Plate shearing machine with a steel cutting capacity of up to 12mm — hydraulic guillotine shearing machine, built by the manufacturer. This machine belongs to the plate-cutting class of shearing machines: it is built to shear steel plate of substantial thickness into rectangular blanks with a straight, square edge, in a single cutting stroke. It is intended for plate fabrication work where the material is measured in millimetres of thickness rather than in sheet gauges, and where the blank that comes off the machine is the starting point for forming, fitting and welding.
It is a guillotine type machine driven by hydraulics. A long straight upper blade descends through the plate against a fixed lower blade and shears it along a straight line across the full width of the machine. The plate is held flat and still by a row of hold-downs beside the cutting line, the blade angle and the blade gap are set to suit the material being cut, and the cut length is set by a back gauge that positions the plate repeatably. The machine is built on a heavy welded frame whose rigidity is what keeps the cut edge square.
The machine is manufactured by the factory and supplied direct. It is produced in this capacity class as a standard machine, and it can also be built to the cutting length and the plate range that a particular workshop needs.
What “up to 12mm” means on this machine, stated accurately.
The cutting capacity of a shearing machine is the point at which a buyer should be most careful, because the figure is correct and still easy to misread. Three things about it are worth setting out plainly, because they describe what this machine will and will not cut.
The capacity figure is stated for mild steel. Cutting capacity is conventionally quoted against mild steel, and this machine’s capacity of up to 12mm is a mild steel capacity. Steel of higher strength requires more force to shear than mild steel of the same thickness, so a plate of a higher-tensile or structural grade of the same thickness is a heavier cut than mild steel plate of that thickness. Stainless steel and duplex plate require more force again. On a machine of this capacity class, the practical consequence is that the thickness the machine will cut cleanly depends on the material in front of it, and the material is what should decide the setting.
Thickness and length are related, and the two extremes are not reached together. A shearing machine cuts its full cutting length in thinner plate and its heaviest plate over a shorter length. The two are the ends of one capability, not a rectangle of capability, so a machine that cuts 12mm will cut 12mm over part of its length and its full length in thinner material. This is how shearing machines of every capacity behave, and it is the reason a plate shop that habitually cuts full-length plate works to the machine’s full-length capability rather than to its heaviest figure.
Capacity is a limit, not a working condition. A machine cutting at its maximum thickness is cutting at the edge of its capability, where the frame, the blade and the hold-downs are all working hardest. Plate work of that kind is done with the blade gap and the cutting angle set correctly for the material, and with the blade in good condition; a machine of this class is built with the rigidity and the clamping force to do that work as normal production rather than as an exception.
Working principle.
The machine shears rather than saws or burns. The upper blade is carried in a blade beam and driven downward by hydraulic cylinders; the lower blade is fixed in the bed. The descending blade and the fixed blade pass each other with a small clearance, and the plate is sheared along that line through its full thickness.
Hydraulic drive is what gives the machine its working character and its flexibility. The cutting force is developed by oil pressure from a hydraulic power unit, so the machine can be set to the material in front of it: the angle at which the blade enters the plate is adjustable, and the clearance between the upper and lower blades — the blade gap — is adjustable to suit the plate thickness. A blade entering at a suitable angle, with a suitable gap, shears the plate cleanly through its thickness. The hydraulic stroke is steady and smooth, and after the cut the blade beam returns to its raised position ready for the next plate.
Machine construction — the main assemblies.
The frame. A heavy welded steel structure with thick side plates and a rigid bed, carrying the full cutting force and holding the blade beam in alignment. Rigidity is the foundation of shearing accuracy on plate: a frame that deflects during the cut lets the blade travel in an arc instead of a straight line, and the plate edge comes off out of square. The frame is built for stiffness, and the guide surfaces along which the blade beam travels are machined so that the beam runs true through its stroke.
The blade beam and the upper blade. The blade beam is the moving member carrying 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. It is clamped along the blade beam so that it is supported over its full length rather than at intervals, and the seating faces are machined so the blade is held straight. On a machine of this capacity, blade section and stiffness matter, because the load on the blade rises with the thickness and the strength of the plate being cut.
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 through the cut and, with the lower blade, establishes the reference face against which the plate is positioned and cut square.
The hold-down assembly. A row of hold-downs immediately beside the cutting line clamps the plate down onto the bed before and during the stroke. Because the hold-downs hold the plate flat and still, the blade shears the plate instead of pushing it, and the cut edge comes off perpendicular to the plate face. Clamping force is a build characteristic of the machine, and on this capacity class it is specified for the heavier plate the machine is built to cut.
Blade gap adjustment. The clearance between the upper and lower blades is set to suit the material. It can be adjusted so that the machine cuts a range of thicknesses cleanly rather than being set for a single thickness, which is what allows one machine of this capacity to handle both heavy plate and thinner work in the same shop.
Cutting angle adjustment. The angle at which the blade descends into the plate is adjustable. A larger angle reduces the peak cutting force required; a smaller angle produces a cleaner edge with more force needed. Adjustability allows the machine to be set for the thickness and material being cut rather than being fixed by gearing.
The hydraulic power unit. Cylinders acting on the blade beam, a pump station with its motor, the valve arrangement that controls the cutting stroke and the return, and an oil reservoir. The hydraulic components are standard-specification items, so that seals, valves and pumps can be sourced and serviced.
The back gauge. 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 stays parallel to the blade along that travel, and it retracts after the cut so the cut blank clears the blade. On this machine the gauge can be set by hand, motorised and set from the control panel, or programmable with stored dimensions or sequences of dimensions.
Support and handling. Support arrangements at the entry side and at the run-out side carry the plate at the correct height along 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 taken away without being lifted clear of the machine, and they keep the ends of the plate from hanging unsupported while it is being positioned against the back gauge.
The electrical control system. The machine is operated from a control panel which runs the cutting stroke, sets the back gauge dimension where a settable gauge is fitted, and sets the blade gap and cutting angle where these are powered. The panel, the foot switch that initiates the stroke, the motor starter and protection, and the safety devices — blade path guards and emergency stop — make up the electrical arrangement, which is built for the electrical supply of the destination site.
Product features and advantages.
Heavy rigid frame for plate work. The welded steel frame with thick side plates resists deflection under the cutting load, so the blade runs straight and the cut edge of the plate comes off square. On a machine of this capacity, rigidity is what keeps shearing accuracy stable through years of plate work.
Hydraulic drive with controlled cutting force. Oil pressure drives the blade through the cut, giving a steady stroke and allowing the cutting angle and the cutting force to be set for the material rather than being fixed by gearing.
Cutting capacity up to 12mm in mild steel. The machine is built as a plate-cutting machine, and its cutting capacity, together with its cutting length, define the plate blank sizes it produces. Higher-strength and stainless plate are cut at a reduced thickness for the same machine, which is the normal behaviour of every hydraulic guillotine shear.
Long straight blade cutting the full width in one stroke. The plate is sheared along a straight line across the full width of the machine in a single stroke, producing a square edge and giving the lowest cost per cut of any plate cutting method.
Adjustable cutting angle. The blade angle is set to suit the plate thickness and material, balancing cutting force against distortion, so that both heavy plate and thinner work 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, extending the blade’s service life before regrinding.
Powerful hold-down clamping. The hold-downs beside the cutting line clamp the plate flat and still through the stroke, preventing the plate from creeping and keeping the cut edge perpendicular to the plate face — the requirement that matters most on thick plate.
Repeatable cut length. The back gauge, guided parallel to the blade along the machine, positions the plate at a repeatable dimension so successive blanks come off at the same cut length.
Choice of back gauge control. The gauge can be set by hand, motorised and set from the control panel, or programmable with stored dimensions and sequences of dimensions.
Support for long and heavy plate. Entry-side and run-out supports carry the plate at the correct height along its length, so heavy plate can be positioned and removed without being manhandled and does not hang unsupported at the ends.
Built for the destination electrical supply. The machine is configured for the voltage, frequency and phase of the site where it will be installed.
Manufacturer direct. The machine is built by the manufacturer and supplied direct, which allows the cutting length and the plate range to be produced to what a workshop actually needs 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 steel plate along a straight line across its full width, and the cut edge is formed in a single stroke. Working capability depends on plate thickness and cutting length together: the machine cuts its full length in thinner plate and its heaviest plate over a shorter length, and cutting capacity is related to the material, since higher-strength plate requires more force to shear than mild steel of the same thickness. A machine of this capacity class is therefore specified against the plate range it will actually be given, and it performs at its best when the blade gap and cutting angle are set to that material.
Cut edge quality depends on three things, all of which are build characteristics and settings of the machine rather than incidental results. 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. And the plate must be held flat and still by the hold-downs, so that the sheared edge is perpendicular to the plate face. Set correctly, the machine produces plate blanks with clean square edges ready for forming, fitting and welding, and with the cut face square enough that the blank can be assembled without trimming.
Materials this machine cuts.
The machine is built to cut steel plate, and in this capacity class it is applied to the plate materials used in plate fabrication and structural work.
Mild steel and structural steel plate. The reference material for the machine’s capacity, and the material of most general plate fabrication.
Higher-tensile and higher-strength plate. Cut at a reduced thickness for the same machine, because these materials require more cutting force than mild steel of equal thickness.
Stainless steel plate. Widely used in water, process, food-related and architectural plate work; also cut at a reduced thickness, and requiring attention to the gap and angle settings because of the way it behaves under the blade.
Duplex and corrosion-resistant plate. Used in water treatment, desalination and process plant fabrication, where corrosion resistance is the reason for the material.
Galvanised and coated plate. Cut with the gap set to suit the coating and the material thickness so that the coating is not unnecessarily disturbed along the cut edge.
Because cutting force rises with the strength of the material, the machine is configured to the material range a workshop cuts, and the capacity of a given machine is stated for the material it is intended to cut. Stating the material is therefore part of stating the specification of the machine, and it is the reason the same nominal capacity can mean different things in two different workshops.
Applications — what this machine produces.
The machine produces rectangular plate blanks cut to length with square edges, which is the first operation in fabricated plate work across industry and construction. In this capacity class its work includes:
Tanks, vessels and process equipment. Plate blanks for storage tanks, process vessels, skids, separators and their supporting structures in oil, gas, petrochemical and process plant fabrication.
Structural plate work. Base plates, connection plates, gusset plates, stiffener plate 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 treatment and desalination plant fabrication. Stainless and corrosion-resistant plate blanks for water 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 the cut edge is visible, or where plate is fitted against other plate.
Maintenance, repair and re-fabrication. Replacement plate cut to match existing structures and equipment — 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 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 verified 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 operated 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 through the working life of the machine, and spare parts are supplied, with the blades and the hydraulic components of the machine given particular attention.
♦ 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.
