Robotics and Computer–Integrated Manufacturing 44 (2017) 242–252

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Robotics and Computer–Integrated Manufacturing

journal homepage: www.elsevier.com/locate/rcim

A novel dynamic holding system for thin metal plate shearing machines
⁎
crossmark
L.M.B. Araújo, F.J.G. Silva , R.D.S.G. Campilho, J.A. Matos
ISEP – School of Engineering, Polytechnic of Porto, Rua Dr. António Bernard ino de Almeida, 431, 4200-072 Porto, Portugal

A R T I C L E I N F O A BS T RAC T

Keywords: Metal shearing machines are heavy equipments usually linked to low added-value due to the small amount of
Shear plate machines technological devices incorporated. However, this situation can be changed through equipment designers'
Cutting processes creativity. Analysing some specific operations, it can be observed that some tools, when coupled to the
Aggregate tools equipment, should substantially increase the cutting process productivity and the final product quality.
Sheet metal cutting
Regarding the thin metal plates shear process, it can be found that in the cutting final stage, the cut material
Design for sustainability
weight is suspended by a small material section still requiring to be cut. This leads to strip tip deformation,
causing poor quality of the final product, which cannot stay fully plan. This work was developed around this
problem, studying the best solution to develop a new tool able to avoid the lack of plate flatness after cut. A novel
equipment was designed, able to be easily connected to the shearing machine, following the blade movement
throughout cut operation. The system is fully-automated, being operated by a single cut instruction given by the
machine operator. This system allows the manufacturing company to increase the added-value of each machine,
offering advanced and desirable solutions to the customers, and contributing as well to the company business
sustainability.

1. Introduction
Although being an old technology, blanking remains nowadays one
of the most used cutting processes in metalworking industry [1]. This
technology was study many year ago but, recent developments brings
new challenges such as adapting finite elements model to these
technologies in order to predict new materials behaviour, explore the
processes capacity having as focus to increase the production rate and
implement new devices leading to a quality improvement regarding the
new market requests and expectations. Accordingly, several studies
have been carried out by different authors regarding, namely in the
field of the parameters improvement, with Breitling et al. [2] exploring
the competitiveness of the process and studying the blanking speed,
concluding that blanking force drops with the increase of the blanking
speed within the range of 1–4 m s−1, results whose were corroborated
by Goijaerts et al. [3] within the range of 0.01–1000 mm s−1. Further
studies have been carried out by Neugebauer et al. [4] and
Subramonian et al. [5] concluding that dynamic effect is higher when
blanking speed increases, using a high speed mechanical press.
Mackensen et al. [6] studied the punch inclination angle, concluding
that cutting forces are lower when punch inclination angle rises.
However, higher punch inclination angles lead to blank curling. As
referred by other authors [7–9], a better geometrical accuracy of the
blanked part can be achieved by an optimization of the punch shape
and die clearance. However, it remains clear that parameters such as
tool wear state, clearance, tool radii and geometry, material geometry,
sheet metal thickness, friction, relevant material properties regarding
the cutting (ductility and hardness), sheet metal coating, lubrication
use, stroke rate and blanking speed are the key-factors affecting the
sheared edge aspect [10]. Thermal effects have been also intensively
studied in order to correlate the temperature with the blanking force
[11–13] leading to realize that blanking forces fall when material
temperature upsurges. These studies include pre-heating processes in
order to lead the material temperature to diverse levels and measure
the needed blanking force to cut different materials. Many other studies
have been carried out in the analytical and numerical methods field,
trying to get reliable models helping researchers to predict blanking
operations effect regarding different materials and cutting conditions
whose are summarized in [10,14–16]. However, despite these strong
efforts, the blanking cutting process still remains an attractive issue to
investigate due to shear band formed narrowness and the lack of an
appropriate fracture criterion.
The guillotine cutting process is also one of the most blanking
processes used in the metalworking industry. To get the final product,
raw materials need to pass through many processes, being usually the
guillotine cutting one of them. This cutting process can be performed
manually or automatically and can be integrated as an initial, inter-
mediate or finishing step [17]. The guillotine cutting process principle,

⁎
Corresponding author.
E-mail address: fgs@isep.ipp.pt (F.J.G. Silva).

http://dx.doi.org/10.1016/j.rcim.2016.06.006
Received 26 November 2015; Received in revised form 23 June 2016; Accepted 30 June 2016
0736-5845/ © 2016 Elsevier Ltd. All rights reserved.
L.M.B. Araújo et al.
as shown in Fig. 1, consists of positioning the plate between a fixed and
a movable blade, which downwards movement penetrates the plate
and, when it exceeds the shear tensile strength, the plate is cut.
This cutting principle is transverse to the different types of shearing
machines, although the handling characteristics of the blade directly
influence the final cut quality. Although the surface quality of guillotine
cutting cannot compete with machined ones, this is the most economic-
al cutting method to obtain straight shapes [19,20].
The guillotining process has some typical associated defects, most
of them related to frame distortion, blades gap or incorrect cutting
angle regulation. Anyway, most of these problems are already fixed or
attenuated with some devices already provided by manufacturers as
option. It is well known that cut surfaces with higher quality will avoid
subsequent finishing operations, as well as that cutting accuracy is
different for the plate that remains in the table and the cut strip which,
not being hold or fixed by hold down jacks, tends to bend or twist
during the cutting process, originating defects as shown in Fig. 2.
Bow is a cutting typical defect resulting from the progressive action
of the movable blade in the cutting process. The cut strip is being
separated without support, bending under its own weight [20]. The
strip bow becomes more pronounced the smaller the cut width and the
greater the cut angle. However, reducing the cutting angle can
minimize but not completely eliminate the bow [19]. Twist is a defect
described as the tendency to roll the cut material trendy a spiral shape.
High cutting angles are usually associated to torsion defect, which also
results from sheet metal internal stresses. This effect is more pro-
nounced in narrow strips, being the last resistant strip-section the one
that more easily attains permanent deformation [20]. Camber is a
defect resulting from the strip separation, being caused essentially due
to material internal stresses [19,21,22].
2. Methodology and results
This section is divided into three subsections: firstly, the problem is
identified, followed by the initially designed solutions to eliminate it
and, finally, the adopted solution to overcome the problem is pre-
sented. As previously mentioned, the shearing process has a few typical
limitations, but some of them are already solved by shearing machines
manufacturers. The problem affects customers that use the guillotine to
cut thin plates provided with high length. The second subsection will
deal with the main initial ideas thought to eliminate the problem, with
some solutions but only one presenting the best cost - benefits relation.
Thus, in the third subsection, the adopted solution is described,
together with some changes from the initial to the final design.
2.1. The problem
During the thin plate cutting process a very specific problem was
detected, which occurs when cutting sheets with smaller thickness than
3 mm and length higher than 700 mm. Because the cutting process is
performed with a programmed blade slope, this leads to warpage in the
latter cut sheet portion (Fig. 3a), induced by the weight of the
sheet already cut, which results in high bending stresses at the small
area that is not yet cut, as illustrated in Fig. 3b. This occurrence
prevents to include the guillotine directly in a processing line because
straightening operations are mandatory before sheets pass to another
processing step. This weakness is a major embarrassment and annoy-
ance when constantly cutting plates with the aforementioned dimen-
sional characteristics, leading to a reduction in productivity. Such
defects have been reduced with some accessories available on the
market. However, the complete elimination of this kind of defect is just
expected by the integration of a dynamic holder during the cutting
process.
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Robotics and Computer–Integrated Manufacturing 44 (2017) 242–252
2.2. Approach
Fig. 4 shows the 3D model of the conceived platform, able to be
assembled on the guillotine structure, which allows giving a real vision
about what can be expected and embodies a good way to detect issues
to be improved. The platform consists of a frame held by four
pneumatic cylinders, in which a guidance system enables the structure
to move up and down, as well as to lean, but always without performing
horizontal movements that would result in hitting the guillotine's main
frame.
The main goal of this device is to be compatible with the new
guillotines in production and with most of the guillotines already on the
market, allowing to easily adapt this device to them.
2.3. Methodology
2.3.1. Dynamic holder
The dynamic holder will support the cut strip during the cutting
process and the first design was a simple plate provided with
reinforcement in the middle and square pipes on the top, but this
structure showed to be very heavy to handle in maintenance operations
and cylinders check, requiring the removal of the whole holding system
for repairing and checking tasks (Fig. 5a). The modular chassis
includes two removable plates around the central one (Fig. 5b), gaining
access to the cylinders and decreasing the structure's weight, thus
facilitating the assembly and maintenance procedures. The removable
plates fastening system is constituted by countersunk bolts and nuts.
As the space between holder and ground in the holder rest position has
restricted access, the nuts were welded to facilitate the cover removal
operation.
2.3.2. Guiding system
Firstly, it is necessary to explain why this system needs a guide. In
Fig. 6 it is pointed out with green arrows the intended freedom degrees,
while the red crosses indicate the restricted movements promoted by
the guiding system.
The first developed design is shown in Fig. 7 and the working
principle was based on two sets of two positioning bearings at each side
of the holder. Bearing A limits the horizontal movements while bearing
B keeps the holding system in the correct vertical path.
Hence, at this stage the system needs to be improved because it is
really hard to fabricate and the final cost will be higher than desired.
The design was rethought and now it will consist of applying a central
guide below the holder, using a rod end bearing to keep the holding
system in the correct position, giving as well the necessary freedom to
the system tilting movement. The rod end bearing allows the inclina-
tion during the cutting process and rotation to extract the strip or keep
the holding system in the rest position. A weak point of this new system
is related to the square shaft and bushing responsible for the vertical
movement, which are difficult to manufacture. Thus, the square shaft
Fig. 1. Guillotine cutting process scheme[18].
L.M.B. Araújo et al. Robotics and Computer–Integrated Manufacturing 44 (2017) 242–252

Fig. 2. Typical defects on guillotine cutting process [19]. Guillotine cutting process [19].

and bushing were replaced by a linear guide. This change makes this
system completely standard and the final result is an easy to manu-
facture system in which all the components can be easily replaced Fig. 8
.
2.3.3. Drive system
The driving system is one of the most important parts of this project
because it represents the biggest associated cost. Thus, to choose the
correct one it is necessary to focus on the required positions:
2.3.3.1. Upper position. In this position the dynamic holding system
is at the same level as the guillotine table, ensuring the horizontal plate
position and the correct measurement of the strip to be cut, using the
back gauge system. After positioning, the hold down jacks immobilize
the plate, and the back gauge automatically retreats 100 mm,
preventing the stress generated by the contact between strip and
back gauge during the cutting process.
2.3.3.2. Intermediate position. Starting the cut, a command is given
for the cylinders to recede from the platform edge at the right position,
resulting in the holder's tilt. Thousandths of a second later, the same
order is given to the cylinders at the opposite side. The cylinders
movement coordination is crucial in order to keep the holding system
close to the strip cut point at each moment.
2.3.3.3. Discharge position. After the strip has been cut, the two inner
cylinders are driven to give as much tilt as possible, leading to the strip
discharge operation.
2.3.3.4. Rest position. This position corresponds to the final stage of
the cycle, being used as well when the sheet thickness exceeds 5 mm,
since the pneumatic components are only designed to handle the
structure and plates up to 5 mm thickness. It was considered necessary
to implement a structure that allows optimizing the unit, making
possible the cut for thicknesses higher than 5 mm. Therefore, it was
decided to include two longitudinal reinforcements that absorb the
impact loads of the strips exceeding 5 mm thickness dropping on the
holder. Other established requirements are related to the very confined
space to place the pneumatic cylinders and that components price
should be as low as possible. After a long and careful market survey, the
best options found are presented as follows.

Fig. 3. Traditional defect (a) and high stress concentration (red zone) (b) (For interpretation of the references to color in this figure, the reader is referred to the web version of this
article).

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Fig. 4. Isometric view (a) and exploded view (b) of preliminary holder version.
2.3.4. Option 1 – conventional cylinders
These cylinders present as advantage the high perpendicular
resistance to the axis loads, adjustable pneumatic damping and can
be easily found in the market. However, to use this solution it is
necessary to use a “Multi-Position Kit”. This kit will dock the two
cylinders coaxially, allowing four possible positions: a fall-back position
and three forward positions, as shown in Fig. 9. The great advantage of
these cylinders is their price.
2.3.5. Option 2 - servo-pneumatic cylinders
This option satisfies the largest number of requirements initially
drawn for this project. These cylinders have the particularity to ensure
greater positioning accuracy and enable stopping in several positions
along its path, contrary to conventional cylinders, which only allow the
retreat and forward positions. These are standard cylinders with a
positioning control, Fig. 10, which let a position accuracy of around ±
0.2 mm [24], thus ensuring the exact positioning of the holder at the
desired position. The position versatility that these cylinders can offer,
allows an exact following of the holding system during cutting process
independently of cutting angle and this is undoubtedly a huge
advantage. However, this system has a drawback: their high acquisition
cost. Therefore, solutions must be found that could meet the needs,
taking into account the system and budgeting constraints.
Regarding these two driving system possibilities, it is possible to
have at least two different manufacturing options. Figs. 11 and 12
presents the general view of the different driving systems. Due to the
longest length of the servo cylinders, their assembly needs to respect
the maximum length available. Thus, their position had to be con-
veniently studied to get the cylinder's holders into the space available
(Fig. 11). The conventional cylinders have a lower length, allowing
Fig. 5. Dynamic holding system evolution: (a) First and (b) final design.
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Robotics and Computer–Integrated Manufacturing 44 (2017) 242–252
their assembly in parallel to the lateral faces of the machine body
(Fig. 12).
2.4. Results
Based on the initial conditions and all work done, the holding
system can be moved as follows:
• Solution 1 - conventional cylinders;
• Solution 2 - servo-pneumatic cylinders;
• Solution 3 - mixed version.
2.4.1. Option 1 - conventional cylinders
This version consists of using four groups of two pneumatic
cylinders assembled with “Multi-Position Kit”. The operation principle
is the following: when the system is activated, all cylinders are
extended to put the platform in the upper position, allowing achieves
the correct plate placement (Fig. 13).
Starting the cutting process, the cylinders of the side where the
blade starts to cut begin to retract (Fig. 14).
In order to accurately monitor the slope of the blade, the cylinders
on the other side also retract, but slowly, allowing that the Z position of
the holding system is in line with the point where the blade is cutting
the sheet metal at each moment. At the end of the cutting process, the
platform assumes a horizontal position and each cylinder assembly is
retracted (Fig. 15).
If it is necessary to continue to cut plates with a smaller thickness
than 5 mm, the cylinders that support the front part of the dynamic
holding system retract, causing the platform tilting and discharging the
cut plate (Fig. 16).
L.M.B. Araújo et al. Robotics and Computer–Integrated Manufacturing 44 (2017) 242–252

Fig. 6. Intended freedom degrees and restricted movements on the system. (For interpretation of the references to color in this figure, the reader is referred to the web version of this
article).

Fig. 7. First approach of the guiding system.

Fig. 8. (a) Second approach of the guiding system and (b) final concept.

After a few seconds, all cylinders are actuated again putting the cylinders that are easily found in the market at reasonable prices. As
holding system in the upper position. Otherwise, all cylinders recede to disadvantages, they present a very limited operation, since they only
put the holding system in the rest position (Fig. 17). consent two positions, extended or retracted, not allowing control
The great advantage of this option is that it uses conventional intermediate positions. In this case, a careful adjustment is also needed

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Fig. 9. (a) Assembly of two cylinders with multi-position kit and (b) possible assembly positions [23].

Fig. 10. Servo-pneumatic cylinder DNCI/DDPC provided by FESTO [24].

Fig. 11. Pneumatic servo cylinders positioning.

Fig. 12. Conventional cylinders positioning.

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Fig. 13. Conventional cylinder – upper position.

Fig. 14. Conventional cylinder – intermediate position.

Fig. 15. Conventional cylinder – final cutting stage.

in order to match the cylinders’ movement and the holder position with
the descending blade and the cutting point.
2.4.2. Option 2 – servo-pneumatic cylinders
The operation principle is similar to that described in option 1.
However, this option uses four servo-pneumatic cylinders. In the upper
position, all cylinders are extended (Fig. 18).
Starting the cutting process, the cylinders at the cutting side start to
retract, following the angle of the blade (Fig. 19).
At the end of the sheet metal cutting process, cylinders put the
holding system in a horizontal position, slightly below the blade
(Fig. 20).
If the operator wishes to continue cutting sheets smaller than 5 mm
thickness, the cylinders that support the holding system in the front
retract, leading to the platform tilt, which in turn leads to the sheet
discharge by gravity (Fig. 21).
If it is necessary to turn off the guillotine or to cut plates higher than
5 mm thickness, all cylinders retract, placing the platform in the rest
position (Fig. 22).
This system presents many benefits such as stop at intermediate
positions or controlling the holder movement speed between stages.
Other advantage of this option is the frontal discharge capability,
because it is possible to give the order to raise the holder slightly above
the “upper” position (Fig. 23).
The back gauge automatically pushes the plate to the front side and
the operator can receive the cut strip at the guillotine frontal side,
avoiding wasting time to collect the plate at the back side.

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Fig. 16. Conventional cylinder – discharge position.

Fig. 17. Conventional cylinder – rest position.

Fig. 18. Servo-pneumatic cylinder – upper position.

2.4.3. Option 3 – mixed version 2.5. Comparing different solutions

Option 3 is a combination of the previous ones. This solution was
idealized to enable the plate extraction by the machine front, which
consists of using two sets of two cylinders with two multi-position kit
and two servo-pneumatic cylinders. Thus, the operation is identical to
that described in option 2, however, when the operator wishes to
remove the plate by the machine front side, the servo-pneumatic
cylinders are placed slightly above the “upper position”, causing the
holder to be positioned somewhat in ramp (Fig. 24). This ramp position
is very important to avoid the collision between the plate and lower
blade when this is pushed to the front side. Furthermore, the servo-
pneumatic cylinders will allow more accurate movements during the
system operation.
Regarding the different options considered in this work, it is time to
summarize the advantages and limitations of each device model
allowing choose the best set of characteristics depending on the
application and customer requirements. Thus, Table 1 intends to
condense the main ideas about all the developments made.
3. Conclusions
This study is proposing a novel technical device for new shearing
machines or machines already in service that will increase their
productivity. The device consists of a novel holder which can be
assembled in the back side of the shearing machines and, provided

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Fig. 19. Servo-pneumatic cylinder – intermediate position.

Fig. 20. Servo-pneumatic cylinder – final cutting stage.

Fig. 21. Servo-pneumatic cylinder – discharge position.

Fig. 22. Servo-pneumatic cylinder – rest position.

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Fig. 23. Servo-pneumatic cylinder – frontal discharge position.

Fig. 24. Option 3 – upper position and frontal discharge position.

Table 1 together or separately with the shearing machines.

Comparative table regarding the different options considered in this work.
• The final price of the system will be competitive, allowing strong
savings in finishing operations when cutting thin sheet metal plates.
Conventional
cylinders
Servo-
pneumatic
Mixed
solution • The problem of sheet metal deformation on the last portion of the
cylinders cut strip was eliminated, giving more profitability to shearing
Option 1 Option 2 Option 3 machines with this device. Furthermore, shearing machines produ-
cers have a new device to commercialize and the customers have a
Advantages Low cost Positioning Front
versatility extraction
new solution able to solve a systematic problem when cutting thin
High accuracy sheet metal plates.
Easy installation
Accurate
• The best achieved solution is based in four servo-pneumatic
cylinders, which allow a complete and coordinated movement of
following cutting
the holding system by adequate electronic control of the same. A
Front extraction
Limitations/ Positioning limitation High cost Positioning low-cost solution can be adopted, using conventional cylinders and
drawbacks Space available for limitation needing an accurate positioning control.
cylinders installation • All the solutions presented through this work are able to be used and
a prototype has been built using the low cost solution, proving that it
works very well, allowing different inclination speeds by program-
with four cylinders and a PLC (Programmable Logic Controller)
ming the control unit. The adjustment of the position is made in
properly programmed, allows a controlled movement of that holder
real-time by the control unit through a feedback position signal.
which will accompany closely the evolution of the shear blade during
the cutting process from one side to the other, avoiding deformations in
• The maintenance of the system was thought in order to keep it
simple;
the last portion of the cut strip when it is thin and wide. The following
conclusions can be drawn:
• This novel device will help ensure the parallel arrangement between
the front and the rear face of the cut metal strip which is the main

•
purpose of this work.
This technical device can be easily implemented in any shearing
machine, new or already in service, does not needing changes in the
general arrangement.
• This is an innovative system, able to be easily commercialized

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Acknowledgements
The authors would like to thanks ISEP – School of Engineering,
Polytechnic of Porto, due to their support and collaboration in this
work.
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