1. Equipment and tool preparation: Ensure a solid foundation
Tool condition (the most crucial!)"
Sharpness of the cutting edge: This is the primary condition for eliminating burrs. Use high-chromium alloy steel or tungsten carbide blades specially designed for stainless steel. The cutting edge must remain mirror-like sharp without any microscopic chipping. The cutting edge must be inspected immediately every 8 to 10 hours of continuous cutting or when a decline in quality is detected.
Cutting edge Angle: Usually, a smaller rake Angle (such as 1°-2.5°) is adopted to enhance the strength of the cutting edge and resist the work hardening of stainless steel.
Tool clearance: It must be precisely set! For stainless steel, the recommended single-sided clearance is 7% to 12% of the plate thickness (for example, for a 3mm plate, the clearance is approximately 0.2 to 0.36mm). Too small a gap can lead to excessive wear of the cutting tool and secondary shearing. Excessive gaps can cause the material to tear and produce large burrs.
Tool parallelism: Use a feeler gauge to conduct multi-point checks throughout the entire length range of the upper and lower blades to ensure that the parallelism error is less than 0.02mm.
Machine status
Hydraulic system pressure: Maintain stable and sufficient pressure to ensure no pressure fluctuations throughout the shearing process, preventing weak shearing due to insufficient pressure and the formation of burrs.
Machine tool rigidity: Inspect the machine tool guide rails, cylinders and frames to ensure there is no vibration or deformation when shearing high-hardness stainless steel.
2. Cutting process parameter setting: Precisely control the process
Precise measurement of plate thickness: Stainless steel plates often have positive and negative tolerances, and the gap must be adjusted based on the measured thickest part.
Set the shear Angle: For thicker stainless steel plates (such as >6mm), a smaller shear Angle (1°-1.5°) should be appropriately used to reduce distortion and edge load, but it will increase the shear force.
Optimize the pressing force: Significantly increase the pressing force to ensure that the sheet is firmly fixed during the shearing process, preventing it from sliding or lifting. This is the key to avoiding tearing.
Control the shearing speed: Use medium and low speeds and uniform shearing. The impact heat generated by high-speed shearing can intensify work hardening and may affect the "fit" between the cutting tool and the material.
3. Operation and Maintenance Skills: Details determine success or failure
Sheet processing: Clean the surface of the sheet, remove hard substances such as oxide scale and sand particles to prevent damage to the cutting edge.
Trial cutting and inspection: Before formal cutting, it is essential to conduct a trial cutting. Inspect the cutting surface
Ideal state: The bright zone should occupy 1/3 to 1/2 of the plate thickness, and the fracture zone should be smooth and flat without burrs.
Fine burrs: Usually indicate that the cutting edge is beginning to become blunt or the gap is slightly larger.
Large, tearing burrs: This indicates excessive clearance, a dull cutting edge or insufficient clamping force.
"Step-by-step" wear management: Do not wait until the blade is completely out of order to replace it. Adopt the strategy of turning around and changing edges to fully utilize all cutting edges. Establish detailed records of tool usage.
Lubrication: It is strongly recommended to use a dedicated stainless steel shearing lubricant. It can reduce friction, lower temperature, delay tool wear and improve the quality of the shear surface. Just apply it to both sides of the cutting line.
4. Emergency plan for burr treatment
Even if the parameters are perfect, tiny burrs will still appear as the tool wears out. For workpieces with extremely high requirements
Minor burrs: They can be removed manually using a deburring scraper or a scouring pad.
Process permitting: A light edge scraping or vibration grinding process can be added after shearing.
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