What Is Metal Shearing
Metal cutting shear is an essential tool in metal fabrication, often serving as the initial step in the production chain. It involves trimming excess material or cutting sheet metal to size, enabling the creation of workable pieces. Metal shearing machines, which have been a staple in manufacturing for years, play a pivotal role in this process and have undergone minimal changes over time.
The specific type of metal cutting shear required depends on the intended application. These machines are categorized based on their capacity to cut a particular thickness of steel to a specific length. However, they come in various designs and configurations, each equipped with different features to meet diverse production needs.
In essence, metal shearing is a process employed to achieve precise cuts in sheet metal, facilitating tasks such as sizing workpieces or preparing blanks for subsequent metal processing, such as CNC Punching.
How Does Metal Cutting Shear Work
Metal shearing is a precise cutting process that involves the use of a specialized machine or tool to cut through sheet metal without the need for heat. Unlike other cutting methods, such as machining or laser cutting, shearing does not produce waste in the form of chips or stray bits of metal, making it a popular choice for manufacturers seeking maximum material utilization.
During the shearing process, the sheet metal is securely held in place by a series of pressurized clamps known as ‘holddowns’. The cutting mechanism consists of two blades: a top blade and a lower blade. These blades are not aligned at the same position but are offset slightly to prevent collision while ensuring a clean sheared edge. This offset, referred to as blade clearance, is crucial for achieving precise cuts.
Typically, the lower blade remains fixed in place while the upper blade is driven downward with significant force. The upper blade is set at a slight angle to the lower blade, allowing the cut to progress smoothly from one end to another instead of all at once. This angle reduces the force required to cut through the metal.
Blades used in metal shearing machines are crafted from various grades of tool steels, each offering specific properties such as hardness, wear resistance, or shock absorption. Selecting the appropriate blade material is essential to ensure efficient cutting performance and prolonged tool life.
Buying A Good Metal Cutting Shear: 5 Factors Need Take Into Consideration
By carefully considering below factors before purchasing a metal cutting shear, you can select a machine that meets your production needs, delivers reliable performance, and offers excellent value for your investment.
What Type of Metal Used For Shear
The type, thickness and consistency of the materials you are shearing will greatly affect the recommended choice of shear you purchase. If you’re shearing thin gage metals or light aluminum you might be fine with an air or electrically operated shear, whereas if you’re shearing ¾” Plate with plasma cut holes throughout you may really need to consider a good mechanical shear for the shock absorption capabilities. It’s not only important to consider the type of material but also the structure of that material as Tread Plate, Expanded Metals, Perforated metal etc all shear differently than flat material of an equal make.
Quantity of Sheared Parts You needed
The quantity of parts you need to shear is almost as important as the type of material you are shearing. While a basic and inexpensive machine might be fine for low-volume intermittent use, a more sophisticated or robust machine would be required for the production duties of, say a steel service center. Not only do the machines have a wide variation of designs but they also can be equipped with a large number of options including conveyor/stackers to bring the sheared material onto a stack on a pallet for quick removal. Other options can include high speed hydraulics or more accurate Front gauging options.
Guillotine or Swing Beam Type
After determining the drive type of the shear, the next consideration is the design style, which can greatly impact its suitability for your needs. There are two primary design types of shears available: Guillotine style and Swing Beam style.
- Guillotine Style: In a guillotine-style shear, the upper blade is driven directly downward by the drive mechanism. This design offers a robust shearing system but tends to be more expensive.
- Swing Beam Style: A swing beam shear utilizes leverage to pivot the upper blade downward. This design allows for the use of smaller drive components, particularly in hydraulic systems, due to the mechanical advantage provided by leverage.
Ultimately, the choice between guillotine and swing beam styles depends on factors such as your budget, desired level of robustness, and specific application requirements. Each design has its own advantages and considerations, so it’s essential to carefully evaluate your needs before making a decision.
Rake Angle, Adjustable or Fixed
The rake angle refers to the tilt of the upper shearing blade, designed to prevent excessive engagement with the material during the shearing process. A lower rake angle typically yields higher-quality sheared edges, minimizing issues such as twist, bow, and camber. However, achieving a lower rake angle requires a more robust and powerful shear to exert the necessary force for cutting, as more blade material is involved in the process.
While a shear with a zero rake angle would theoretically produce the most ideal sheared edges, the immense forces required to shear even thin materials would render such a machine prohibitively expensive. Adjustable rake angles offer a compromise, allowing smaller shears to handle thicker materials, albeit at an additional cost.
As the rake angle increases, the quality of the sheared edge, blade lifespan, and machine stress all tend to increase as well. However, heavy rake angles may result in twisted or bowed sheared strips, particularly when dealing with thinner materials. Thus, finding the optimal balance between rake angle and material thickness is crucial to achieving desired shearing results.
Space and Power Requirements
When evaluating space and power requirements for a metal cutting shear, it’s essential to thoroughly assess your workshop’s layout and infrastructure. Begin by measuring the available space where the shear will be installed, taking into account not only the footprint of the machine but also the surrounding clearance required for safe operation and maintenance access.
Consider factors such as aisle space for material handling, proximity to other machinery, and accessibility for operators. It’s crucial to ensure that the chosen location can accommodate the shear’s size and any auxiliary equipment, such as material handling systems or conveyor/stackers.
Moreover, don’t overlook the power requirements of the shear. Verify that your facility’s power supply can provide the necessary voltage and current for the shear’s operation. Consult with an electrician or facility manager to assess the electrical infrastructure and determine if any upgrades or modifications are needed to support the shear’s power needs.
Additionally, consider the availability of backup power sources or surge protection measures to safeguard against power outages or fluctuations that could disrupt production.
Taking these factors into account will help ensure that you select a metal cutting shear that not only fits within your workshop space but also operates reliably and efficiently within your facility’s power constraints.
Budget
Establish a budget for your shear purchase and compare options within your price range. Balance cost considerations with the shear’s features, capabilities, and long-term value to make an informed decision.
Find Your Best Fit Among Metal Cutting Shears
Klaus Machine Tool (KRRASS®) is a high-end sheet metal equipment brand with a long history. Our products and services are spread all over the world, so far we have established branches in China, Germany, the United States, Mexico, Australia, Malaysia, the Philippines, Indonesia, Slovenia, Russia and Ukraine.
KRRASS stands out as a premier manufacturer of metal cutting shear based in China. As your reliable partner, we offer a comprehensive range of highly efficient Guillotine Shears to clients worldwide. Beyond merely providing machinery, our commitment extends to tailoring solutions that precisely match your unique requirements.
At KRRASS, we prioritize delivering Guillotine Shears that enhance productivity and efficiency. Our machines are engineered with advanced features to ensure optimal results, whether you’re executing precision cuts or handling high-volume tasks. We understand the diverse needs of our global customers and strive to offer new customized solutions and easy-to-use option suites that cater to their specific requirements.
With KRRASS Guillotine Shears, you can expect consistent and reliable performance in your operations. Our machines are built to deliver enhanced productivity, offering the reliability and precision needed to meet the demands of modern metal fabrication tasks.
