The initial and crucial step in sheet metal component fabrication is cutting materials to size, a task expertly performed by hydraulic shearing machines and shearing machinery. These versatile devices play a pivotal role in cutting alloys and various sheet metals, employing different cutting actions tailored to diverse requirements. This article explores the intricacies of shearing machines, delving into their functionalities, cutting mechanisms, types, features, specifications, and design ideas.
Shearing Machine Mechanisms
At the heart of shearing machines are their diverse cutting mechanisms. Some employ a scissor-like, angular shear action, delicately shaping metal into sheets or strips. Larger machines opt for a straight shear action, with the blade fixed at an angle, deviating from angular movement. These operations are orchestrated by two blades—one fixed in the shear bed and the other moving vertically with minimal clearance. The angular configuration of the blades, known as the rake, and clearance are finely tuned based on the material’s type and thickness.
Press type shears introduce an additional precision element, with the upper blade inclined at about 0.5 to 2.5 degrees in relation to the lower blade. This design enhances control during the cutting process.
Types of Shears
Shearing machines come in various types, each catering to specific job requirements:
- Air/pneumatic shears use a pneumatic cylinder for power.
- Hydraulic shears are driven by a hydraulic cylinder, capable of generating high cutting forces.
- Hydromechanical shears utilize a hydraulic cylinder or hydraulic motor.
- Mechanical shears have the moving blade driven by a rotary motor through various mechanisms.
- Servo-driven shears are directly connected to a servo motor.
- Manual shears are operated by hand or manual force, often magnified through screws, levers, or other mechanisms.
Characteristics
High precision: The high-precision shearing machine adopts advanced control system and transmission system, which can achieve high-precision shearing with an error within ±0.1mm.
High degree of automation: The high-precision shearing machine is controlled by a CNC system, which can realize automatic shearing, reduce manual intervention, and improve production efficiency.
Wide range of applications: High-precision shearing machines can be applied to plates of various materials and thicknesses, such as metal, plastic, glass, etc., and can meet the needs of different industries and users.
Application scenarios of high-precision shearing machines
Application Scenarios
Manufacturing industry: Manufacturing industry is one of the most widely used industries for shearing machines, especially in sheet metal processing, machinery manufacturing, automobile manufacturing and other fields. High-precision shearing machines can provide higher-precision shearing, improving product quality and production efficiency.
Construction industry: The construction industry requires a large amount of metal materials and plastic materials. High-precision shearing machines can provide more accurate shearing and improve construction quality and construction efficiency.
Scientific research institutes: Scientific research institutes need to continuously conduct material testing and processing. High-precision shearing machines can provide more accurate testing conditions and more efficient processing processes.
Automobile maintenance: The automobile maintenance field requires the use of plates of various shapes and sizes to repair vehicles. High-precision shearing machines can provide more accurate shearing and improve the quality and efficiency of repairs.
Design ideas of High-Precision Shears
Transmission system design: High-precision shearing machines require advanced transmission systems to ensure the stability and accuracy of the machine. Common transmission methods include screw transmission, gear transmission, chain transmission, etc. Choose the appropriate transmission method according to different application scenarios and material requirements.
Control system design: The control system is the core part of the high-precision shearing machine. It can realize automatic control and precise displacement control. The control system can adopt CNC system, PLC control system, etc.
Tool design: The tool is one of the important components of the high-precision shearing machine. It needs to have high strength, high hardness and good wear resistance. Design cutters of different shapes and sizes according to different material and thickness requirements.
Frame structure design: The frame is the basic part of a high-precision shearing machine. It needs to have high strength, high stability and good vibration resistance. The frame structure design needs to consider factors such as the machine’s accuracy, weight, and usage environment.
Actual Usage
In actual use, high-precision shears show good performance and stability. For example, in an automobile manufacturing company, high-precision shears are used to cut steel plates into parts of different shapes and sizes. The machine’s precise shearing and automated control reduce manual operations and errors, improving production efficiency and product quality. Another example is that in a scientific research institution, high-precision shearing machines are used for material testing and processing research. The machine’s high precision and efficiency shorten the test cycle and processing time, providing scientific researchers with more accurate test results and more efficient processing methods.
In conclusion, shears play a pivotal role in achieving precision and efficiency in sheet metal fabrication. Understanding their diverse mechanisms, types, features, and safety considerations is essential for harnessing their capabilities in various applications. Regular maintenance, including shear blade sharpening, guarantees prolonged and reliable operation in the fabrication process.
