Product Description
Plate shearing machine — hydraulic guillotine shearing machine for steel plate cutting. The machine is built by the manufacturer and supplied factory direct. It is designed to cut steel plate of substantial thickness and length into rectangular blanks, with a straight blade that descends through the material in one controlled movement. Its purpose in a fabrication shop is to prepare plate blanks to accurate size and square edges, so that the plate can be formed, fitted and welded without further trimming.
The machine is the first stage in a plate fabrication sequence. Plate is brought to the shearing machine and cut into blanks; the blanks pass to a press brake or a plate roll to be formed, and then to welding. Because every later stage works from the blank the shearing machine produces, the accuracy of the whole sequence begins here. The plate shearing machine is therefore built around rigidity of the frame, control of the blade through the cut, firm clamping of the plate, and repeatable positioning of the cut length.
Working principle.
The machine cuts by shearing. A long, straight upper blade is carried in a blade beam and driven downward by hydraulic cylinders through the plate, against the fixed lower blade set into the bed. The descending blade and the stationary lower blade pass each other with a small clearance between them, and the plate is sheared along that line.
Hydraulic drive is what gives the machine its working character. The blade is driven by oil pressure from a hydraulic power unit rather than by a flywheel and clutch, which means the force through the cut is generated and controlled by the hydraulic system. This allows the machine to be set for the material in front of it: the cutting angle at which the blade meets the plate can be adjusted, and the gap between the upper and lower blades can be adjusted to suit the plate thickness. A blade meeting the plate at a suitable angle and with a suitable gap shears the plate cleanly through its thickness; a machine set incorrectly to the material produces a rough, torn or curved edge. The hydraulic arrangement also produces a steady, smooth cutting stroke, and the blade performs a full stroke and returns to its raised position ready for the next cut.
Machine structure — the main assemblies.
The frame. The frame is a heavy welded steel structure, with thick side plates and a rigid bed, which carries the whole cutting force and holds the blade beam in alignment. Frame rigidity is the foundation of shearing accuracy: if the frame deflects during the cut, the blade does not travel in a straight line and the plate edge comes off out of square. The frame is built for stiffness, and the guiding surfaces along which the blade beam travels are machined so that the blade beam runs true through its stroke.
The blade beam and the upper blade. The blade beam is the moving member that carries the upper blade. The blade is a long, straight, rectangular section of tool steel, hardened and ground, with more than one usable cutting edge so that a dulled edge can be turned or reversed before the blade is finally reground. The blade is clamped along the blade beam so that it is supported over its whole length rather than at intervals. Blade section and stiffness matter most on plate work, because the load on the blade rises with the thickness and strength of the plate being sheared.
The lower blade and the bed. The lower blade is set into the bed and forms the fixed cutting edge. The bed carries the plate during the cut and, together with the lower blade, establishes the reference face against which the plate is positioned and cut square.
The hold-down assembly. Immediately beside the cutting line, a row of hold-downs clamps the plate down onto the bed before and during the cutting stroke. The hold-downs prevent the plate from lifting, creeping or tilting as the blade descends, and they are the reason the plate is sheared rather than pushed or bent. Clamping force is a build characteristic of the machine rather than an adjustment, and it is specified for the plate range the machine is intended to cut, including the heaviest plate.
The blade gap adjustment. The clearance between the upper and lower blades is set to suit the material. On a suitably equipped machine the gap is adjusted by a powered or mechanical arrangement so that it can be changed as the plate thickness or material changes, which allows one machine to cut a range of plate thicknesses cleanly rather than being set for a single thickness.
The cutting angle adjustment. The angle at which the blade descends into the plate is adjustable, and the setting balances cutting force against distortion of the plate. A larger angle reduces the peak force needed, at the cost of more tendency for the material to be pushed aside; a smaller angle gives a cleaner edge with more force required. Adjustability is what allows the machine to be set for the plate and material in front of it.
The hydraulic power unit. The hydraulic system comprises cylinders acting on the blade beam, a pump station with a motor, a valve arrangement that controls the cutting stroke, and an oil reservoir. The system provides the cutting force and controls the stroke, including the return of the blade beam after the cut. The hydraulic components are standard-specification items, so that seals, valves and pumps can be sourced and serviced.
The back gauge. The back gauge is the stop that positions the plate at the required cut length. It is carried on a mechanism that travels the length of the machine and is guided so that it remains parallel to the blade along that travel, and it is positioned by a powered arrangement under the control of the operator, on machines equipped with a settable gauge. The back gauge is what makes cut length repeatable from one plate to the next, and it retracts after the cut so that the cut blank clears the blade.
Support and handling. The machine is provided with support arrangements at the entry side and the run-out side, so that the plate is carried at the correct height across its whole length before, during and after the cut. Support arms, roller supports and ball-transfer supports allow heavy and long plate to be moved into position and removed without being lifted clear of the machine, and they prevent the plate from hanging unsupported at the ends.
The electrical control system. The machine is controlled from a panel that operates the cutting stroke, sets the back gauge dimension where a settable gauge is fitted, and sets the blade gap and cutting angle on machines where these are powered. The control panel, the foot switch that initiates the cutting stroke, the motor starter and protection, and the safety devices — including guards over the blade path and an emergency stop — form the electrical arrangement of the machine. Machines are built for the electrical supply of the destination site.
Optional and alternative configurations. The machine can be built in differing configurations: as a standard machine with a hand-set back gauge; with a motorised back gauge set from the control panel; or with a programmable back gauge in which dimensions or sequences of dimensions are stored and indexed by the control system. A machine can be built with manual or powered setting of the blade gap and cutting angle. Support and handling arrangements are selected to suit the plate sizes to be cut. The machine can also be built with the cutting length and the cutting capacity that the buyer’s plate range requires, which is the particular advantage of buying from the manufacturer.
Product features and advantages.
Heavy rigid frame. The welded steel frame with thick side plates resists deflection under the cutting load, so the blade travels in a straight line and the cut plate edge comes off square. Rigidity is what keeps shearing accuracy stable over years of plate work.
Hydraulic drive with controlled cutting force. Oil pressure drives the blade through the cut, giving a steady and smooth stroke and allowing the cutting angle and the force to be set for the material rather than fixed by gearing.
Long straight blade cutting the full width of the machine. The plate is cut in one straight line across its full width, producing a square edge in a single stroke and with the lowest cost per cut of any plate cutting method.
Adjustable cutting angle. The blade angle can be set to suit the plate thickness and material, balancing cutting force against distortion so that both thin and heavy plate are cut cleanly on the same machine.
Adjustable blade gap. The clearance between the upper and lower blades is set to the material, so that the plate is sheared cleanly through its thickness instead of being torn or left with a curved edge.
Tool steel blade with multiple usable edges. The hardened and ground blade carries more than one cutting edge and can be turned or reversed when an edge dulls, which extends blade service life before regrinding is needed.
Powerful hold-down clamping. The row of hold-downs beside the cutting line holds the plate flat and still through the stroke, which is what prevents plate from creeping and keeps cut edges perpendicular to the plate face.
Repeatable cut length. The back gauge, guided parallel to the blade along the machine, positions the plate at a repeatable dimension so that successive blanks come off the machine at the same cut length.
Powered and programmable back gauge options. The gauge can be set by hand, motorised and set from the control panel, or programmable with stored dimensions and sequences, allowing the machine to suit the production pattern of the shop.
Support for long and heavy plate. Entry-side and run-out supports carry the plate at the correct height along its length, so that heavy plate can be positioned and removed without being manhandled and does not hang unsupported at the ends.
Built for the destination electrical supply. Machines are configured for the voltage, frequency and phase of the site where they will be installed.
Factory direct. The machine is built by the manufacturer and supplied directly, which is what allows the cutting length and cutting capacity to be produced to the plate range required rather than being limited to a catalogue size, and allows technical questions to be answered by the people who build the machine.
Cutting performance and edge quality.
The machine shears plate along a straight line across its full width. The cut face is clean and square, and the cut edge is formed in a single stroke. Capability depends on the relationship between plate thickness and cutting length together: the machine cuts its full length in thinner plate and its heaviest plate over a shorter length, and the two extremes are not reached at the same time. Cutting capacity is also related to the material, because higher-strength plate requires more force to shear than mild steel of the same thickness.
The quality of the cut edge depends on three settings and build characteristics of the machine. The blade gap must suit the material so that the plate is sheared and not torn. The cutting angle must suit the thickness so that the plate is not distorted as it is cut. The plate must be held flat and still by the hold-downs so that the sheared edge is perpendicular to the plate face. When these are right, the machine produces plate blanks with clean square edges ready for forming and welding.
Materials cut.
The machine is built to cut steel plate, and it is suitable for the plate materials used in fabrication and structural work: mild steel and structural steel plate; higher-tensile and higher-strength plate, which requires more cutting force than mild steel of the same thickness; stainless steel plate, which is widely used in water, process and food-related plate work; duplex and other corrosion-resistant plate; and coated and galvanised plate. Because cutting force rises with the strength of the material, the machine is configured to the material range the buyer cuts, and the plate capacity of a given machine is stated for the material it is intended to cut.
Applications — what the machine produces.
The machine produces rectangular plate blanks cut to length and cut square, which is the starting point for the fabricated plate work used across industry and construction.
Tanks, vessels and process equipment. Plate blanks for storage tanks, process vessels, skids, separators and the associated support work used in oil, gas, petrochemical and process plant fabrication.
Structural plate work. Base plates, connection plates, gusset plates, stiffeners and bracket plate for steel buildings, industrial sheds, warehouses and infrastructure.
Pipe racks, platforms, stairways and ladders. Cut plate for walkways, handrail plate, tread plate and access structures.
Ductwork and heavier HVAC fabrication. Plate and heavier-gauge blanks for duct sections, plenums and equipment housings where material runs thicker than light sheet metal.
Water and desalination plant fabrication. Stainless and corrosion-resistant plate blanks for water treatment, desalination and process plant equipment.
Trailer, tanker, container and heavy vehicle bodies. Cut plate for chassis plate, body panels, reinforcement plate and structural sections.
Architectural and general metalwork. Plate blanks for fabrications where a square cut edge is visible or where plate is fitted to other plate.
Maintenance, repair and re-fabrication. Replacement plate cut to match existing structures and equipment, which is a substantial and continuing demand wherever industry is already established.
Machine build quality.
The machine is built as a heavy fabricated structure rather than assembled from light components. The frame is welded from steel plate and sections, and the side plates and bed are built to carry the cutting load without deflection. The surfaces on which the blade beam travels are machined so that the blade beam is guided true through its stroke, and the blade seating faces are machined so that the blade is held straight and properly supported along its length. The hydraulic system is assembled from standard-specification components. The electrical system is wired and tested as a complete arrangement, and the machine is run and checked before shipment so that the cutting stroke, the blade gap setting, the back gauge travel and the safety devices are functioning as a complete machine.
Service and support.
Machines are supplied with documentation covering the machine, including the operating manual, the electrical drawings and the hydraulic arrangement. Installation and commissioning are carried out with technicians attending site, and operator training is provided so that the machine is set correctly for each material and handled safely. Illustrated manuals and video guidance cover the settings used most often, including the blade gap and cutting angle settings and their relationship to the plate being cut. Engineering support is available for technical questions during the working life of the machine, and spare parts are supplied, with particular attention to the blades and to the hydraulic components that the machine uses.
♦ COMPANY PROFILE:
Hebei Xinnuo Roll Forming Machine Co., Ltd., not only produce different types of professional roll forming machines, but also develop intelligent automatic roll forming production lines, C&Z shape purline machines, highway guardrail roll forming machine lines, sandwich panel production lines, decking forming machines, light keel machines, shutter slat door forming machines, downpipe machines, gutter machines, etc.
Advantages of Roll Forming A Metal Part
There are several advantages of using roll forming for your projects:
- The roll forming process allows operations such as punching, notching, and welding to be performed in-line. Labor cost and time for secondary operations are reduced or eliminated, reducing part costs.
- Roll form tooling allows for a high degree of flexibility. A single set of roll form tools will make almost any length of the same cross-section. Multiple sets of tools for varying length parts are not required.
- It can provide better dimensional control than other competing metal forming processes.
- Repeatability is inherent in the process, allowing easier assembly of roll formed parts into your finished product, and minimizing problems due to “standard” tolerance build up.
- Roll forming is typically a higher speed process.
- Roll forming offers customers a superior surface finish. This makes roll forming an excellent option for decorative stainless steel parts or for parts requiring a finish such as anodizing or powder coating. Also, texture or pattern can be rolled into the surface during forming.
- Roll forming utilizes material more efficiently than other competing processes.
- Roll formed shapes can be developed with thinner walls than competing processes
Roll forming is a continuous process which converts sheet metal into an engineered shape using consecutive sets of mated rolls, each of which makes only incremental changes in the form. The sum of these small changes in form is a complex profile.
