Iron cutting shearing

Types of Iron Cutting Shearing

Iron cutting shearing is cutting metal iron using a guillotine-like machine called an iron cutter/shearer. An iron cutter operates on the same principle as a paper cutter. Blades are used to carry out the shearing process, and the lower blade is usually fixed, while the upper blade moves up and down to make cuts. Various types of shearers are used to cut different types of metals in specific ways.

• Guillotine Shear

In terms of size, the shear is relatively small but can cut thick gauge metals--some models up to an inch. It can be power-assisted by hydraulic electric, manual lever, or el-stopped. The shear works like a knife, cutting straight lines, not curves or circles. Car repair shops use it to cut metal repair parts. Using a guillotine shear requires a certain level of manual skill to ensure the proper alignment of the cutting material.

• Rotary Shear

Rotary shearers are also sometimes referred to as circle shears. They use a circular blade to cut through metal sheets to create precise edges. A big plus of rotary shearers is that they do not distort the metal. Another advantage is that they can easily be used to make multiple cuts in rapid succession. They are often electrically or pneumatically powered. Car body repair professionals can use rotary shears to cut rust areas on the chassis or firewall, which will later be replaced with new metal. Rotary shearers can also be used to cut metal profile parts.

• Circular Iron Cutter

Circular iron cutters are handheld tools that cut metal profiles and pipes using a circular blade. They are easy to use and can access hard-to-reach areas. Limitations include making only straight cuts in materials up to an inch in thickness. Precision cutting is another limitation, so linear guides or jigs are required to make accurate cuts. Types of circular iron cutters include cordless, cordless, and diesel-powered.

• Nibbling Machine

A nibbler machine cuts sheet metal by making incremental linear cuts, or it 'nibbles' away at the material. They are operated manually or pressurized with air, electric or hydraulic power options. The nibbler cuts straight, curves, circles, and radii down to an eighth of an inch. Precision work is one of its advantages, and distortion of the metal is relatively less than when other cutting methods are used. The nibbler does not have drop cuts like a shearer does, which means less metal material is wasted when cutting out parts.

Specifications and Maintenance

Iron cutting shears are designed to cut ferrous and non-ferrous metals at varying levels of thickness. They come with an array of specifications as detailed in the table below.

• Type: Shears can be manual, power-press, or motorized shears. Operative ease and cutting capacity increase from the manual to the motorized variant.
• Capacity: Shears are rated for cutting capacity in terms of the maximum thickness and width of the material they can cut. For example, a shear may be rated for a maximum thickness of 6 mm for mild steel.
• Cutting Speed: Generally, the speed of a shear is measured in meters per minute. For example, a shear may have a cutting speed of 5 meters per minute for steel sheets of 2-6 mm thickness. The cutting speed will vary depending on the material thickness, type, width, and shear machine.
• Motor Power: Shears' motor power is usually measured in horsepower (HP) or kilowatts (kW). A standard industrial shear may have a motor power of 5 HP (approximately 3.7 kW). This ensures the machine can cut to specifications and at the desired speed.
• Blade Length: The blade length of a shear can range from 1 to 3 meters. This includes the standard industrial shear. A blade with a greater length can cut a wider sheet in a single stroke. For example, an iron plate cutting machine with a blade length of 3 meters can cut a 3-meter wide plate with a single stroke.
• Weight: The weight of the machine is crucial for understanding its portability and installation. A standard iron cutting shear can weigh anywhere between 1000 and 7000 kg, depending on its specifications.

Maintenance

The maintenance schedule is typically based on machine usage, machine condition, and inspection findings. This includes regularly checking the hydraulic system for leaks and conducting frequent visual inspections of the blades, belts, and other components to notice any signs of abnormal wear and tear.

Regular lubrication is important for the longevity of an iron cutting shear. The machine parts that require lubrication will be explicitly mentioned in the manual. Regular cleaning is equally important. Remains of oils and metal shavings tend to accumulate throughout the machine and must be removed to prevent damage and maintain performance standards.

Scenarios

• Construction Sites:

  On construction sites, shearing machines can precisely cut and trim steel beams, angles, channels, and plates, ensuring they meet exact specifications for structural elements, frames, and reinforcements.

• Fabrication Shops:

  In metal fabrication shops, shearing machines are workhorses for cutting various metal profiles, including sheets, plates, tubes, and rods. They are used to create components for machinery, structural assemblies, and enclosures.

• Automotive Industry:

  Automotive manufacturers and repair facilities use shearing machines to cut and shape metal parts, such as body panels, chassis components, exhaust systems, and custom fabrication projects for vehicles.

• Aerospace Industry:

  Aerospace shearing machines are specialized to cut lightweight alloys, such as aluminum and titanium, commonly used in aerospace applications. These machines can create components with intricate geometries that conform to industry standards.

• Electronics and Appliances:

  Shearing machines in electronics and home appliance manufacturing cut metal parts for devices and appliances. Common materials include stainless steel and galvanized iron, which are cut to precise shapes for assemblies.

• Shipbuilding and Maritime:

  In the shipbuilding industry, shearing machines cut large sheets and plates of heavy-gauge metal for constructing ship hulls, decks, bulkheads, and maritime structures. These machines handle high volumes and thicknesses of material.

• Energy and Power Generation:

  Within energy production facilities, shearing machines shape components used in power generation equipment, like turbines, generators, and structural elements for energy conversion systems, including solar, wind, and fossil fuel plants.

• Medical and Healthcare:

  Shearing machines can create specialized instruments, implants, and medical devices used in healthcare applications. They ensure precise and accurate cutting for devices that meet regulatory guidelines and quality standards.

How to choose iron cutting shears

Before stocking any guillotine cutting machine, consumers should conduct thorough research on their target clients' needs and preferences. When selecting an iron cutting machine for sale, the following factors are important to consider.

• Range of materials and sizes

  Identify the types of materials and sizes the machine can handle. It is important to align capabilities with the target clientele's needs. Find out whether they will require cuts of various shapes and sizes. Consider focusing on a machine that could be versatile with multiple applications if they will need to cut various material types. A specialized machine that can handle a particular material could work better for specific customers.

• Production volume and cutting speed

  Retailers should understand their clients' required production rates. In cases where a customer base demands high volumes, it could be ideal to invest in a more sophisticated—perhaps automated—shearing machine. Cutting precision is also important.

• Operational complexity and safety features

  Indenture machines with safety standards is a must. Also, look for machines that have easy operational processes. Salespeople will need to educate and train buyers on the use of the machines. Considering a machine that is easy to operate will make the training process easier for the retailer.

• Cost-effectiveness and energy efficiency

  Cutting buyers will not only need to look at the initial costs of the machines but also at the maintenance, operational, and energy expenses. Consider machines with energy-saving options and those that are not too demanding in terms of maintenance requirements.

Q&A

Q1: Can all types of metals be cut using a shearer blade?

A1: In most cases, shearing blades can cut different types of metals. However, depending on the metal's hardness, thickness, and density, some may require specialized blades. Better customization can ensure effective and safe cutting.

Q2: Is it possible to achieve curves and notches using a shearer?

A2: The iron cutter cannot achieve notches and curves since it can only make straight cuts. To achieve notches and curves, one would need to use other types of cutters, thus combining them with shearing machines for better results.

Q3: Do shear cuts leave rough edges?

A3: Unlike the cuts made by saws, shearing cuts are usually clean. Nonetheless, depending on the type of machine and blade used, the cut can be rough or smooth. Some shearing parts can also be used after, resulting in a smoother finish.

Q4: Do automated shears require regular maintenance?

A4: Just like any other machine, automated shears require some maintenance to function well. They might also require periodic blade exchanges and lubrications. Automated shears are easy to maintain compared to the ones that require constant manual input.