Quick Tips to Maintain Shear Blades

Shear blades are one of the most important tools when it comes to the metal fabrication industry. Shearing, also known as die cutting is a process of cutting metal. The most common materials cut using shearing are in the form of a sheet or metal plates.

The process in which the cutting blades are straight is shearing and if there are curved blades then the process is known as shearing-type operations. There are four types of operations include blanking, piercing, roll slitting, and trimming. To improve the uptime of shear blades & to reduce the maintenance costs, it is important to keep those blades in shape.

Here are some tips to maintain your shear blade in top shape:

Understand the Root Cause

First of all, it is important for any fabricator to understand the functions, designs, and operation of each machine in the plant. One of the major causes of shear failure is the overloading on shear blades beyond its parameters. When you attempt to cut the metal beyond the recommended limits, it could possibly damage your machines as well as shear blades.

In order to maintain the shear blades, it is important to perform standard maintenance every day. Plus, using quality products is also a must. Amada shear blades are among the top market leaders known for its quality and low maintenance cost.

Inspections on Regular Intervals

Make sure to perform scheduled downtime maintenance in order to ensure the smooth operations of the machine. It is important to test all the functions used in day-to-day activities. Examine all the bearing for the emergency and safety functions of the machine as it is an important aspect.

Once done with the examination, documentation is important as well. With the help of it, you can reveal potential issues beforehand so that an immediate repair can take place by an expert. These documents will help in analyzing and prepare preventive measures in case of future emergency problems.

Set the Blade Properly

Before starting the process make sure that you fit the blade properly in the machine. When you set the shear blade properly it helps to extend the blade's life and machine efficiency. Therefore, make sure to set the proper clearance for the finer cut quality.

Additionally, it is important to clean the blades. If the clearance is high, metal would jam between the blade and machine. Hence, if the blade has no clearance, it would work smoothly. But if you set the clearance too loose, it might cause premature failure of the system.

Have a Basic Maintenance Plan

1. As per your machine requirements, you can set a basic maintenance plan to ensure the smooth working of your blade.
   
2. Make sure that the air system is working properly for cleaner air. It is important to maintain the regulators to help the pneumatic mechanism for proper functioning.
   
3. Remember to check the lubrication before starting any operations. It is a must to keep the lubrication system clean and filtered.
   
4. Whenever you wish to replace the parts, try searching "Amada Machine replacement parts", as they are the best in the market, in the search engine and you would find a number of them.
   
5. Check machine clutch and brakes for thickness, lining, clearances, and signs of failure. In any case, they've worn out, replace them immediately to avoid costly repairs.
   
6. Keep in mind that air leaks or failure of the counterbalance cylinder need your immediate attention. They ensure the proper operations of shear and its tooling.

If at any stage you feel that the shear blades need immediate assistance, you would find a number of Amada Machine replacement parts or Amada shear blades online for the same. Other than that, it is advisable to contact the experts quickly if you find something unusual in shear blades or any machine in general.

Source:- https://www.sooperarticles.com/business-articles/industrial-mechanical-articles/quick-tips-maintain-shear-blades-1723775.html

How to Get Rid of Shearing Defects?

Shearing is a fabricating process used to cut metal sheets. The Shear blade machine consists of a shear table, blank holders, upper and lower blades. A back gauge is used to make sure that the cutting process is streamlined. When it comes to a perfect cut of the metal you need a high-quality shear blade like Amada shear blade which reduces the effects of variable sheet metal characteristics, internal stress, geometry to reduce the possible defects in the shear blades.

In this case, you need to take care of these natural effects. As they can make your shear blades defected and may reduce the final cutting quality of the product. If you work at the metal forming factory you must know that it is important to maintain your shear blades time-to-time. In this article, we have a list of variables used in this process along the solutions to get rid of possible shearing defects.

Cutting Angle
It is the cutting-edge angle of the blade. With two square edge blades, it requires higher cutting force than the upper blade. It is at an angle of 87°. And the lower blade is always at 90°. These are the ‘four-edge’ blades. Angled blades are called ‘two-edge’ blades.

Shearing Angle
This angle has a great effect on the shearing force. When you shear thin strips, this angle has an important effect on twisting. The shearing angle is less than 3°.

Blade Clearance
It’s the perpendicular distance between the shearing blades. The quality of results depends on plate thickness and material strength. If the cutting clearance is too small, the costs will be higher. If it’s too large, the result will be precise and large plastic deformation.

Clearing Angle
The clearing angle is fixed and set to 1.5°. The Blade ram is not perfectly vertical but is tilted pointing towards the backside to facilitate the piece separation.

The Shearing Defects and Solutions:

Twisting
In shear blades, this defect twists the plate with its axis. When shear narrow down the strips, it results in twisting. Other responsible shearing conditions are related to metal geometry. For example, high thickness and short length reduce the width, material characteristics like the soft material, uneven stress distribution and cutting parameters like high rake angle, high cutting speed etc.

To get rid of this defect it is recommended to lower the rank angle. This way, it would become useful to add an anti-twist device. Also, this option consists of a series of cylinders that push the plate against the top blade. This force applies when it corresponds to the plate thickness.

Poor Edge Quality
During the shearing process, the material initially deforms in a very small area, with a residual deformation. Then the upper blade penetrates the material where cutting is neat and clear. At the end of the shearing process, the material would give up. Because of that, the material cracks with a rough and irregular surface known as the fractured zone. This is often not perpendicular to the plate but a variable angle. You can improve edge quality by adjusting blade clearance, and keeping blade wear under control.

Crooking
In this defect, the surface stays flat, and a plate is curved along its plane. The responsible conditions include strip width, thickness, material strength, and previous cold rolling direction. The best way to reduce crooking is to use a smaller shearing angle and performed-cuts along rolling direction. Guillotine shear is another condition where blade ram supports its ends instead of the entire length.

Even during the shearing process the blade will become crooked because of the cutting force and will tend to open in the center. The best solution is to choose a shear with adjustable blade pads to keep it perfectly liner. You can opt for ‘Amada shear blades’ as they come with these specifications.

Bowing
In such a situation, the metal is no longer flat as this effect results in bowed sheet metal. Generally, it is related to cutting angle and plate strength. The best way to reduce this is by using a smaller shearing angle and hold the sheet metal with back support.

Does your shearing blades have experienced such defects? Amada Replacement Parts help you to avoid such types of defects for a period of time with their high tech functionalities. Although the regular maintenance and above-mentioned steps would help you to eliminate the shearing deficiencies.

What Makes Amada the Best Machinery for Metal Fabrication?

Professional metal fabricators must know about the most efficient and latest metal cutting machinery. Right from laser cutters and shear blades to CNC machining software and metal working machinery, it is important for them to have knowledge about the brand they can rely upon.

Now, let’s talk about efficiency and precision. When one needs to take care of these two aspects, the one name which always pops up on the lips of manufacturers is – Amada. Search online and you will come across several companies that provide Amada machine replacement parts at cost effective rates.

So, what are the qualities that make Amada the best machinery when it comes to metal fabrication. Let’s find out:

Impeccable Production

When it comes to the task of metal fabrication, precision and consistency are important. If there is a smallest amount of flaw in the manufacturing process, whether with the laser cutting process or CNC punching, one might have to remake the product. This is more likely to happen when you have a lot of orders to fulfil.

Through Amada technology, be it laser cutting machine or Amada shear blades; you can keep these issues at bay. Most of these machines are known for their stability and reliability. Also, they prevent the metal sheets from flexing or bending if/whenever they go through the CNC punching process.

Saves Time

Delay in turnaround times can upset the clients and spoil their schedules. Now, although laser cutting process is faster as compared to other methods, Amada laser cutters reduce this time even further. Some machineries also work with the software using which, one can define the process and automate it. Result? Large batches of orders within the required timeframe.

When it comes to meeting targets and ensuring client satisfaction, Amada always fulfills the expectations. The manufacturers across the world invest in equipment like CNC punching machines, press breaks and other Amada machine replacement parts to meet with the deadlines.

Offers Creativity

There are unique ways to produce high quality metal fabricated sheets. But this is possible only if the companies using Amada technology invest into metal fabrication machinery and software. However, one thing is for sure. Whether you want to implement laser cutting or use press brakes, shear blades or other replacement parts, Amada will serve your needs by ensuring superior production quality.

Some More Information

The scope of utility of sheet metal parts is huge. Manufacturers use them in several equipment including smartphones, elevators, aircraft, traffic signals, rockets etc. Through Amada, you can get integrated solutions for sheet metal fabrication business. This includes peripheral devices and control software to other consumables needed for maintaining laser cutters.

Given below are some of the popular Amada products:

• Laser machines
• Turret punch presses
• Press brakes
• Welders
• Software

There are several companies that provide manufacturing industry customers with a wide range of parts and consumables. Which means, you can get all the parts you need to keep your Amada laser cutting systems working smoothly.

You also need to ensure that the Amada laser parts that these companies provide meet with the OED specification standards. If you are a manufacturer based in USA, you will come across several companies that sell Amada machinery online. Ensure that you buy from the best!

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