrecommendabletomakesomeprocessingtrials
withthetoolsandmachinesthatwillbeusedlateron.
Milling and drilling
MILLINgANddRILL INg
ToolsSlitcutter
(removingthecorrugationatthesides)
Slitcutter(removingthecorrugation
atthesides)
Typegroovingcutter22.5x4(millingdepthmax.8mmperoperationalstep)
T-groovingcutter45x8,2(hastobegroundtothe
requestedwidth)
speed 10.000min-1 10.000min-1
feed 5m/min 5m/min
SupplierHoffmanngmbH
http://www.hoffmann-tools.comLeitzgmbH&Co.Kghttp://www.leitz.org
Slit cutter
Removingthecorrugation(slitcutter)
Tool parameters
Modifications and errors reserved 8
Prismatic cutter
Milledgrooveforfolding(prismaticcutter)
ToolsCNCv-groovecutter(0.5mmfoldingradius)
CNCv-groovecutter(2.5mmfoldingradius)
CNCv-groovecutter(approx.4mmfolding
radius)
Typev-groovecutter(withchangingblades)
v-groovecutter(withchangingblades)
v-groovecutter(withchangingblades)
speedmax.
10.000min-1max.
10.000min-1max.
6.200min-1
feed 6m/min 6m/min 5m/min
SupplierLeitzgmbH&Co.Kghttp://www.leitz.org
LeitzgmbH&Co.Kghttp://www.leitz.org
LeitzgmbH&Co.Kghttp://www.leitz.org
Milling and drilling
Router
Millingcontours(router)
ToolRouter8mm
(millcuttingofcontours)
Endmill4mm(Innercorners,bottomholesanddrillholes)
Type
vHMcontourmiller8x30x80mm
solidcarbidecontourcutter,oneblade,righthandtwist,right-cutting,TiAlN-coating
vHMcontourmiller4x15x40mm
solidcarbidecontourcutter,oneblade,righthandtwist,right-cutting,TiAlN-coating
speed18.000min-1to30.000min-1
8.000min-1to30.000min-1
feed5m/min
to10m/min0,5m/minto10m/min
SupplierREXIMgmbH
http://www.rexim.deREXIMgmbH
http://www.rexim.de
Notedependingontherequiredradiiandtheavailablesurfaceofthepanel,theappropriatemillingtoolshavetobedefined.
Potentialrestrictionsandinstructionsoftherelevantsuppliershavetobeobserved.
Modifications and errors reserved 9
Specifications Bondingistheconnectiontechniquebestsuitedtothenatureofasandwichpanel:
•Theuniformstressdistributionoverthewholeofthebondedsurfaceensuresstaticanddynamicrigidity.Bondingacrossthewholesurfaceprovidesbettervibrationdampeningthanrivetedorscrewedconnections.•Theuseofbondingensuresthatthesurfacesremainsmechanicallyandvisually unimpaired.•Adhesivesareparticularlypopularforlightconstructionssinceverythincomponentscanbefixedtoeachotherwithoutaproblem.•Adhesivescanalsoserveassealantagainstfluids.•Whenconnectingdifferentmetals,theadhesive‘sinsulatingeffectspreventthe build-upoflocaleffectsandtheformationofcontactcorrosion.•Agreatvarietyofcontactadhesives(constructionalglues),surfaceadhesivesand adhesivestripsareavailableonthemarketandhaveprovedtheirperformancein themostdifferentapplicationsforyears.
Adhesivesarenormallymagneticallyneutralandprovideelectricalandthermalinsulation.SincetheindividuallayersofMetawell®panelsarebondedtoeachotherandthereforealreadyoptimallypreparedforbondingatthefactory,onlylittleadditionaltimeandexpenseisrequiredforthisconnectiontechnique.
Thechoiceofthebestadhesionsystemforaparticularapplicationdependsonthematerialsbeingjoinedandtherequirementsthathavetobemet.Thetraditionalgluingsystemsofferagreatchoicewithregardtostrength,adhesion,lifetime,processingconditionsandfurthertechnologicalcharacteristics.
Pleasecontactourfactoryortheadhesivemanufacturertodeterminethebestsuitableadhesionsystem.
SikadeutschlandgmbHhttp://www.sika.comSystems:SikaflexandSikaTack
3MdeutschlandgmbHwww.3mdeutschland.de
Source of supply
Bonding
Bonding
Modifications and errors reserved 10
Metawell® Metawell®panels,ase.g.thepaneltypeAluCC08-02-05/H6whichisfrequentlyusedininteriorconstructions,canbeplasticallyshapedaroundoneaxiswithappropriatedevices.Theformingprocesscreatestensilestraininonecoversheetofthepanelandcrushingstrainintheoppositecoversheet.Theloadingdirectionhasalsoaninfluenceonthepanel,whichisduetothefactthatthecoreofMetawell®panelsisacorrugatedsheet:
•Whenbendingparalleltothecorrugationtops,thecoversheetwhichisundercrushingstrainmaybucklebetweenthecorrugationpeak.Thereforeonlylargebendingradiicanberealizedinthatdirection.Mostlyitisadvantageoustouseathickercoversheet.
•Bendingperpendicularlytothecorrugationtopsisconsiderablyeasier.Thebehaviourisdependentonthecoversheets(tensilestrength,thickness)aswellasonthecorrugation.Toonarrowbendingsmayleadtoopticalimpairmentsbecausethecoversheetsdeformabitmorebetweenthecorrugation.
•Theplasticdeformationofthepanelsleadtoinherenttensionsinthepanelswhichmayhaveaneffectonthefurtherprocessingsteps.Particularlyaftersubsequentcuttinginherenttensionscouldbecomenoticeableintheformofdistortions.
NoteInordertodetermineappropriateworkingparametersitisrecommendedtomakebendingtrialswithsuitablesamples.Inviewoftheproblemofinherenttensionsthemodelsampleshouldbeasclosetotherealelementaspossible.Thisrefersinparticulartomechanicprocessingstepsafterthebendingprocesssuchaschangingcontours,makingcut-outsorinsertingslots.
formedMetawell®panels
foRMINg
Forming
Modifications and errors reserved 11
Metawell®Aluflexconsistsofathincorrugatedaluminiumsheetthatisgluedtooneflatcoversheet.Thismakesforapanelthatisveryflexibleinonedirectionbutrigidintheother,whichisidealforformedstructures.
Forming parallel to the corrugation ThankstoitsspecialstructureMetawell®Aluflexcanbeveryeasilytransformedaroundtheaxisparalleltothecorrugationtops,withsmallerbendingradii(e.g.forMetawell®Aluflex05-02/H4.7smallerthan200mm)evenplastically(seefig.1).Thebendingparametershavetobedeterminedcase-wisetomakesurethatbothbendingradiiandbendinganglecanbereproduced.Inordertocompensatethespring-backeffectofthematerial,the´over-bending‘isveryimportant.Therigidityaroundthisbendingaxisisrelativelysmall.Itmaybenecessarytoadditionallystiffentheelemente.g.bygluingametalsheetorothersurfacematerialtothecorrugationinordertoobtainatwo-dimensionallyformed„panel“.Withthisbendingtechniqueradiiof30mmandmorecaneasilyberealizedwithMetawell®Aluflex05-02/H4.7.
Forming perpendicularly to the corrugation Anytransformationperpendicularlytothecorrugationmakesthestructuralelementconsiderablystiffersothatitcanfrequentlybemounteddirectly(e.g.forcurvedceilingliningsinrailvehicles).Particularlyadvantageousistohavethecorrugationexposedtotheoutside(fig.2).Metawell®Aluflex05-02/H4.7isthussuitableforbendingradiiofmorethanapprox.100mm.Withsmallerradiithecorrugationtendstobe„pulledflat“andthecorrugationisseenthroughthecoversheet.Isthebendingdonewiththecorrugationontheinnerside,highermin.bendingradiiarerequestedtoavoidthatthecorrugatedsheetbuckles.
NoteItisstronglyrecommendedtomaketrialswithsuitablesamplesinordertodeterminetheworkingparametersase.g.theoverbendingangle.
Metawell® Aluflex
fig.1:Transformationparalleltothecorrugationtops
fig.2:Transformationperpendicularlytothecorrugation
fig3:formedstructures
Forming
Modifications and errors reserved 12
Painting ThankstotheirevensurfacesMetawell®panelsareparticularlysuitedasdesignmaterialforsurfacesthathavetomeethighdemandsregardingtheirvisualeffect.Withthemultiplepossibilitiestherearesomeimportantaspectswhichhavetobeconsidered:•Themaximumtemperaturethepanelscanbeexposedtois100°C.Higher workingtemperaturesmightbetolerableforspecialpaintprocedures,butmust beverifiedbytheplant.•Toreceiveanopticallyevensurfacetheminimumthicknessofthecoversheet (visibleside)shouldnotbelessthan0.8mm.•Thetypeofpaintingisdependendonvariousparameters,butalsoonthetotal quantityandthegeometryofthepanelsthathavetobepainted.
Bascially,therearethreedifferentpaintingtechniques:
• Coil-Coating Certaincoloursareavailableexstock.Specialcolourscanbesuppliedwithbigger purchasequantities.
• Powder-coating Newtechniquesallowpowder-coatingforbiggerordervolumes.Ifnecessary, pleasecontacttheusdirectly.
• Spray painting Spraypaintingoffersamaximumflexibilityregardingsurfacedesign.Paintsystem, thicknessandnumberoflayersaswellasmanyothercharacteristicscanbe individuallyadjustedtotheapplication.
Metawell®panelswithaprimeredtopsheetcannormallybelacqueredwitha coatingvarnishdirectlyafterremovaloftheprotectionfoiloraftercleaning thesurfacefromoilanddirtwithoutanyadditionalpretreatment.
Working steps with spray painting Paintpreparationandpaintingshouldbeperformedinthefollowingsteps (steps1to3canbeomittedifprimeredpanelsareused): 1.Roughenorsandthesurface. 2.Primerthepanels,usingprimerorpaintbase. 3.Applyalayeroffillersasvapourdiffusionbarrierifthepanelisforexterioruse. Commerciallyavailableprimersformetalsurfacestendtobewatersensitiveand mustbesealedwithsuchacoating. 4.Applyamin.30μmlayerofcoatingvarnish.Whencoloursarecritical (e.g.RAL9016)pleasecheckwiththepaintsupplier. 5.Ifneededthecoatingvarnishcanalsobecoveredwithaclearcoat.
Therelevantpaintmanufacturer‘sprocessinginstructionsmustbeobservedwhenselectingandprocessingthepaintsystem.Painttrialswiththepreferredpaintsystemarehighlyrecommendedbeforeuse.
Individual colouring
INdIvIdUALCoLoURINg
Modifications and errors reserved 13
Coating BecauseofitsflatsurfaceMetawell®panelsareanidealsubstrateforavarietyofcoatings.However,basicaspectshavetobeconsidered:
•Themaximumtemperaturethepanelscanbeexposedtois100°C.Higher workingtemperaturesmaybepossibleonrequest.•Whenselectingacoatingthedifferentexpansioncoefficientsofpanelsand coatingmaterialmustbetakenintoaccount.
Preliminarytestsshouldalwaysbecarriedouttocheckthesuitabilityoftheselectedcombinedsystem.
Filler and plaster coatingsInprinciple,anyfillerssuitableformetalsubstrates,suchasthoseusedintheautomobileindustry,aresuitableforfillingMetawell®panels.Preparingthepaneledgesbyappropriatemeasures(e.g.pressingdownthecoversheet)helpstoavoidsharpjointsandimprovestheadhesionofthefillerconsiderably.Therewiththeriskofcracksisenormouslyreduced,too.Separateworkinginstructionsregardingsmoothingandplasteringworksforinteriorconstructionsareavailableonrequest.
Foil coatingTherearethreemethodstoapplydecorativefoilsonMetawell®panels:1.Laminatingwithself-adhesivefoils,e.g.forlabellinganddecorativepurposes2.foillaminationusingtransferadhesivefoils(doublesidedadhesivefoils)3.foillaminationusingapaint-onorspray-onsurfaceadhesive
Themostappropriatefoilandcoatingtechniqueshouldbechosenwithrespecttothefinalambiantparametersthesystempanel-glue-foilwillbeexposedto.Hereparticularlyclimaticinfluenceshavetobeconsideredandpossiblypreliminarytestsshouldbemade.
High pressure laminatesWhenapplyingHPLthechoiceofanappropriategluingsystemisparticularlyimportant.dependendonthefinalplaceofuseofthepanelitmustbeexaminedifadouble-sidedcoatingofthepanelwithlaminateandbackpullisnecessaryinordertoavoiddeformationscausedbythedifferentmaterialextensionofthetwopanelsides.TheprocessinginstructionsofthesuppliersofbothgluingsystemandHPLmustbestrictlyobserved.
Other coatingsPleasecontactthefactoryforadvicebeforecoatingwithanyothermaterialsuchase.g.wood,glass,tiles,stoneetc.
Noteforsurfaceswithcarpets,asismainlyusedforfloorsandplatforms,Metawell®panelswithahighercompressivestrengthareavailable.
Individual colouring