Minimizing Shearing Machine Blade Wear: Techniques and Tips

Shearing machine is one of the key equipment commonly used in metal processing. It can accurately cut metal sheets into parts of required sizes. However, the problem of shearing machine blade wear often plagues the production process, affecting production efficiency and part quality. This article will introduce some techniques and methods to help you minimize shearing machine blade wear and improve production efficiency.

Table of contents

1. Reasons for shearing machine blade wear

2.The impact of shearing machine blade wear on production

3. Identify shearing machine blade wear

4. Technologies and methods to reduce shearing machine blade wear

5.Conclusion

1. Reasons for shearing machine blade wear

shearing machine blade wear is caused by a combination of factors. Here are some common reasons:

Material properties:

1. 
   Uneven hardness: If the metal material being cut has uneven hardness, the blade may experience uneven wear.
2. 
   Material structure: The lattice structure of some metallic materials may make them more susceptible to wear, such as materials containing hard grains.

Processing environment:

1. 
   Temperature and humidity: High temperature and humid environments may cause oxidation and corrosion of the blade surface, exacerbating blade wear.
2. 
   Cutting speed: Too fast a cutting speed may cause the blade to heat up too quickly, causing accelerated wear.

Improper operation:

1. 
   Improper Cutting Angle: Incorrect cutting angles can cause additional stress on the blade and increase wear.
2. 
   Improper Blade Usage: Choosing an inappropriate blade type or specification may result in the blade being prone to wear or damage.

Blade design and material selection:

1. 
   Blade material: Choosing a blade material that is not suitable for a specific application may result in increased wear.
2. 
   Blade design: Improper blade design may cause the blade to be susceptible to stress concentration and increase the risk of wear.

2.The impact of shearing machine blade wear on production

Blade wear may have many impacts in metal processing production. These impacts are not only limited to a decrease in production efficiency, but also have a negative impact on part quality and production costs.

Production efficiency decreases:

1. 
   Slowed processing speed: A damaged blade will encounter greater resistance during the cutting process, causing the processing speed to slow down, thereby reducing production efficiency.
2. 
   Increased downtime: The need to frequently replace or adjust damaged blades will increase the downtime of the production line, affecting the execution of the production plan and production efficiency.

Decreased quality of parts:

1. 
   Poor surface quality: A severely worn blade may cause defects such as burrs and cracks on the cutting edge of the part, affecting the appearance and quality of the part.
2. 
   Dimensional inaccuracies: Blade wear will affect the accuracy of the cutting process, causing parts to have excessive dimensional deviations that do not meet design requirements.

Increased production costs:

1. 
   Blade replacement costs: Frequent replacement of damaged blades increases blade maintenance and replacement costs, as well as the cost of downtime.
2. 
   Increased scrap rate: Due to reduced part quality, the scrap rate may increase, increasing production costs and scrap disposal costs.

Decreased customer satisfaction:

Extended lead times: Reduced productivity and increased scrap rates can lead to longer lead times, reducing customer satisfaction and trust.

3. Identify shearing machine blade wear

The most important thing is to be able to identify if the shear blades are worn. Here are some tips and tricks to help quickly identify if your blade is worn.

Observe surface wear:

1. 
   Blade edge wear: Observe the cutting edge of the blade. If there is obvious wear or chipping on the edge, it indicates that the blade has been severely worn.
2. 
   Surface smoothness: The surface of a damaged blade usually loses its original smoothness, showing obvious signs of wear or unevenness.

Check cut edge quality:

1. 
   Burrs and cracks: Observe whether there are burrs, cracks, deformations and other defects on the cutting edge. These are signs of blade wear.
2. 
   Cutting force: If the cutting force needs to be increased or abnormal sounds are produced during the cutting process, it may be caused by blade wear.

Monitor abnormal phenomena when the blade is running:

Vibration and Noise: Damaged blades may cause abnormal vibration and noise when the shear is running, and these phenomena need to be identified and resolved promptly.

Observe surface wear:

1. 
   Blade edge wear: Observe the cutting edge of the blade. If there is obvious wear or chipping on the edge, it indicates that the blade has been severely worn.
2. 
   Surface smoothness: The surface of a damaged blade usually loses its original smoothness, showing obvious signs of wear or unevenness.

Check cut edge quality:

1. 
   Burrs and cracks: Observe whether there are burrs, cracks, deformations and other defects on the cutting edge. These are signs of blade wear.
2. 
   Cutting force: If the cutting force needs to be increased or abnormal sounds are produced during the cutting process, it may be caused by blade wear.

Monitor abnormal phenomena when the blade is running:

Vibration and Noise: Damaged blades may cause abnormal vibration and noise when the shear is running, and these phenomena need to be identified and resolved promptly.

4. Technologies and methods to reduce shearing machine blade wear

After identifying blade wear, you must also learn to take measures to reduce blade wear. Here are some commonly used methods.

Optimize cutting process parameters:

1. 
   Adjust cutting speed and pressure: Adjust cutting speed and pressure according to the hardness and thickness of the material to avoid excessive wear on the blade.
2. 
   Control the cutting angle: Choose an appropriate cutting angle to avoid unnecessary additional stress and friction on the blade.

Choose the right blade material and coating:

1. 
   Blade material selection: According to the characteristics of the processing material and processing requirements, select the appropriate blade material, such as high-speed steel, carbide, etc.
2. 
   Coating technology: Use advanced coating technology, such as TiN coating, TiCN coating, etc., to enhance the wear resistance and corrosion resistance of the blade.

Enhance blade care and maintenance:

1. 
   Regular cleaning and lubrication: Clean the blade surface regularly and replenish lubricant in time to reduce the friction between the blade and the processing material and extend the blade life.
2. 
   Check and adjust the blade: Check the status of the blade regularly, and adjust the position and gap of the blade in time to ensure the normal operation of the blade.

Use assistive devices and tools:

Cooling system: Install an effective cooling system to cool the blade and processing area in time to reduce heat and wear of the blade.

5.Conclusion

Through this in-depth exploration of this article, we detail ways to identify shearing machine blade wear as well as techniques and methods to reduce wear. The wear problem of shear blades will not only affect production efficiency and part quality, but also increase production costs and work pressure. However, by optimizing process parameters, selecting appropriate blade materials and coatings, and strengthening blade care and maintenance, we can effectively reduce blade wear and improve production efficiency and part quality.

As a manufacturer of professional shears for 25 years, KRRASS provides high-quality shear blades, and our experts provide guidance to help you use the shear better. If you need it, please contact us.