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design process due to conceptual design usually with the process of design-evaluationredesign. Hierarch
y grey relational analysis is developed because of the evaluation indexes system with the
characteristic of hierarchy for mechanism scheme. As a example, the analytic method is
used to the selection of shear mechanism in flying shear machine, resulting in selecting the
eccentric tilting shear mechanism as the optimum one.
Technique of working sheet metals, pipes and sections. Trainees' handbook of lessons
(Institut fr Berufliche Entwicklung, 17 p.)
(introduction...)
Preliminary
Remarks
Hints on Labour
Safety
1. Purpose of
Shearing
2. Tools and
Machines
3. General
Construction of
Shears
4. Mode of
Operation of the
Shearing Process
5. Shearing
Techniques
6. Sequence of
Selected
Shearing
Operations
Steel
- 0.7 mm
Brass
- 0.8 mm
Copper
- 1.0 mm
Aluminium
- 1.0 to 2.5 mm
Techniques
6. Sequence of
Selected
Shearing
Operations
The blade clearance also affects the sheet of slightly pitching down that can be compensated
by an adjustable hold-down bar on hand-lever shears and shearing machines.
Figure 13. Effect with to great a blade clearance - sheet is bent off
1 upper shear blade, 2 sheet, 3 lower shear blade
The penetrating shear blades squeeze the material together between the blades, resulting in
a material solidification. Since the blades are not able to further penetrate the material, they
tear the residual material apart under continued effect of force.
These stages can be seen at joint faces of thick sheets.
5. Shearing Techniques
The different shearing techniques are distinguished by the kind of cutting.
Cutting-in
A cut is performed that is only partially penetrating the material. Thus, the material is not
cut completely.
Cutting-in is mostly effected in preparing the subsequent bending-off procedure.
The material is completely cut alongside a line closed in itself. The material cut out is scrap,
the material surrounding is the workpiece.
- Completely cut the sheet through at the end - again lock the hand lever.
- Release toe dog and pull sheet out of the shear.
- Immediately throw the extremely bent waste material always rendering on the shears
right-hand side (in line of vision to the shear) into the waste container.
Do not let cut-off and bent sheet pieces lie on ground - risk of getting injured
What is to be expected in the sheet metal when the shear blades are completely closed?
_____________________________
_____________________________
_____________________________
Why should the scrap side of a sheet be always situated on the right-hand sheet side?
_____________________________
_____________________________
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oke and clamp assembly 5 holding shear or nibbler 6 is positioned upon support frame 1 so as cutter head 7
is on horizontal alignment with the top center axis of electro-magnet 3 at a distance relative to the diameter
of the circle to be rendered; workpiece 8, on which the cut is to be made, is positioned on top of electromagnet 3 with one edge in contact with cutter head 7; AC to DC current rectifier 4 is switched to the "on
mode" energizing electro-magnet 3 causing workpiece 8 to be magnetically held in position; electro-magnet
3 is rotated upon shaft & bearing assembly 2 by hand 360 deg. in either clockwise or counter-clockwise
direction feeding workpiece 8 through cutter head 7 producing a circular cut; AC to DC current rectifier 4 is
switched to the "off mode" de-energizing the electro-magnet 3 and the workpiece 8 is removed.
he System
Hydraulic Decoiler.
Hydraulic Straightener.
On Line Rotary Shears.
Idler Conveyors & Power Conveyor.
Hydraulic Cut Off Shear.
The Principle
The Principle of Shearing Circles is by On Line
Rotary Shearing Method - that is, while the
sheet is held rigidly, a pair of cutters rotates
around the cutting tool and produces a
perfect circle.
Online Rotary Shearing can be done in a
single row, double row or in triple row where
2 / 3 Nos. of On Line Rotary Shears are
placed diagonally opposite to perform Jig-jag
Blanking.
Hydraulic Decoiler and Hydraulic Straightner
are provided to decoil and straighten the
decoiled sheet. After circle blanking by the
On Line Rotary Shear, Hydraulic Cut Off Shear
cuts off the scrap.
The Advantages
Blanking of Circles out of Mild Steel, Stainless Steel, Aluminum & other non-ferrous
materials, from coils -eliminating the need to make squares and hence the
elimination of Guillotine Shear, Presses and Blanking Tooling.
Blanking of large Dia Circles up to 1500mm, which otherwise is very difficult to
produce from presses, which should be of high capacity & huge Blanking Tooling.
Blanking of Circles in 2 /3 rows in Jig-jag
position, thereby effecting a saving of 7-10%
on material.
Substantial Reduction in manpower-by
eliminating operations like shearing, Press
Blanking & Intermediate Material movements.
Simplicity in operation & maintenance
compared to huge press & press tool
maintenance.
MODEL
OSN-S
500
600
750
Diameter of
the Circle
mm Dia
425
to
550
550
to
675
675
to
825
825
to
975
Maximum thickness
of
sheet in Mild Steel
mm
MODEL
OSN-D
Diameter
of Circles
mm Dia
Maximum
thickness of sheet
in Mild Steel
mm
500
600
700
675 to 825
MODEL
OSN-T
Diameter
of Circles
mm Dia
Maximum
thickness of sheet
in Mild Steel
mm
500
600
700
675 to 825
With a circle shear you will be able cut your own metal circles to whatever size or
quantity you need:
I consider a circle shear as important as a spinning lathe to the serious metal spinner.
Many wannabe metal spinners (people who want to learn to spin metal) have
contacted me indicating that they can not find or afford a circle shear. This homemade
circle shear might be of use to those with rather limited budgets. It was constructed
from a Harbor Freight beading tool. These are on sale every now and then for around
$100.
In order to make this shear, the spinner must have access to several machine tools and
welding equipment. In addition to access to these items, the skill to use them is, of
course, needed. Every city of any size has local machinist clubs. Members of these
clubs might be willing to assist in making this shear.
Note: I am not providing measured drawings. If you want to make this, you will be
able to figure out the dimensions. The only thing critical is that the two pinch bearings
line up perfectly. Please do not email me asking for measurements.
The bottom pinching adaptor is shown here. Basically it merely slides into position
perfectly aligned below the top adjustable adaptor.
Each of these adaptors requires a machined "T" pad (not shown) to plug into the
bearing. The tops of these pads are covered with thin rubber sheet or leather. This
securely grips the metal without scratching it. Shown below are the opposing pinch
adaptors.
The original blades must be machined or ground as shown here. The bottom cutter
blade supports the metal as it is being cut. The top cutter is angled to allow required
clearance - especially on smaller circles.
In action, the Riser Circle Shear looks like this. Shown here is a 9" disc being cut.
Notice in the image below that the screw mechanism which raises and lowers the
blades is not there. It needed to be ground off in order to slide on the pinching
adaptors. I will replace it with a bolt on mechanism which can be removed if desired.
Here is a view of the back of the shear showing the knobs for locking the pinch
adaptors in position.
Here is how the bearings line up. The thin "T" pads are not shown.