I. Standard Operating Procedures for Shearing Machines
Preparation
Operator Qualifications: Operators must be familiar with the structure and performance of the shearing machine, master the safe operating procedures, and hold a valid operating certificate.
Environmental Inspection: Ensure the operating area is free of obstructions, the ground is dry and clean, the power cord is securely connected, and the power switch is in the off position.
Equipment Inspection
Check that the blade edges are sharp, without cracks or wear, and that the blades are securely fixed without looseness.
Check that all moving mechanisms (such as clutches, brakes, and transmission components) are flexible, without damage or abnormalities.
Check that the lubrication system has sufficient oil, the oil is clean, and all lubrication points are lubricated.
Check that safety protection devices (such as guardrails and photoelectric protection devices) are intact.
Start-up Procedure
Starting the Equipment: Turn on the power switch and confirm that the power indicator light is on.
Start the oil pump (hydraulic shearing machine) and check that the oil pressure is normal and there are no leaks.
Press the motor start button and wait for the equipment to run stably before proceeding to the next step.
No-load Test Run: Set the manual switch to the single-stroke position and manually test the shearing action to ensure smooth operation without abnormal noise or vibration.
Perform 1-3 no-load strokes to verify the normal operation of the lubrication and transmission systems.
Parameter Settings And Material Preparation
Adjust blade gap: Adjust the gap between the upper and lower blades according to the thickness of the material being sheared (see below for details).
Adjust template or clamp: Adjust the position of the back gauge according to the material width to ensure accurate material positioning.
Place material: Place the material to be sheared on the worktable, align it with the cutting line, and secure it firmly using the clamping device, avoiding excessive tightness or looseness.
Shearing Operation
Start shearing: Press the cut button or step on the foot switch to begin shearing. Keep your hands away from the cutting area during operation to ensure stability.
Monitoring operation: Observe the cutting process to confirm that the straightness and parallelism of the sheared surface meet the requirements, without twisting or burrs.
Complete shearing: Press the stop button. After the blades have completely stopped running, turn off the power switch and disconnect the power cord.
End of Operation
Clean Up the Site: Clean up any remaining materials and waste around the workbench and equipment, keeping the environment clean.
Equipment Maintenance: Clean the blades, check for wear on the cutting edges, and replace or sharpen them if necessary.
Check all bolts for looseness and tighten them promptly.
Add lubricating oil to lubrication points to ensure long-term stable operation of the equipment.
II. Blade Clearance Adjustment Method
Adjustment Principle
The blade clearance needs to be determined based on the thickness of the material being cut, typically 5%-10% of the material thickness. For example, when shearing a 5mm thick sheet, the clearance can be set to 0.25-0.5mm.
Too small a clearance will lead to accelerated blade wear and even chipping; too large a clearance will cause burrs or distortion on the sheared surface.
Adjustment Steps
Remove Blades: Remove the lower blade, clean each one thoroughly, and check its straightness in both horizontal and vertical directions.
Remove the upper blade, clean it similarly, and check its straightness. The blades can be used from all four sides; select the side in good condition for installation.
Install Blades: The upper blade is fixed to the blade holder and cannot be adjusted; the lower blade is fixed to the workbench using adjusting bolts. When installing the lower blade, first loosen the four bolts on the left and right sides of the worktable, but do not completely remove it.
Coarse gap adjustment: Manually rotate the machine to lower the upper blade to the appropriate position. Use a feeler gauge to measure the gap from the left side where the upper and lower blades are not engaged, adjusting it to 0.5mm.
Repeat the above steps, adjusting the gap to 0.5mm at the middle position of the blade and the right side where they are not disengaged.
Fine gap adjustment: Manually rotate the machine again to lower the upper blade to the appropriate position. Use a feeler gauge to fine-tune the gap from the left side until the gap is “three micrometers can penetrate, five micrometers cannot” (i.e., 0.03-0.05mm).
Repeat the fine-tuning steps, adjusting to the same gap at the middle and right sides of the blade.
Special case adjustments: For older equipment or when shearing thicker materials, the gap can be appropriately widened to “ten micrometers can penetrate, twenty micrometers cannot” (i.e., 0.1-0.2mm), or adjusted according to 1/10-1/20 of the material thickness.
If burrs appear on the edge of the sheared sheet material, the gap can be appropriately reduced.
Verification of Adjustment Results
After adjustment, use a feeler gauge to check if the gap between the upper and lower blades is uniform.
Perform a trial cut and observe the quality of the cut surface to confirm there are no burrs, twisting, or other defects.
III. Safety Precautions
Operational Safety: Protective gloves and goggles must be worn during operation to avoid injury from flying debris.
Do not place fingers or other objects into the cutting area. Do not adjust the blade gap or clean up waste while the equipment is running.
If any abnormality is detected (such as noise, odor, or vibration), stop use immediately and notify maintenance personnel for inspection.
Equipment Maintenance: Regularly check the blade wear and replace or sharpen them as needed to ensure a sharp cutting edge.
Regularly check whether the bolts on all components are loose and whether the lubrication system is functioning properly to avoid equipment failure due to improper maintenance.
Environmental Requirements: Waste generated during the cutting process should be sorted and recycled to avoid resource waste and environmental pollution.
Use environmentally friendly lubricating oil to reduce environmental pollution.
