Keeping your Shear Blade in Top Shape
Pro Tips on Keeping your Shear Blade in Top Shape
For fabricators, the shear is one of the most important and diverse tools in metal fabrication. To improve the uptime and reduce maintenance costs, here are some tips on how you can keep your shear blade in top shape.
Take time to Understand Your Machine
It is important for a fabricator to understand the functions, design and the operation of each machine. The main cause of shear failure is overloading it beyond the OEM’s parameters. Shears are designed to cut metal, depending on its thickness and width. Going beyond the recommended limits can damage your machine and shear blade.
Standard adjustments and maintenance should be attended to every day. Manufacturer recommended service requirements should also be followed. Lubrication and fluids should also be used in accordance with manufacturer’s instructions to avoid damage.
Regular Inspection and Documentation
Scheduled downtime maintenance should also be a priority in order to check the machine over once in a while. The ability of the shear to execute all the functions during operations should be tested, all bearings should be checked for wear and all emergency and safety functions of the machine should be examined.
After the inspection, documentation should also be written and examined. Documentation can reveal patterns and potential problems so that immediate repair can be made by an expert. Documents can be analyzed to prepare a preventive maintenance plan to eliminate the requirement for emergency repairs in the future.
Set the Blade and Clearance Properly
Make sure that the blade is properly set before you start your process. Setting the shear blade properly is the key to extending the blade’s life and machine efficiency. Set proper clearance to ensure proper cut quality. Before setting the blade, check the blade seat is flat to ensure that the tooling is set properly to eliminate blade chipping during shifting.
Clearance is also important for blades. If the clearance is too high, metal jams between the blade and machine. If the blade has no clearance at all, it will break. Setting the clearance are too loose will cause premature wear and failure.
Basic Maintenance Plan
Here are some of our recommendations for your basic maintenance plan:
The Air system should be properly maintained to ensure clean air. Regulators should also be maintained to help the pneumatic mechanism to properly function.
Lubrication should be checked before you begin operation. The lubrication system should be cleaned, filled and properly filtered.
Machine clutch and brakes must be examined for lining, thickness, clearances and signs of failure. If these are worn out, they should be replaced immediately to avoid costly repairs.
Air leaks or failure on the counterbalance cylinders should be dealt with immediately.
Call in the experts quickly if you find unusual wear or need for adjustment. Disastrous failures often start with little problems that are ignored. Addressing these problems quickly is less expensive in the long term.