In this high-tech era, cutting thick metals has become easier and easier, and one of the machines is the hydraulic shearing machines. These machines have become a wonder in all metalworking industries. But here comes the question: What is a hydraulic shearing machines?
Familiarity with this machine is crucial whether you are a simple machinist or an industrial professional. Its understanding will help you operate your project more efficiently. Are you curious about these cutting-edge machines? Keep reading, as this article will explain everything related to shearing machines.
Was ist eine hydraulische Schermaschine?
A hydraulic shearing machine is a reliable tool that cuts metal sheets. As the name indicates, these shearing machines use hydraulic force. This force operates the blades that cut the metal piece in definite size. Unlike manual cutting machines, hydraulic shearing machines are automated. So they provide faster and more precise results.
Hydraulic shearing machines have two main components. The first part is a hydraulic cylinder. The cylinder uses a fluid that generates significant pressure. This pressure operates two blades, which are the other main components. One blade is on the upper side, and one is on the lower side. The upper blades move downward and cut the workpiece (metal sheet).
The main reason shear machines are popular is their advanced design. These designs make them compact but improve their dynamics and functionality. We at Miharmle CNC company offer the latest hydraulic shearing machines with optimized size and design. These machines reduce material waste and ensure accuracy.
Hydraulic shearing machines are innovative and serve many industries. For example, they are used in manufacturing automotive parts. These cutting machines have a dominating presence in the aerospace industry. Engineers use them to cut and shape airplane wings and other parts. Other applications of hydraulic shearing machines are in the marine and metalworking industries.
Components of a Hydraulic Shearing Machine
I hope you grasped the basic concept of hydraulic shearing machines. Before understanding how the sharing machine works, let’s first discuss its components. Mastering their work will be much easier once you know the components. So, let’s discuss the major parts of these machines.
- Frame or Structure: This is the main body of the hydraulic shearing machines. It holds all other secondary components. The frame of these machines is made of robust materials such as cast iron and steel to ensure efficient working. Manufacturers design this frame to absorb vibrations to ensure accuracy.
- Hydraulic System: This hydraulic forced-based system is the heart of shearing machines. It contains a hydraulic pump that generates pressure by circulating fluid. A hydraulic cylinder converts this pressure into force. Control valves used in this system regulate or check fluid flow in hydraulic systems. Lastly, a reservoir holds fluid and keeps the system lubricated.
- Blades: Hydraulic shearing machines contain two blades: the upper and lower blades. These blades cut the metal piece into specific shapes. The material of these materials matters a lot when cutting metals. So, mostly, they are made of high-carbon steel and iron.
- Hinteranschlag: The Bachgauge is a moveable part that helps you adjust the material. You can think of it as a ruler that measures the distance between cutting blades and metal pieces. In simple words, it helps you cut the material in measured size. In some shearing machines, it is an automatic part. However, some machine designs offer manual back gauge adjustment.
- Clamping System: The precision of the entire cutting process depends on the clamping system. This system includes clamps of different sizes that hold the material firmly. They ensure the stability of the material during the cutting process. As a result, the blades of the shear machine cut metal sheets with precision.
Working Principle of Hydraulic Shearing Machines
The operating principle of a hydraulic shearing machine is straightforward. To better understand it, let’s explain its working procedure step-by-step.
1- Hydraulic Force Generation
The working of hydraulic shearing machines starts with generating hydraulic force. The hydraulic system of the shearing machines generates this force. HOW? There is a hydraulic pump that contains fluid, mainly oil. When the operator starts the system, pressure is generated inside the pump. This pressure pushes the fluid to the hydraulic cylinder. As I said above, a hydraulic cylinder converts this pressure into force. This force is then used to initiate the cutting procedure.
2- Upper Blade Movement
The second step in working a sharing machine is moving the cutting blades. A hydraulic shearing machine mainly contains two blades. One blade is moveable and connected to the ram. The second blade is present on the lower side and is immovable. The hydraulic system’s generated force pushes the upper blade to move.
3- Cutting Action
The cutting action starts with the movement of the upper blade. Let me explain this procedure in simple words. The metal sheet is placed between the upper and lower blades of the shear machine. However, ensure that it is stable to maintain accurate cutting. After placing the material accurately, the cutting action starts. The generated force moves the ram with a blade. When this blade comes downward, it presses the material with force and cuts it.
4- Adjustable Features for Accuracy
The design of hydraulic shearing machines offers some adjustable features. This means that you can make some adjustments during the cutting procedure. For example, this machine allows you to adjust the distance between the upper and lower blades. This adjustment helps you control the quality of the cut. Moreover, you can adjust the back gauge to change the size of the cut. Lastly, the shearing angle is also adjustable to ensure accuracy.
5- Return Stroke
After the cutting action, this is the last step. All the tools come to their resting positions. When the operator turns off the system, hydraulic pressure is released. The hydraulic fluid goes back to the reservoir. As a result, the upper blade also comes to its original. It allows you to remove the cut material and load the next.
Types of Hydraulic Shearing Machines
These hydraulic-powered machines come in various types. All those types have different designs, production volumes, and cutting edges. These types help you choose the design that meets your requirements. Let’s dive and explore some common types.
1- Swing Beam Shearing Machine
This is the most common type of hydraulic shearing machine. The name comes from the logic that the upper blade moves in the swing motion. The upper beam is connected to a beam. When you operate the system, this bem moves downward. However, the blade moves in a swing motion. In simple words, the upper blade moves in a curve or arc. This allows you to cut the material from different angles. You can imagine its design as just a seesaw.
2- Guillotine Shearing Machine
This type of hydraulic shearing machine contains an old design. The upper blade moves vertically downward. So, you can obtain straight cuts using this type. The lower blade remains fixed during the entire cutting procedure. However, Guillotine machines are suitable if you want to get repetitive cuts. Moreover, their simple design requires a lower cost. So, it is a cost-effective option.
3- CNC Hydraulic Shearing Machine
It is the most advanced shearing machine. Let me explain its design and features. CNC( Computer Numerical Control) shearing machines use CAD/ CAM software. This software contains all information about tool path, speed, shape, and angle. So, when you start the machine, this software directs the shearing tools to cut the material. Humans do not contribute to these machines so that you can obtain the most precise cut.
4- Hydraulic Notching Shearing Machine
Notching shearing machines are designed to create notches or corners on a metal piece. These machines contain two blades at 90-degree angles. When you operate the system, these blades move and make a precise notch or groove in the material. What I like about this type is its smaller size. This means it is easy to operate and can be used for small-scale production.
5- Hydraulic Plate Shearing Machine
These are large hydraulic shearing machines. Plate shearing machines have a straightforward design. But they are designed to cut and shear large metal pieces. A plate shearing machine contains a large platform to handle large workpieces. Two blades are also present, and the upper blade is moveable. This blade moves down and cuts the material when you operate the system. You can achieve large and straight cuts using these machines.
Hydraulic Shearing Machine Operation Requirements
Do you think operating a hydraulic shearing machine is just about pushing the button? You are wrong! These simple-looking machines require proper attention. A slight mistake can ruin the entire shearing procedure. But you need not worry! In the section below, I will discuss your operation requirements to succeed.
1- Proper Installation and Setup
Proper installation of the hydraulic shearing machine is crucial to achieve the desired outcomes. So, what steps do you need to take for the right installation? Let me help you out. First, you should place the machine on a stable surface. A leveled surface prevents unwanted vibrations. The second step is checking the power supply. Make sure that you supply the voltage according to the machine’s requirements.
2- Skilled Operators
Hydraulic shearing machines require skillful operators. If you are the owner, you must hire skillful operators who know everything about these machines. A skilled operator can handle issues during shearing operations. Moreover, he knows the procedure requirements, which are crucial to achieve precision. However, if you want to operate the machine yourself, ask the expert for advice.
3- Material Preparation
As I said above, there are different types of shearing machines. All those machines vary in handling the material. So before you operate the machine, know about its material handling nature. For example, some hydraulic shearing machines handle thin materials. In this case, you should not operate them using thick material. Lastly, clamp the workpiece accurately to prevent any mishap.
4- Operational Settings
Hydraulic shearing machines require an operational setting before starting. For example, inspect and adjust the cutting angles. A wrong cutting angle can affect the results as well as the blades. Moreover, the speed of the cutting tools should be checked. The speed mainly depends on the nature of the material and tool. Lastly, adjust the batch setting every time for repetitive tasks.
5- Safety Precautions
Safety is the primary factor that you should never neglect. As you know, hydraulic shearing machines use fluid. This fluid can harm you if not handled properly. So, during the shearing operation, wear goggles and gloves. Most shearing machines have emergency stop buttons. So, if you have an emergency, immediately press the button. Lastly, carefully clean the debris on the platform to prevent injury.
Hydraulic Machine Maintenance Requirements
Do you want your machine to deliver precise cuts day after day? If so, you have to take care of it properly. But how? Let’s explore some care tips for your shearing machine.
- First, you should inspect the machine daily. For example, check the wear and tear of valves, cylinders, and blades. A small leak can cause serious injuries. Moreover, hydraulic pumps require a definite oil volume, so monitor the oil level frequently.
- Lubrication is a vital factor that runs the machine efficiently. They reduce the fraction and help the cutting parts move quickly. Dry machine parts are more prone to wear and tear. So, apply lubricants regularly.
- Blades of shearing machines become dull due to continued use. A dull blade can cause harm and does not cut the material effectively, so you should sharpen the blade often. If it requires replacement, do it immediately.
- You must clean the leftover debris after every option. They can harm the operators and machine parts. External cleaning of the machine is also crucial. Remove dust regularly to ensure the machine works efficiently.
- The modern design of hydraulic shearing machines offers a safety system. It includes an emergency shut-off button and alarms. Their proper functionality is crucial to prevent any mishap. So, you should constantly check this system to see if it works correctly. In case of any wear, replace the system.
Advantages of Hydraulic Shearing Machines
Why are the hydraulic shearing machines the heart of modern metalworking? The answer lies in their advantages. They bring exceptional value to every industry they serve. Let’s explore the significant benefits these cutting machines offer.
1- Precision Cutting
As I said above, hydraulic shearing machines are automated. Their modern design features a CNC system. This is a computerized system that directs the cutting tools. The design, cutting angles, and tool paths have already been decided. It reduces the human error chances. So you can achieve a higher level of precision using these machines. Moreover, you can also adjust blade clearance to enhance further accuracy.
2- Versatility
Versatility is another advantage that hydraulic shearing machines offer you. Their adaptability is top-notch when it comes to cutting different types of material. It means you can shear various materials, from soft to hard. For example, these machines cut soft metals such as aluminum. Other than this, they can also cut rugged and robust metals such as steel and copper. The versatile design of these machines offers adjusting of blade clearance and cutting angles. So, you can easily cut and shear several materials.
3- Durability and Reliability
Hydraulic shearing machines stand out in durability. They are manufactured using robust materials. For example, the frame structure is made using steel and iron. The blades of these machines are made with high-carbon steel. Moreover, their design also contributes to enhancing durability. HOW? Actually, they come with fewer moving parts. As a result, they are less prone to unwanted vibrations that cause wear and tear. So, you can use these machines for an extended period.
4- Energy Efficiency
Hydraulic shearing machines also benefit us with their energy-efficient design. All the traditional cutting machines require energy, even if they are inactive. But this is not the case with these machines. Hydraulic shearing machines only use energy when they are actively shearing the material. Moreover, they use hydraulic liquid to run the blades. So, you can save energy by using hydraulic shearing machines in your project.
5- Safety Features
Safety is a significant concern for every machine operator. However, hydraulic shearing machines offer top-notch safety features. For instance, they feature an emergency stop button. This button shut down all the machinery in no time. So you can quickly save yourself and your surroundings in case of any mishap. Moreover, these machines also have safety guards for blades and cutting areas. This saves you from injury in case of sudden contact.
6- Cost-effective
Besides all the above, hydraulic machines are cost-effective. No doubt, their modern design cost high initially. But when in case of the long run, they are cost-effective. HOW? As I said above, they are more energy-efficient than manual cutting machines. So you can save on electricity bills. Moreover, their robust structure reduces the cost of maintenance and frequent replacements. Lastly, with basic operating skills, you can also reduce labor costs.
Häufig gestellte Fragen
Q1: What is the angle of the blade of a shearing machine?
The angle of shearing machines is the angle or distance between the upper and lower blades. This angle reduces the cutting force and produces a precise cut. You can control this angle between 0.5 and 3 degrees.
Q2: What are hydraulic shears used for?
Hydraulic shears are used to cut metal sheets, plates, and bars. They can easily handle all materials, from hard to soft, and are ideal for creating clean, sharp, straight, and precise cuts.
Q3: What fluid is used in hydraulic shearing machines?
Hydraulic oil, which can be synthetic or mineral-based, powers the cutting tools in hydraulic shearing machines. It is a non-compressible fluid.
Schlussfolgerung
Hydraulic shearing machines are specialized cutting tools. This article discusses everything from basic to advanced about these machines. For instance, they use hydraulic force for their work. This force drives all the parts. Moreover, shearing machines come in various types. Among those, CNC shearing machines are advanced and more popular.
Hydraulic shearing machines require proper maintenance. For example, you should inspect wear and tear frequently for their efficient working. Lastly, these machines are very beneficial in many aspects. They are energy-efficient options compared to other machines. So you can save money with their durable and advanced designs.