AUSTRIA, Gerwin Iver Luis

CALINTANG, Maria Angelica

ESPINOSA, Rech

MELOCOTON, Anthony

BETMxET 2B

Machine Tool Operations

TOPIC: SHEAR (Metal Sheet)

-----AUSTRIA-----

INTRODUCTION

Shearing is a process of cutting sheet metal to size using a specialized machine

with cutting blades that fracture the material into smaller pieces. This process provides
clean cuts that require no burning or melting of the material, making it ideal for materials
such as stainless or aluminum. Shearing processes are performed by applying a shearing
force with two tools, one above and one below the sheet, and the size of the clearance
between the tools varies depending on the specific project. Shearing is a fast and efficient
way to create a large volume of simple shapes.

WHAT IS METAL SHEARING?

Simply put, metal shearing is a finishing process that removes unwanted material
from sheet metal. It’s widely become the preferred process for major manufacturers due
to the ease with which it can be performed, and the lack of wasteful byproducts that it
produces.

UNDERSTANDING THE SHEARING PROCESS

 Shearing is performed by slicing through a piece of sheet metal with a blade that’s
most often affixed to a tool or machine. The location of the cut is controlled by a
squaring arm that allows a sheet of metal to be placed in a precise location.

Shearing - Separating material into two parts

-----CALINTANG-----

Types of Shear

1. Alligator shear
2. Bench shear
3. Throatless shear
4. Snips
5. Metal guillotine
 

Shearing tools and equipment play a critical role in the metal fabrication and

manufacturing industry. Naturally, there will be a variety of these devices that are suited for
different types of shearing functions for a smooth, accurate, and tight-tolerance finish. In this
guide, we’ll look into some of the most common types of shears used in sheet metal. While most
of them are capable of cutting different sheets of metal — be it aluminum, steel, or stainless
steel, these devices differ in the method of cutting and appearance.

Alligator Shear

The alligator shear is a hydraulic cutting machine used to cut prefinished long metal
stocks such as angle bars, rebars, I-beams, and L-beams. Its cutting motion is produced by a
piston that extends, causing the upper jaw to clamp down on the metal. While it is cost-effective
and widely used, it may produce inaccurate and rough finishes.
Bench Shear

Bench shears are powerful cutting tools that can be powered by hydraulic or pneumatic
energy. They come in various sizes, from small hand shears to electric shears with high power
and strength for cutting thicker, stronger metal stocks. These shears have a compound
mechanism that enables them to cut through different metal thicknesses and types, resulting in
rough or smooth edges, as configured by the operator. While larger bench shears can resist
increased material stress, they produce the same efficiency as smaller ones and are preferred over
alligator shears as they leave smooth and clean edges.

Throatless Shear

Throatless shears allow for intricate patterns and shapes to be cut from metal specimens,
unlike traditional shearing equipment which can only make straight cuts. Throatless shears do
not have a "throat" and allow for greater flexibility in moving the metal specimen around the
cutting blade. They are best suited for cutting thin and lightweight metals, but may not be
suitable for thicker materials which require a sharper cutting blade.

Snips

Snips are hand shearing tools that come in two forms: tinner snips and compound action
snips. Tinner snips are strong and can easily cut through mild steel or low carbon steel. They
come in different blade designs for straight or curved cuts. Compound action snips are used for
modifying aluminum, mild steel, or stainless steel. The blades in compound snips are linked
together to improve flexibility and mechanical advantages.

Metal Guillotine

A metal guillotine is a machine used to cut various thicknesses of metal. It consists of an

upper and lower blade, hydraulic pistons, compressors, a blank holder, and a clamp. Guillotine
shears have varying lengths and can cut through up to 30 mm of metal sheets. The upper blade is
tilted at an angle to accommodate curved and asymmetrical designs. Once cutting is complete,
the clamping unit ejects the precision-cut component from the machine.

-----ESPINOSA-----

CONCLUSION

Covered in this short guide are 5 of the most common types of shears used in sheet metal
fabrication. The alligator shear, for example, has a unique design that allows it to form rough
cuts on different metals. For cleaner looks and smoother finishes, other kinds of shears are also
available, such as the throatless shear, on the bench shear. Although each metal shear has its own
advantages and disadvantages, manufacturers understand when and where to use the correct
machinery to achieve a specific design. Nevertheless, these shearing devices remain an important
tool in the world of manufacturing and have benefitted a number of industries for many
decades now.

MAINTENANCE

The shearing process is needed in metal fabrication to achieve clean cuts and straight-
edged custom pieces. While the process can result in defects, these can be avoided provided that
you follow these recommended methods:

Know your machine — each shearing machine model will have different designs,
functions, and shearing ability. Operators must understand how their machine shears, and its
capacity for various sheet metals.

Inspect regularly — Shearing is a demanding job that causes wear and tear to the
machine’s parts. To reduce possible defects, regular inspection is a must. Look for any signs of
damage, lack of lubrication, and other factors that can contribute to faulty operations.
Sharpen your blades — to get the best shear quality, your machine’s blades must be properly set
and sharpened to process the workpiece. Make sure to always inspect the blades before starting
the shearing process.

Immediate repairs — when you spot defects or unusually sheared workpieces, stop the machine
immediately. Continuing to shear when the machine is defective can lead to further issues. Make
sure to perform troubleshooting and repairs quickly to prevent future issues.

-----MELOCOTON-----

PRECAUTIONARY MEASURES

Mechanical and hydraulic shears are heavy-duty pieces of fabricating equipment used by
many machine shops to, well, shear through sheet metal and other tough materials. As with any
fabricating machinery, it is extremely important to exercise proper shear safety when using these
machines.

Failure to take the appropriate shearing machine safety precautions can lead to time-lost
safety incidents in the workplace—ones that can permanently disable your workers. While there
is always an element of risk in operating any piece of heavy machinery, you can easily prevent
injury to workers and damage to your equipment by following a few simple shear safety rules,
such as:

   

1. Keep Your Metal Shear Well-Maintained

Keeping shearing machinery in good condition is crucial for safety. A quick inspection
of major components should be conducted before use to make sure they are not worn or rusted.
The specific components that need checking depend on the type of shearing machine. Hydraulic
shears, for example, require an inspection of hydraulic pistons.

2. Keep the Shop Well-Lit

 Proper lighting is important for hydraulic shear safety, as it helps prevent on-the-job
accidents and injuries. Energy-efficient LED lighting is a good solution, as it is brighter and lasts
longer than traditional lighting, saving money on lighting and requiring less frequent
replacement.

3. Familiarize Employees with the Shear

Even if a particular employee isn’t going to be operating the shear any time soon, it can be
helpful to familiarize them with the shear and how it works anyways. Giving workers a crash
course on basic shear safety rules (such as don’t go near the shear when the yellow lights are
flashing) can help to ensure that every employee is aware of the potential dangers of the shear. In
fact, you may want to do this for all of the fabricating equipment you use in your machine shop
for all employees as you onboard them.

4. Make Sure Employees Wear Proper Protection

It should go without saying that employees in a machine shop should wear proper protection at
all times—but failure to wear proper protection is a frequently-cited OSHA standard violation.
When working with shears, operators should wear gloves, goggles, boots, and thick clothing, at
the very least, to prevent injuries.

5. Make Sure Safety Signage is in Place and Readable

This is another frequently-cited OSHA violation (number two on the list, in fact). It’s easy to
neglect to take care of warning signage—after all, everybody knew what that faded sign said 10
years ago, surely everyone in the shop now knows it too, right? Unfortunately, you cannot rely
on everyone to pass down every bit of information from every warning sign posted on any of
your fabricating machinery. So, an important shearing machine safety precaution is checking all
of the OSHA-mandated signage on your shearing equipment every so often to make sure that:

 The signs are where they should be;

 Said signs are legible; and
 No signs are missing or damaged.

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