Shearing Operation Fundamental

A shear force is applied that will cut off part of a sheet. The cut off ‘blank’ becomes the
workpiece.
Shearing, also known as die cutting, is a process which cuts stock without the formation of chips
or the use of burning or melting. In strict technical terms, the process of “shearing” involves the
use of straight cutting bladesorm of sheet metal or plates, however rods can also be sheared.
Shearing-type operations include: blanking, piercing, roll slitting, and trimming.

When you apply a high pressure tool through a metal plate and remove part of the metal, the
process is called shearing. Shear machining devices include punching machines, which make
small discs, and blanking machines, which produce washers and similar objects.

Direct tool ordinary machining is NOT the same as shear machining. With standard tool
machining, a single or multiple point tool can be employed to take out a piece of metal from the
metal sheet and/or block. This process required repeated pounding of the metal until the required
dimensions are achieved. With shear machining, the tool’s cutting edge removes the metal from
the plate. While this happens, maximum pressure is applied. The tool, however, only touches the
metal one time.

Both mechanical and hydraulic machines can perform shear machining. Hydraulic shears cut and
score sheet metal quickly and accurately. They work well for factories that do a lot of metal
fabrication. In addition, hydraulic shears are best if the operation requires intense pressure. They
don’t require a lot of maintenance, will operate continuously, and are fast and quiet. Hydraulic
shear machines also take up less space than mechanical shear machines while applying the same
amount of pressure.
In shearing or cutting operation as or blade descends upon the metal, the pressure exerted by the
blade first cause the plastic deformation of the metal. Since the clearance between the two blades
is very small, the plastic deformation takes place in a localized area and the metal adjacent to the
cutting edges of the blade edges becomes highly stressed, which causes the fracture to start on
both sides of the sheet as the deformation progresses and the sheet is sheared.

Types of shearing Machine:

1) Pneumatically operated

2) Hydraulically operated

3) Electro magnetic shearing machine

4) Laser cutting machine (Rack and pinion operated )

Brief description of all the types is as follows.

1) Pneumatically operated:-

Here the advancement of the header is carried out in the upward and the downward direction
using the pneumatic double acting piston and cylinder unit arrangement along with the foot
operated direction control valve. In this type of machine high pressure air is used as the working
fluid for the transfer of power and the motion.

Working:

Initially the air-compressor is started and allowed the receiver tank air pressure to reach up to 8
bar. The supply air is then passed to the manifold through FRL unit to condition the air and
eligible to industrial use.

From the manifold a separate supply for the machine is taken out and given to ON-OFF switch,
so as to operate the machine at will without interrupting the running of compressor.

Then the pipe carries compressed air first to machine’s Direction Control Valve. At position ‘A’
shows the non-actuated circuit diagram. At this position the piston is steady and locked. All ports
are in closed condition.

At position ‘B’, the DC valve is at left hand position as shown in figure. The cap end port &
pressure port get connected to each other and the rod end port gets connected to the exhaust port.
The compressed air comes in the cap end of the cylinder and pushes the pistons outwards. The
air already present in the rod end side is pushed out of the cylinder.

When the piston moves outwards, the force is transmitted through the connecting link and the
upper blade moves downwards. Before the actuating DC valve the sheet is inserted in between
the upper & lower blades. As upper blade moves downwards, the stress is generated in the sheet
metal and goes beyond ultimate shear stress of sheet metal. And thus the shearing action takes
place.

Now the DC valve is operated to come at position ‘C’, as shown in figure. The rod end port &
pressure port get connected to each other and the cap end port gets connected to the exhaust port.
The compressed air comes in the rod end of the cylinder and pushes the pistons inwards. The air
already present in the cap end side is pushed out of the cylinder.

The sheet metal is either again inserted for further cutting in case of large pieces; the small cut
pieces are removed and the next sheet is inserted to cut.
Hydraulic Shearing Machine

When the metal is inserted into hydraulic machines, it is secured by clamps so it does not shift
under high pressure. To ensure that the cut is smooth and even for a 90 degree cut, a squaring
arm or back gauge must be used. Minute burrs may be formed by the edge of the cut metal; these
must be removed by grinding. If you use hydraulic shears, be careful of the little marks left by
the cutting blades and holding clamps while working. You will need to remove them or
otherwise account for them.

Principle Of Shearing
To find the shear force for a cut we can go back to the basic mechanics of materials (with
one adjustment factor).

F = 0.7twUTS

where,

F = force needed to shear

t = thickness of sheet

w = width of sheet

UTS = Ultimate Shear Strength of material

Electro magnetic shearing machine

As industrial is coming up across the glob various inventionand innovations are being carried by
human to fasten various processes associated with manufacturing and align things. One such
thing is industrial automation unit. In this automation units various machines those can be
adopted easily are also getting developed. Considering the example of piping industry
(manufacture of small pipes) where plastic are PVc pipes are needed to be cut, shearing
machines are used. There can be various types of shearing machines depending on parts to be cut
process of cutting, requirement of cutting length, etc. now a days hydraulic shearing machine,
pneumatic shearing machine and mechanical type shearing machine are popular type of shearing
machines used in above industries. These machines are certainly good at work but as with almost
all types of machines there are certainly pros and prones association with them to for the purpose
various work is being carried out to solve the dilema. In this project shearing m/c of a new type
i.e. electromagnetic shearing m/c is decided to be fabricated. Along with it has also been decided
to develop automation unit for the same so that m/c can easily be adopted in todays automated
plants.

shearing m/c that is capable of shearing PVC / plastic / rubber pipes upto 6 mm in dia. Also it is
pre- assigned work to furnish the same m/c alongwith an automation unit as previously
mentioned.
As simple layout and tricky operational enables this type of m/c to work practically at low cost,
low maintenance, low capital investment in less space. It may be forecasted that in future this
m/c may have its unparallel place in the industry mentioned previously.
The work is carried out using MDF (Medium Density Fiber) core hardwood plywood. Also some
connecting components like studs are used the plunger is made up of high density polymer pipe
and the core of electromagnetic is made up of again high density polymer pipe. Rest of the
construction is made in MDF sheet cut to requirement. It can be noticed that in the fabrication of
the project
many parts are manufactured other than ferrous material. It is done so because ferrous is
conductor of magnetism and controller be magnetised very easily for avoiding the flux generated
for getting disturb with surrounding material.

The mat in surrounding is used the non ferrous. The only major component is the iron core which
is
needed to be made up of ferrous to get attracted to electromagnet when live next part that is
fabrication out of ferrous is stud nut bolt. It is very necessary that for structural support that this
part should be made in strength and support for solving the problem. It has been allowed to use
ferrous material for the same. Also care have been taken to keep this ferrous material part away
from electromagnet as for as possible.
Whenever electromagnet is made live it sucks the iron core in between the cavity of the
lectromagnetic because of high flux generated. This iron core there by pushes the plunger in the
same direction which activates the cutter blade subassembly forcing the same in the blade
subassembly forcing the same in the direction of material to be cut. This is simple procedure of
cutting by this type of m/c.

Another part of the project includes development of automation unit for running this m/c on
automation mode for cutting the mat as per required. This part include a Microcontroller a motor
drives a relay driver etc

Rack and pinion operated

Laser cutting machine is now the most advanced mechanical processing equipment, laser is first
used in the field of mechanical processing, brought unprecedented promotion to the development
of mechanical processing.

What is the working principle of laser cutting machine?

A lot of people to the laser cutting machine is not very understanding, most of whom were heard
someone mentioned in the peer, but don’t know what was the basic working principle, let us
giveyou a detailed explanation of the;

Laser cutting machine is mainly composed of two parts, one is the CNC work station, another is
the machine tools.We can pass the CNC work station, processing drawings will need input, after
the operation, will conduct instructions to the machine tools, machine tools will be according to
the instruction work out to sheet metal design.

The core part of the machine tool is one of the laser generator, it is the core of the whole
equipment.Why do you say so?Because it is the secret of the cut metal device.It can convert
electrical energy into light energy, release the remarkable feats of laser beam, and with a lot of
energy, laser beam by irradiation in sheet metal surface, make the light surface quickly reaching
high temperature, radiation surface melting and evaporation of components, through the
displacement of the cutting head to achieve the purpose of cutting and engraving.

Generally there are many kinds of laser cutting machine laser, can according to different material
to different kinds of laser cutting machine.We have in common solid laser material as medium,
its representatives have solid YAG laser cutting machine.With gas as the medium of laser, its
representative has CO2 laser cutting machine.Based on optical fiber laser medium, its
representatives have optical fiber laser cutting machine.The three machining effect and the
thickness is different.

Here the lowering and the raising of the header are carried out manually using the rack and
pinion arrangement. In this case the required pressure is applied manually using direct hand
pressure on the rack using pinion and lever arrangement. Since the machine is robust and
requires large pressure, hence it is not suitable.