Modern industries need fast and accurate cutting methods to cut metal. Metal shearing fulfills these needs with special cutting methods. In this blogpost we will cover metal shearing types, methods, benefits as well as its uses.
What is Metal Shearing?
A metal fabrication procedure that is used to cut metal along straight lines is called metal shearing. This method uses one moving and one fixed blade. These blades use shear force to cut metal into pieces. This method helps you to prevent the metal from different distortions such as cracking, chipping as well as melting. Many industries prefer this method because it gives precise cuts & reduces material waste.
Types of Metal Shearing
1. Guillotine Shearing
It is one of the most broadly used methods for cutting metal sheets in a straight line. It uses two main tools _ a moving upper blade and a fixed lower blade. Upper blade descends with a lot of force to cut through metal sheets. This method works impressively well with thick materials.
2. Alligator Shearing
This type has a hinged mechanism which looks like alligator jaws. Here a hydraulic piston operates the upper jaw to cut materials like beams, pipes & rebar. This method is cheaper and durable but leaves rough edges so it’s not suitable for projects which need smooth finishes.
3. Power Shearing
Pneumatic or electric systems drive the blades in power shearing. This operation gives large radius curves and straight cuts in sheet metal.
Industrial settings prefer power shearing because of its accuracy, speed and capability to handle high volume workloads.
4. Bench Shearing
Bench shearing uses a bench mounted shear tool to cut materials. This procedure is good for medium sized bars and sheets. Mechanical design of this method gives clean cuts with no burrs. Small fabrication projects take the most advantage from this shearing.
5. Throatless Shearing
Throatless shearing is best for cutting irregular patterns and complex curves. This type of shearing supports unrestricted material movement during cutting. Metal fabricators prefer this method for specialized designs and artistic projects which need intricate shapes.
Metal Shearing Procedure
Metal shearing is an accurate and fast process. This section breaks down every step from starting to final standard testing.
Prep & Setup
Operator places the metal sheet on the shearing machine’s cutting bed as a first step. They set the backgauge for the desired cut. Then they use hold‐down clamps to fix the sheet in place for a precise cut. Machine calibration also needs attention for two things_ setting the clearance and choosing the right blade. This clearance should be 5 to 40% of the material thickness depending on the type of metal.
Cutting
Actual cutting process happens in three stages. First the metal deforms plastically and a roll‐over or edge radius is created. Next the blade cuts through about 1/3rd of the material thickness to produce a smooth cut band. Finally the material separates by means of fracture and a clean edge is formed.
Post Shear
Quality controllers inspect the cut pieces for defects like rough edges and burrs. Correct clearance settings and sharp blades help minimize burr formation. Some projects need additional procedures such as leveling or flattening to get desired dimensions and shape.
See Also: Reducing Burrs in Aluminum Alloy Machining
Benefits of Metal Shearing
Accuracy and Precision
Metal shearing gives clean and straight cuts with less distortion. It can hold tolerances up to ±0.005” perfect for accurate component manufacturing.
Versatility
Metal shearing can work on almost all metals. It can cut soft metals such as brass, aluminum as well as harder metals like stainless steel.
Speed and Efficiency
It is a fast process as high output operations can produce thousands of pieces in one hour. Moreover, no preheating is needed which helps meet tight deadlines and saves time.
Minimal Material Waste
It avoids the loss of excess material or chips during cutting so manufacturers can maximize their material usage.
Affordability
Metal shearing procedure produces minimal waste material or kerf. This in turn reduces cost.
Uses of Metal Shearing
Many industries use metal shearing because of its adaptability & precision. Here are some uses of metal shearing in different sectors:
Aerospace Industry
Aerospace manufacturers use metal shearing to process lightweight materials like titanium and aluminum. These materials are necessary for aircraft fuselages, structural parts and wings. This process gives the accuracy required for these sensitive applications.
Industrial Manufacturing
Industrial manufacturing uses metal shearing to make machine tools, components as well as equipment parts. It gives clean cut edges and homogenous dimensions. Manufacturers can produce high volumes of panels, brackets as well as enclosures.
Construction Industry
Metal shearing is used in construction projects as fabricators use it to make structural steel beams, trusses, columns and roofing materials. Higher accuracy of this process assures exact fits between parts which is necessary for their structural safety and integrity.
Automotive Sector
Metal shearing is necessary in automotive manufacturing. It supports the production of body panels, engine parts as well as chassis components. This procedure meets strict tolerance needs and produces clean cuts which directly impact aerodynamic functionality and vehicle safety.
Custom Metal Fabrication
Versatility of metal shearing allows you to use it for custom fabrication work. For example throatless shears can make complicated shapes and cuts. It is particularly useful to produce artistic pieces and custom metal products.
The Limitations of Metal Shearing
You must understand the following limitations of metal shearing to get the best results:
Only Straight Cuts
Metal shearing procedure is best suited to give only straight cuts. So projects which need irregular or curved cuts should use other methods such as laser cutting. This limits the range of possible applications.
Edge Quality Issues
Metal shearing can cause burrs or edge deformation. These imperfections mostly need additional finishing procedures like deburring or grinding. The need for these extra steps increases cost as well as production time, in particular when smooth finishes are needed.
Material Thickness Restrictions
Ability of metal shearing decreases upon increasing material thickness. Standard shearing machines can work best with thin to medium thickness sheets, for example up to 6.35 mm (0.25 inches) for mild steel. So thicker materials need some special tool or other cutting methods.
To Sum Up
Modern manufacturing uses metal shearing because of its accuracy in cuts and flexibility of use. Construction, aerospace as well as automotive industries benefit from this fabrication process. Although it has some limitations yet fabricators worldwide use metal shearing as a necessary tool in their work．
If you’re looking for reliable metal fabrication solutions, then Richconn is your best option. You can contact us anytime.
Related Questions
What materials can be cut with metal shearing machines?
Aluminum, copper, steel, stainless steel, different alloys as well as high strength materials can be cut using metal shearing machines.
Can metal shearing be used for non metallic materials such as composites or plastic?
Yes some shearing machines can also cut non‐metal materials such as plastic and composites.
How is metal shearing different from plasma & laser cutting?
Metal shearing uses mechanical force to make a straight cut whereas laser and plasma cutting use heat to do the same job.
How does blade wear affect metal shearing?
Blade wear degrades surface quality, causes dimensional errors & creates burrs as well.
What is the common tolerance level in metal shearing work?
Metal shearing usually gives tolerances of ±0.1 to ±0.5 mm; it depends on machine settings & material thickness.
What safety measures should be taken during the shearing procedure?
Operators should follow safety protocols such as wear protective PPE, keep proper blade clearance and check machines before use. They should keep their hands away from blades and must not overload the machine.
Is metal shearing appropriate for high volume production?
Yes metal shearing outperforms other cutting methods in high volume production. It gives fast as well as homogenous cuts with low material waste.
What maintenance methods extend the life of shearing equipment?
Regular blade sharpening, bolt tightening & cleaning are important ways to extend life. Equipment life is also dependent on regular hydraulic system checks and proper lubrication.
