What is a metal shearing machine?
Aug. 26, 2024
What is a Shearing Machine? Essential Guide
I. Overview of Shearing Machine
1. Shearing Machine Definition
A sheet metal shearing machine is a machine used in metal fabrication industry for cutting metal plates into various desired shapes and sizes.
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The components of a shearing machine are blades, pulleys, baffles, and an electric control system. The machine's die, used to cut various materials, can be found in different shapes, commonly two blades: straight blades and round blades.
Shearing operations are widely used in various industries, such as automotive and aerospace manufacturing, machinery production, household appliance production, and construction.
The effectiveness of a sheet metal shearing machine is determined by several factors such as its shearing capacity, accuracy, speed, and reliability.
2. Key Technical Parameters of Shearing Machines
ParameterDescriptionShearing ThicknessMaximum thickness of sheet metal that can be cut (typically 6-40mm)Shearing LengthEffective length of the worktable, determining maximum width of sheet (typically 1-6m)Shearing AngleAngle between upper and lower blades (typically 1-3°; smaller for thin sheets, larger for thick)Blade ClearanceDistance between lower and upper blades (8-12% of sheet thickness; affects burr formation and shearing force)Shearing SpeedSpeed of the shearing stroke (typically 8-20 strokes per minute; affects efficiency and vibration)Holding ForceForce applied by hydraulic hold-down cylinders to clamp the sheet (e.g., 13 tons for mm length&#;Backgauge StrokeLength of backgauge movement for precise positioning (e.g., mm or more)Backgauge AccuracyPrecision of backgauge positioning (e.g., ±0.2mm or better)Blade MaterialTypically high-carbon, high-chromium steel (e.g., HCHCr/D2) with hardness of 55 HRC or higherThe term &#;rake&#; refers to the angular configuration of blades. Both rake and clearance are functions of the type and thickness of the material to be cut.
II. What Are the Types of Shearing Machines?
Depending on the drive mode, common types of shearing machines mainly include manual sheet metal shearing machines, mechanical shearing machines, hydraulic shearing machines, and pneumatic shearing machines.
1. Manual Sheet Metal Shearing Machine
Manual sheet metal shears are equipment that can perform cutting of plates by manually moving the blade up and down. These shears are powered by hand, easy to operate and suitable for cutting small plates, but their cutting accuracy is low and cannot meet the requirements of large plates.
2. Mechanical Shearing Machines
The mechanical shearing machine operates using a power device consisting of a motor, flywheel, worm shaft, and clutch. It has faster cutting speeds and more strokes per minute compared to the hydraulic shearing machine.
The flywheel of the mechanical shearing machine stores energy, allowing a motor with lower horsepower to be used. Based on the operation mode, mechanical shearing machines can be further divided into up-moving and down-moving types.
3. Hydraulic Shearing Machines
The hydraulic shearing machine is powered by a hydraulic cylinder and motor. The motor drives the hydraulic cylinder, applying hydraulic oil pressure to the piston, providing power to the upper blade's piston.
The hydraulic shearing machine has a longer stroke and can handle different load capacities. Materials cut using a hydraulic shearing machine have a smooth surface with minimal markings. These machines are known for their large shearing force, stable operation, and good controllability.
The hydraulic shearing machine can be categorized into two types: the swing beam shearing machine and the guillotine shearing machine.
The swing beam shearing machine performs the shearing movement by swinging the tool rest, resulting in high speed, high shearing accuracy, and high efficiency.
The guillotine shearing machine can be powered either by hydraulic or mechanical means. It consists of a working table, upper and lower blades, a hydraulic piston, a clamping tool, and a blank holder.
This machine can cut plates of varying thicknesses and lengths due to their ability. The movable blade of the guillotine shearing machine can be straight or angled to reduce the cutting force.
Equipped with CNC system, the guillotine shearing machine can handle large cutting thicknesses and lengths with fast cutting speed, making it ideal for mass production. However, the cut edges produced are rough and unattractive.
Comparison of Mechanical and Hydraulic Shearing Machines
FeatureMechanical ShearingHydraulic ShearingTransmissionMechanical (crank linkage, gear)Hydraulic (hydraulic cylinders)Cutting SpeedFaster in full-cycle modeSlower, but can operate continuouslyCapacityLimited to thinner materials (up to 1/4" plate)Can cut thicker materials (3/8" to 1" plate)PrecisionLower accuracy and adjustabilityHigher accuracy and precise adjustmentsNoiseLoud during operation, but quieter overallConstant noise from hydraulic systemMaintenanceSimpler mechanisms, easier to maintainMore complex, but designed for easy operation and maintenanceSafetyCan be stopped mid-cycle, but more hazardsAutomatic reverse, light curtains, overload protectionCoolingNot requiredHydraulics run hot and require coolingEnvironmental ImpactNo hydraulic waste (oil, filters)Produces hydraulic wasteShock ResistanceMore shock resistant due to robust constructionLess shock resistant due to hydraulic cylinders4. Pneumatic Shearing Machines
The pneumatic shearing machine refers to the equipment that uses a pneumatic system to control the up-and-down movement of the blade for plate cutting.
The pneumatic plate shearing machine offers high shearing speed and accuracy, as its blade movement can be adjusted through air pressure. It is commonly used for cutting special plates, such as those with high hardness and strength.
Thanks to its high cutting speed and accuracy, the pneumatic shearing machine is ideal for high-speed and high-precision cutting.
There are two main types of shearing machines for cutting plates: linear and circular. The linear shearing machine is powered by hydraulic devices and can handle thicker metal plates.
The circular plate shearing machine is powered by a motor and can cut circular metal plates. Each type of shearing machine has its own advantages and is suitable for different cutting needs.
Users can select the most suitable type of shearing machine based on their needs and the properties of the material.
For instance, manual shearing machines are ideal for cutting small plates, while large plates may require a guillotine shearing machine or a pneumatic shearing machine.
III. What Are the Main Components of the Shearing Machine?
The main components of shear equipment are the working table, upper and lower shearing blades, clamping tools, baffles, and electrical elements.
The blades, typically made from high-strength steel with good hardness and wear resistance, are the primary working component of the machine.
They can be moved up and down to perform the cutting of the sheet metal. The clamp is used to secure the metal sheet in place for accurate cutting.
The baffle serves as a protective measure for the plate shearing machine. Made from high-strength metal materials, it guards against external forces impacting the plate. The baffle is typically installed near the blade edge of the machine for maximum safety of the workers.
The electrical elements control the operation of the shearing machine and consist of a circuit board, motor, and controller. These elements monitor and control the machine's running state to ensure safe operation.
IV. What Is the Working Principle of the Shearing Machine?
The working principle of a shearing machine is to cut sheet metal into the desired size and shape by moving its blade up and down. To begin, the plate must be placed on the blade, ensuring it makes contact with the blade.
The machine is then activated by controlling the electrical elements to start the motor, causing the blade to move up and down. The driving system then powers the blade to shear the sheet.
Throughout the shearing process, a protective device is in place to ensure safety and prevent the plate from being affected by external forces. The speed of the blade is also adjusted by the shearing machine, based on the type and size of the material being worked on, to ensure accurate shearing of the plate.
V. Features of the Shearing Machine
The shearing machine precisely cuts metal plates to the desired size through a moving blade that moves up and down. The speed of the blade can be controlled via electrical elements, ensuring accurate cuts.
This machine is capable of cutting a wide range of materials, including stainless steel, aluminium, copper, and other types of plates. It is user-friendly and safe, requiring only a basic understanding of its operation for successful use.
The shearing machine also has safety features that protect both the plates and workers from external forces.
VI. What Is the Shearing Machine Mainly Used for?
The shearing machine provides efficient support for industrial production with its high-precision and high-speed cutting capabilities.
These machines are specialized tools used in industries such as machinery manufacturing, aerospace, and automobile manufacturing.
In the aerospace industry, for instance, the shearing machinery can be utilized to cut high-strength steel plates to produce aircraft parts.
The machine can also be utilized in the production of automobile components, such as bodies and doors, by cutting both steel and aluminum plates.
In addition to industrial applications, shearing machines are also used in various other fields, including household appliances, electronics, and building decoration.
For example, in the household appliance industry, the shearing machine is used to cut stainless steel plates for products such as refrigerators and air conditioners.
In the electronics industry, it can be used to cut aluminium plates for the production of computer and mobile shells.
VII. What Are the Blade Materials of the Shearing Machine?
The blades of the shearing machine are mainly composed of high-speed steel, carbon steel, and other materials. High-speed steel is a commonly used blade material that is characterized by its high wear resistance and rigidity.
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Thanks to its high stiffness, high-speed steel blades can significantly enhance the cutting efficiency of the shearing machine.
After undergoing fine processing, they can also improve the machine's shearing accuracy. Carbon steel, on the other hand, is an economical blade material with high toughness.
The high toughness of carbon steel blades makes them resistant to vibrations and deformations during shearing. Additionally, after undergoing heat treatment, they can also improve the shearing accuracy of the machine.
In conclusion, the blade materials of the shearing machine can include high-speed steel, hard alloy, carbon steel, and others. The choice of blade material depends on the specific working conditions and budget of the machine.
VIII. Future Development Trends of the Shearing Machine
The future direction of the shearing machine's development may be impacted by various factors, including economic growth, market demand, and technological advancements.
With the rise of intelligent technology, the shearing machine is expected to become more advanced, featuring additional intelligent functions such as automatic blade position adjustment and automatic plate type and thickness identification.
The implementation of digital technology can lead to more efficient production management and quality control, making the shearing machine even more efficient.
In addition, the integration of the shearing machine with other equipment is expected to improve production efficiency and quality by achieving seamless connections.
Finally, the shearing machine will strive to reduce its environmental impact by reducing energy consumption and the emission of pollutants.
IX. Maintenance of Shearing Machine
1. Daily Maintenance
Before each start-up, add lubricating oil on time, at fixed points, and in fixed quantities according to the lubrication chart. The oil should be clean without sediment. The machine must be kept clean frequently, and rust-proof grease should be applied to unpainted parts.
10 minutes before getting off work every day, lubricate and clean the machine. Clean the machine every week, and add lubricating oil to each guide surface, sliding surface, ball, and lead screw.
2. Regular Inspection
Regularly check the straightness and axial clearance of the lead screw. If it exceeds the tolerance or is too large, replace or adjust it in time. Regularly check whether the V-belt, handle, knob, and buttons are damaged. Those with severe wear should be replaced in time.
Regularly inspect and repair switches, fuses, and handles to ensure their reliable operation. The lubricating oil in the motor bearing should be replaced regularly, and check whether the electrical parts work normally.
3. Blade Maintenance
Regularly check the wear of the blades. Dull blades should be sharpened or replaced in time. Stop the machine first when replacing the blade, and ensure that the new blade is installed securely.
4. Other Key Points
Strictly follow the operating procedures and eliminate illegal operations. Keep the working environment clean and clean up the cutting waste in time. Turn off the power when leaving the machine for a long time to prevent non-professionals from operating.
If there is any abnormality during operation, press the emergency stop button immediately and troubleshoot the cause of the fault.
X. Conclusion
This article provides an overview of the main types, components, working principles, features, applications, and blade materials of shearing machines. Plate shearing machines are widely used in the manufacturing industry and are a highly versatile piece of equipment.
When choosing a shearing machine manufacturer, it is important to consider its common shearing machine prices, functions, warranty, and other factors in detail.
ADH is a reputable sheet metal processing machine manufacturer with 20 years of experience. The quality and performance of their press brake, plate shearing machine, laser cutting machine, and other machines are guaranteed.
Shearing Machine Technology: Enhancing Precision and ...
Metal shearing is widely used in several industries to cut and trim metal sheets and metal plates precisely. A specialized machine, called a sheet metal cutting machine, steel cutting machine, metal shear machine, etc., is used to apply shear force on the metal to separate the desired part from the sheet metal effectively.
The metal shearing machine makes clean, straight-line cuts through various types and thicknesses of metal materials.
Thus, if you are looking forward to shear metal sheets or other products, it is crucial to understand metal shearing technology to choose the right metal shearing machine for the process.
What is Shearing Metal Technology?
Metal shearing technology has several scientific aspects that effectively produce desired sheet metal cuts.
- Metal deformation is the first one. As the blade descends on the metal, it pushes it downward against the resistance of the lower blade, causing the metal to deform. Thus, there is a gap between the two blades to allow the metal to deform, ensuring a clean cut.
- Stress concentration is another aspect. As the two blades come closer, the stress level of the metal increases, resulting in deformation, creating a neck, where the metal eventually fractures.
- Fracture mechanics is very crucial. In shearing, the material undergoes a controlled fracture along a designated path created by the blades. The material&#;s resistance to this fracture, known as its shear strength, determines how easily it can be cut.
- Elastic recovery is self-explaining. As the blades descend and the metal separates, resulting in plastic deformation, the metal returns to its original shape, which is called elastic recovery.
- The clearance gap is the gap between the lower and upper blades, which is crucial to ensure cleaner and precise cuts. The clearance gap is based on the thickness of the metal, which can be cut through the metal shearing machine. If the gap is too small, it leaves no space for the metal to bend and separate.
Evolution of Metal Shearing Technology
The evolution of metal shearing technology has been a fascinating journey. From manual shears to advanced automated processes, metal shearing has transformed significantly. You will learn about the evolution of metal shearing technology and different types of metal shearing machines in the next section of the blog.
Types of Metal Shearing Machines
Here are different types of metal shearing machines which came into use as the technology progressed:
Manual Shearing
At the earliest stage, metal shearing was entirely manual, where metal operators used hand tools to shear metals. It was a labor-intensive, slow, and imprecise process because the clarity of cuts depended on the skilled operators.
Lever Operated Shears
Lever-operated shears were introduced in the 19th century and transformed metal shearing. These shears used mechanical leverage to multiply the force applied to the blades, enabling the cutting of thicker and larger metal sheets.
Mechanical Metal Cutting Shears
As the industrial revolution progressed, it also changed metal shearing machines, transforming metal shears and powering them with steam engines and electric motors. They had adjustable blades, back gauges for precise positioning, and improved cutting capabilities, making it easier for the operators.
Hydraulic Shearing Machines
Hydraulic shearing machines received popularity in the 20th century. The power of pressurized hydraulic fluid generates force and cuts through thick and thin metal sheets. They are versatile, safe, and offer more control to the operator.
CNC Technology
CNC stands for Computer Numerical Control technology. It allows for precise and complex cutting without manual intervention, ensuring consistency and quality.
Variable Rake Angle Shears
The variable rake angle shears are very popular due to their ability to adjust the upper blade angle, which allows for precisely cutting metals of varying thicknesses.
Applications of Metal Shearing
Metal shearing is a versatile process that is used across various industries. Some of the applications of metal shearing are listed below:
- Sheet Metal Fabrication
- Metal Roofing and Siding
- Metal Stamping
- Machine Parts and Components
- Architectural Metalwork
- Shipbuilding
- Aircraft manufacturing
- Metal Cabinets and enclosures
- Agricultural machinery
- Renewable energy systems
Choosing the Right Shearing Machine
The right metal shear machine is crucial to ensure the quality of your operations. So, whether you are a metal operator or a DIY enthusiast, check out these important considerations to help you choose the right machine.
- The type and thickness of the metal you need sheared is a primary factor. Some machines are suitable for thin sheets, while others shear thick metal sheets effectively.
- Shearing machines come in various lengths and widths, so you need one that fits your workspace.
- The production volume also impacts the decision significantly. If you aim for mass production, you need a fast-cutting metal shear machine.
- Back gauges and positioning systems are vital for precise cutting. Ensure your shearing machine has an accurate and easily adjustable back gauge to ensure consistent cuts and minimize material waste.
- If you are investing in a machine, you must set a budget. List the quality and features you need, then choose the right one. If you are only looking for a DIY project, then it is advised to choose an expert with the right shear machine for your needs.
Metal Shearing in Albuquerque
If you are looking for an expert for your metal shearing needs, then New Mexico Metals LLC is the right place for you. We house three metal shearing machines fit for shearing different metal types of varied thicknesses.
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Frequently Asked Questions
Que: Is metal shearing a complex process?
Ans: Yes, it is a complex process that requires skills and a steady hand to produce desired cuts.
Que: What types of metals can be sheared?
Ans: Metal shearing is a versatile process that is used on various metals such as steel, aluminum, brass, copper, etc.
Que: Is metal shearing different than die-cutting?
Ans: Yes, metal shearing is different. In die-cutting, a die of the desired shape is used, which is a 2D model of the required shape and works as a cookie-cutter to separate the metal.
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