CNC shear machines are essential equipment in metal fabrication factories, used to cut sheets into desired sizes. Accurate cutting is crucial for quality fabrication. And that’s why shearing machines must be calibrated regularly. Calibration ensures that the machine operates at its optimal performance, providing accurate and consistent cuts. In this blog, we will discuss the steps involved in calibrating a shearing machine.
Step 1: Clean CNC Shear MachineNS
Before beginning the calibration process, it is important to ensure that CNC shear machines are clean and free of any debris or dust. This will ensure that the calibration process is accurate and precise.
Step 2: Check CNC Shear Machines Blade
The blade is the most important component of the shearing machine, and it is crucial that it is in good condition. Check the blade for any nicks, cracks, or signs of wear and tear. If there are any issues with the blade, it must be replaced before proceeding with the calibration process.
Step 3: Verify The Material Thickness
Measure the thickness of the material you will be cutting and compare it to the machine’s specifications. If the material is thicker than what the machine is designed to handle, it may result in inaccurate cuts.
Step 4: Check The Blade Gap
The blade gap is the distance between the upper and lower blades when the machine is in the open position. To check the blade gap, turn off the machine and remove any material from the cutting area. Then, use a feeler gauge to measure the clearance between the upper and lower blades.
The ideal blade gap will depend on the thickness of the material being cut. As a general rule, the blade gap should be 0.1mm to 0.4mm for materials up to 3mm thick, and 0.4mm to 0.8mm for materials up to 6mm thick. If the blade gap is not within the recommended range, it will need to be adjusted.
Step 5: Adjust The Blade Gap
To adjust the blade gap, turn off the machine and loosen the bolts that hold the upper blade in place. Then, use shims to adjust the clearance between the upper and lower blades. Once the desired blade gap has been achieved, tighten the bolts to secure the upper blade in place.
Step 6: Check The Blade Angle
The angle of the blade is another important factor in achieving accurate and precise cuts. To check the angle of the blade, turn off the CNC shear machines and remove any material from the cutting area. Then, use an angle gauge to measure the angle of the blade.
The ideal angle of the blade will depend on the material being cut. As a general rule, the blade angle should be between 1 and 3 degrees for materials up to 3mm thick, and between 3 and 5 degrees for materials up to 6mm thick. If the blade angle is not within the recommended range, it will need to be adjusted.
Step 7: Adjust The Blade Angle
To adjust the angle of the blade, turn off the machine and loosen the bolts that hold the blade in place. Then, use a protractor or angle gauge to adjust the angle of the blade. Once the desired angle has been achieved, tighten the bolts to secure the blade in place.
Step 8: Verify The Cutting Accuracy
Run a test cut on a scrap piece of material and measure the cut with a micrometer. Compare the measurement to the desired specifications to ensure that CNC shear machines are cutting accurately.
Step 9: Adjust As Necessary
If the machine is not cutting accurately, adjust the blade gap or other settings as needed and retest until the desired accuracy is achieved.
Step 10: Check The Cutting Speed
The cutting speed determines how quickly the material is cut. Adjust the cutting speed according to the material being cut, the blade clearance, and the blade angle.
Step 11: Check The Back Gauge
The back gauge is the component that controls the distance between the blade and the backstop. To check the back gauge, turn off CNC shear machines and remove any material from the cutting area. Then, use a ruler or tape measure to measure the distance between the blade and the backstop.
Step 12: Adjust The Back Gauge
To adjust the back gauge, turn off CNC shear machines and loosen the bolts that hold the backstop in place. Then, use a ruler or tape measure to adjust the distance between the blade and the backstop. Once the desired distance has been achieved, tighten the bolts to secure the backstop in place.
Step 13: Test CNC Shear Machines
Once the machine is calibrated, test it by cutting a test piece. The test piece should be the same material and thickness as the workpiece to be cut. Measure the cut piece using a precision measuring tool to verify its accuracy. If the cut is not accurate, recheck the calibration and make necessary adjustments.
Step 14: Repeat Calibration
Calibration is not a one-time process; it must be repeated regularly. Regular calibration ensures that the machine is operating at optimal performance and producing accurate cuts consistently. The frequency of calibration depends on the usage of the machine, but it should be calibrated at least once a year.
Step 15: Document The Settings
Once you have calibrated CNC shear machines, document the settings so that they can be used for future reference. This will save time and ensure that the machine is always calibrated correctly.
By following these steps, you can calibrate CNC shear machines and ensure their accuracy and precision in cutting materials. In conclusion, calibration is essential for achieving accurate cuts on hydraulic shearing machines. Regular calibration ensures that the machine is operating at optimal performance and producing consistent results. Following these steps will help you calibrate your shearing machine and achieve accurate cuts. Always refer to the machine manual for specific instructions and guidelines.