Cutting sheet material into pieces is carried out using various tools. Roller shears for sheet metal cutting are popular, a trend due to their simple design and high productivity. The device is used in industrial and small workshop environments.
Characteristics of scissors
The intended purpose of roller knives is to cut steel sheets up to 1 mm thick. They are necessary at the site for the production of ventilation ducts, when working with roofing metal, during the construction of a fence and arrangement of the roof.
The mechanism is used to produce semi-finished products for subsequent bending of profiles for various purposes. The equipment is installed in car body repair shops. In auxiliary production, blanks are prepared for the assembly of racks and cabinets.
Scissors with rollers will successfully replace manual option or guillotine due to a number of advantages:
- Compact dimensions and light weight.
- Simple device.
- Convenient to use.
- Just getting set up.
- Suitable for working with sheets of different materials: aluminum, tin, steel, roofing iron.
The processed product is obtained with a clean cut and no burrs or bends. Leaf view It is easy to cut metal with such a device.
Scissors can be purchased at a specialized store or made independently. It all depends on the volumes performed and the economic component. With a daily cutting rate of 30–50 meters or more, an industrial design will be required.
Description of scissors
The task of dividing a sheet of metal into parts is solved by destroying the strength bonds on a local segment.
The power part consists of two cutting roller discs with multidirectional rotation. Their cutting edges lie in the same plane. When rotating, the rollers are pressed into the surface and cutting occurs due to shear deformation. Innings sheet stock on the tool occurs through the friction of knives on metal.
The design of the cutting mechanism includes two rotating rollers located one above the other. Depending on the design of the cutting part, roller knives are distinguished:
- With one inclined edge for straight longitudinal cutting and cutting out round and ring workpieces.
- With parallel position of knives, cutting material in strips with high quality. They occur most often.
- With several inclined edges for convenient cutting of curved, round and ring-shaped workpieces with a small radius.
All types of scissors provide cutting of sheet material with high quality, without the need for subsequent cleaning of the cut edge.
To increase productivity and obtain an even cut, the housing with roller knives is installed on a stationary machine.
The cutting equipment includes a bed with supporting surfaces, equipment for fixing the material and a roller knife. The latter contains a body made of steel gauge, an overhead handle, cutting rollers, and a mechanism for adjusting gaps in several planes.
The material for cutting discs is tool steel.
The manufacturer sets an average service life of 25 km to cut sheet metal with a thickness of 0.5 mm. With increasing thickness, the service life decreases proportionally. The cutting element is subject to regrinding, which significantly increases the service life.
How to make a roller knife
A purchased model of roller shears, even of the simplest design, is unprofitable for purchase in a small workshop or private household. It is not necessary to use it often, and the device is expensive. The optimal solution is making scissors with your own hands.
The design of the mechanism may be different, but at the core there will always be a cutting knife in the shape of a roller. The selected material for making knives determines the performance of the device and the quality of the cut. Knives must be strong and reliable, with a surface hardness significantly greater than the hardness of the material being cut. Otherwise, you won’t get a high-quality cut; the edges will have to be processed additionally.
Homemade roller knives are made from bearings. To do this, the ends are sharpened to create a cutting edge. The drive roller is mounted on the handle. When working with it, the knife is pressed into the workpiece. The lower roller is installed permanently. During the cutting process, you need to press the handle with the roller with one hand and pull the sheet of metal with the other.
Selecting a larger bearing diameter will increase cutting speed.
For convenience and precise cutting, additional guides are installed.
Adjustment is carried out using oval holes, a set of spacers and special bolts.
If you are proficient in metalworking techniques, manufacturing a cutting device takes 7–10 days, including setup.
The canning industry is gaining momentum, supplying the market with countless amounts of agricultural canned food. Tinplate ensures reliable safety of food products. Obtaining quality raw materials for business promotion has important. Cutting sheet metal ensures the production of various packages, containers, containers, etc. The Tinplate-Service company is ready to offer the best services.
Types of cutting tinplate
Sheet metal cutting can be done in two main ways: manual and automatic. Manual method aimed at cutting strips, blanks along the contour, grooves using scissors or hacksaw machines. This process is very labor-intensive and takes a lot of physical effort. When cutting, you should follow safety precautions to avoid getting splinters in your eyes.
Cutting on automatic lines is a priority and more in demand. The equipment consists of several devices:
- Serving;
- Unwinding;
- Cutting block;
- Control panel.
All operations are carried out automatically without the involvement of workers, which is very convenient. Only one operator controls. After cutting, finished blanks are stacked in packs of up to 2 tons and sent to wholesale and retail customers.
Blanks and figured cutting of sheet metal
We supply sheet metal various types, with increased requirements, varnished and lithographed. There are sheets cut according to prepared designs and sizes. Bottoms and lids are then made from these templates. Thanks to blanks with figured cuts, you can get an economical product. This method is more convenient and more profitable than purchasing in rolls. You can order cutting of sheet metal of various formats from us. We will carry out cutting to cut metal of certain sizes and thicknesses, according to individual requests.
Advantages of purchasing from Tinplate-Service
We will fulfill orders in Moscow and other CIS cities. Cooperation with our organization will leave positive points aimed at partnerships. Profile equipment, the presence of a high-speed cutting line, machines, and figured knives allow us to fulfill orders of complex configurations of any volume. We value our clients and provide quality services. With us you will receive benefits:
- Low prices;
- We sell tin in sheets;
- Varnishing and lithography in the shortest possible time;
- Material efficiency with correct cutting is up to 15%;
- Prompt delivery;
- Special offers, discounts;
- Quality guarantees.
The company's priorities are aimed at improving service, promoting latest technologies, with the help of which wastelessness is achieved. Reducing production surplus reduces financial costs and helps our customers grow their businesses.
Cutting metal at home is a rather tedious process. And its quality often leaves much to be desired, forcing additional processing of the resulting edges. The situation can be corrected in many ways by using special devices, including those made by yourself. We will talk about one of these devices, namely the roller knife, today.
Roller knives for metal
The roller knife is gaining more and more demand and popularity today. This is not only due to high productivity similar device, but also with a fairly simple structure. The principle of operation of the mechanism is simple - two cutting disc rollers rotate in different directions, pressing into the surface of the metal and thus cutting it. Friction between the metal and the knives ensures unhindered movement of the workpiece along the tool.
In the vast majority of cases, roller knives for cutting sheet metal include two rotating rollers - an upper and a lower one. Depending on the variation of the cutting element used, such tools can be classified as follows:
- Parallel position knives - used for cutting metal into strips, while providing very acceptable quality;
- Edges with one slope - this group allows not only longitudinal cutting of material, but also cutting out ring and round workpieces;
- Knives with several inclined - such devices make it possible to effectively cut round, curved or ring-shaped workpieces with a small radius.
It is worth noting that all of the above variations cope perfectly with cutting sheet steel, while the cut edges do not require additional attention and subsequent processing.
Homemade roller knives
With all its undoubted advantages, even the most simple model A roller knife has a pretty decent price. This is the reason why it is inappropriate to purchase it for one-time work or periodic use. However, the optimal solution from a financial point of view still exists - a roller knife can be made with your own hands at home.
The design of such a device can be very different. The most common variations are presented below (photo, photo 2). But in any case, the main part remains unchanged - the cutting knife. It should be made from the most durable and reliable steel alloy, the strength parameters of which must necessarily exceed those of the material being cut. If this condition is not met, the quality of the cut will be low, which will require additional processing of the cut edges.
Practice shows that the working life of factory-made knives is about 25 km of sheet steel, provided that its thickness is 0.5 mm. With greater thickness, the resource will be correspondingly lower. However, the tool can be sharpened without any problems and continue to function effectively.
If we talk about the resource homemade knives, then it is directly dependent on the material from which the cutting parts of the unit are made.
What can a knife be made from?
The options can be very different; here you need to pay attention to what exactly you plan to cut. So, if it is not the most durable sheet steel in its structure, including aluminum, galvanized metal and other similar materials, the most ordinary bearings will be a completely suitable solution. True, for this you will have to pre-sharpen their ends.
To carry out cutting, one of the rollers, the one that will play the role of a drive, is installed on the handle, due to which the knife will be pressed to the metal. Please note that the larger the diameter of the bearings, the faster the material can be cut.
In order for the cutting process to take place with maximum comfort and precision, the device can be additionally equipped with guides - this will not be particularly difficult, but it is guaranteed to serve you well in the future.
The resulting tool is quite versatile and can be used in conjunction with a wide variety of metalworking equipment, including sheet metal bending machines, which can also be made independently at home.
DIY roller knife for sheet metal - homemade instrument, the demand for which is growing every day, which is explained by the productive speed of work similar device and its simple design. The mechanical basis is extremely simple, and is based on two metal knives rotating in opposite directions, pressing into the steel plane of the workpiece, which leads to its cutting.
The classic design involves the installation of rotating disks at the top and bottom, classified according to the material of manufacture:
- Parallel roller knives - used for cutting steel sheets into strips, while maintaining good quality blanks.
- Roller knives with one inclined edge - this design, in addition to slicing, allows you to cut workpieces with rounded shapes.
- Roller knives with multiple slanted edges - maintaining a small radius helps produce parts with curved lines and rounded shapes.
Design
Roller metal shears, assembled at home with your own hands, have a common essence that remains unchanged - the presence of a cutting knife. It is made from steel alloys with a maximum strength threshold and other characteristics that should be higher compared to similar parameters for steel that will be processed on a cutting machine.
In practice, it is known that roller knives for cutting metal produced at the factory have a service life of about 30 km of steel sheets, with a caveat to the maximum sheet thickness, which will not exceed 0.5 mm.
Accordingly, if the thickness of the material is higher, then the durability of the tool is reduced. However, nothing prevents you from sharpening the tool and thereby extending its service life.
Required materials
A machine for cutting sheet metal, constructed with your own hands at home, requires knives, the range of materials for which is very wide, and the choice of one of them mainly depends on the type and thickness of the material that will need to be cut. If you have to work with not the most durable, thin sheet steel, such as aluminum, then ideal option the simplest bearings will become. But for the required functionality of a roller knife, they lack sharpening, which should be carried out independently along the entire end of the future tool.
The main roller knife is installed on a movable part of the structure with a pressure handle, which, when pressed, clamps the workpiece between two cutting surfaces. The diameter of the bearings directly affects the speed of work performed. That is, the larger the bearing diameter, the higher the production speed on the machine.
To simplify the work with the tool and make it more convenient, it would be nice to equip the sheet cutter with a guide plane.
The manufacture and installation of this part is not very difficult, and in return it will greatly simplify the entire process. The output is universal machine with roller knives, which can interact with other metalworking equipment, which can also be easily constructed at home.
Manufacturing instructions
Factory models of cutters sold in stores, even in standard configuration, will cost a large amount. The price of models offered on the market starts from 20,000 rubles. Such conditions are not beneficial in purchasing tools for home use or in a small workshop, and it will be used extremely rarely.
To begin with, the main body of the instrument is designed, which everyone chooses for themselves. The main attribute of the machine is manufactured - a roller knife for sheet metal. The material from which the part is made directly affects the durability and performance of the unit. As mentioned above, the strength characteristics should be significantly higher than the similar characteristics of the material being cut. Otherwise, the minimum problem will be a low-quality cut, forcing the craftsman to clean and process the edges of each cut piece.
Do-it-yourself roller metal shears are mostly made from bearings. Sharpening the ends of the part forms the cutting surfaces. The main roller, connected to the drive, is attached directly to the handle. The lower one is installed on a stationary bottom part machine If you have skills in processing iron alloys, manufacturing such a device will take a maximum of a little more than a week, including setting up the unit.
Features of cutting metal at home
Circular knives are an excellent replacement for metal shears, having a number of advantages:
- Small dimensions and dimensions.
- Simplicity of design.
- Easy adjustment.
- Convenience and ability to work with a wide range of materials.
Do-it-yourself sheet metal cutting at home is usually done with cutters or drills. Of course, this approach helps to give the part the desired shape, and at the same time polish the surface. However, it will be much more practical to construct a machine with roller knives with your own hands once (unless, of course, we are talking about cutting scrap metal, since accuracy is not so important there), thereby reducing both the time allotted for processing and minimizing the amount of debris and defects that may occur when using hand tools. To put it simply - disc knives perfect replacement metal shears and even an industrial guillotine.
To everyone industrial enterprise or an individual who is engaged in metalworking requires a metal cutting machine that meets specified requirements for cost, productivity and safety. Today they highlight large number different methods of metal processing - metal processing with plasma, laser and pressure, as well as manual cutting metal with scissors. If you haven't decided yet optimal method and suitable equipment for cutting metal, our article will help you do this.
Types of metal cutting
The process of cutting metal is the separation of workpieces from cast, long or sheet metal. The most common and economically effective methods today are plasma, laser and gas cutting. Very often, metal is cut with press shears, which are capable of punching grooves and holes of various shapes in steel of various strengths.
When choosing one metal processing method from those listed above, it is recommended to focus on the quality of the work process itself, the amount of final waste and the accuracy of execution. An important point There is also the possibility of creating a small batch of parts in the most compressed lines with optimal price cutting in specialized industries.
Moreover, the choice of one of them is justified taking into account certain criteria, such as work efficiency, final result, and cost of the product. At the same time, there is a certain list of metals and alloys with which it is advisable to work with one or another equipment.
Gas metal cutting
Gas cutting is a process of cutting metal products, which is based on the property of metals that are heated to a certain temperature (1200-1300 degrees) to burn in pure oxygen. Thanks to gas cutting of sheet metal, nowadays it is possible to carry out a wide variety of types of processing - preparation of edges for the welding process, straight cutting of metal, bevel cutting procedure.
The essence of technology
It is customary to start cutting from the edge of the sheet. The surface intended for cutting must be cleaned of rust, scale and dirt. Oxygen and gas are supplied to the burners from cylinders, where they are kept in a compressed state. The mass of one cylinder is 70 kg. The working pressure of oxygen per square meter is 300 kN, and that of gas reaches 50 kN.
In this case, the pressure can be adjusted in the device’s reducer, which is screwed onto the fitting of the oxygen cylinder. The gearbox is equipped with a pressure gauge high pressure, which shows the oxygen pressure in the cylinder and is also equipped with a low pressure gauge, which provides information about the operating pressure.
The metal sheet is burned and cut by a stream of oxygen, which is supplied under high pressure. The resulting iron oxides flow out in a molten state and are blown out of the cut cavity. The technology of gas cutting of metal involves the use of a cutter, which is a kind of welding torch with a special device for supplying oxygen.
Types of gas cutting
This type of welding traditionally uses hydrogen (coke, petroleum and natural) and acetylene, kerosene and gasoline vapors, which can reach temperatures of 3200 degrees during the combustion process. Depending on the combustible gas used, hydrogen-oxygen, acetylene-oxygen and gasoline-oxygen cutting are distinguished, as well as machine and manual cutting.
A separate type of gas cutting is flux-oxygen cutting, which makes it possible to separate difficult-to-cut metals - chromium-nickel and high-chromium steels, aluminum alloys and cast irons. In this case, the procedure is facilitated by powdered fluxes, which are injected together with oxygen.
In addition to separation oxygen cutting, when the cutting jet is almost perpendicular to the metal surface, oxygen processing is used, during which the cutting jet is directed to the metal surface at an acute angle.
This method is used to cut sheets of carbon medium- and low-alloy steels, which have a thickness from 1 to 200-300 millimeters. In the video about gas cutting of metal, you will see that gas cutting of steel thicker than 2 meters is considered possible. Oxygen cutting is widely used in non-ferrous and ferrous metallurgy, as well as in private construction.
Requirements
To complete this process, a number of requirements must be met. Remember that the metal must have a higher melting point than the combustion temperature in oxygen. On the contrary, metal oxides must have a melting point lower than the melting point of the selected metal.
Ensure that the thermal exposure level is sufficient to ensure continuity of the cutting process. The metal being processed should not have too high thermal conductivity, otherwise thermal energy will be quickly withdrawn. According to these criteria for gas cutting, low-carbon and low-alloy steels and iron are ideal for this procedure.
Advantages of gas cutting
The main advantage of gas metal cutting is the ability to cut metal sheets that are thick - up to 200 millimeters. In this case, the cutting width is 2-2.5 millimeters. Using equipment for gas cutting of metal, you can make a vertical cut edge, which will not be hardened during the process.
One cannot help but recall the economic efficiency of this technology - gas cutting does not require large financial investments. The minimum requirements associated with technical maintenance process. Undoubted advantage gas welding metal is also the fact that it does not require any mechanical processing.
Plasma cutting of metal
Cutting metals using a plasma jet instead of a cutter is called plasma cutting. The plasma flow is formed as a result of blowing compressed electric arc a gas that is heated and ionized in the process - breaks up into positively and negatively charged particles. The plasma flow usually has a temperature of close to 15 thousand degrees Celsius.
Plasma cutting methods
There are surface and separation plasma cutting. However, in practice, it is the separation technology of metal cutting that has become widely used. The cutting process itself is carried out using two methods - plasma arc and jet.
When cutting metal with a plasma arc, it turns on electrical circuit. The above-mentioned arc occurs between the workpiece and the tungsten electrode of the cutter. If you chose the second method, then remember that in the cutter an arc is formed between two electrodes. The sheet being cut is not included in the electrical circuit.
By performance plasma cutting superior to oxygen. But if you need to cut titanium or thick metal, it is recommended to give preference to oxygen cutting. When cutting non-ferrous metals, plasma cutting is considered indispensable. This is especially true for aluminum.
Plasma cutting machines
To form plasma, it is customary to use active and inactive gases. The first group includes air and oxygen, which are used when cutting ferrous metals (copper, steel and aluminum), and inactive ones - hydrogen, argon and nitrogen for cutting alloys and non-ferrous metals (high-alloy steel, which has a thickness of up to 50 millimeters, brass, copper , aluminum and titanium).
To mechanize the procedure, metal cutting devices were developed - semi-automatic and portable machines of various modifications. Semi-automatic machines work with inactive and active gases, while portable machines use exclusively compressed air.
Metal cutting with plasma at home is carried out using hand-held devices, the set of which includes a cutting plasma torch, a manifold, a cable-hose package and a lighter designed to excite the cutting arc. Such kits allow you to perform a limited amount of work with equipment utilization of no more than 50%. Therefore, it is recommended to equip them with welding converters and rectifiers during operation.
The essence of technology
The beginning of the metal cutting procedure is the moment when the plasma arc is excited. Having started cutting, you should maintain a constant distance between the metal surface and the plasma torch nozzle, which is 3 - 15 millimeters.
Strive to ensure that the current is minimal during operation, because as the current increases and the air flow increases, the service life of the electrode and plasma torch nozzle decreases. But the current level should ensure high cutting performance. The most difficult operation is punching holes, since a double arc may form and the plasma torch may fail.
Remember that the tool for cutting metal when punching should rise above the surface of the part by 20 - 25 millimeters. The plasma torch is lowered into the working position after the sheet is pierced through. If you are punching holes in sheets that are thick, it is recommended to use protective screens that have holes with a diameter of 10-20 millimeters. Screens must be placed between the plasma torch and the product.
When cutting aluminum using an argon-hydrogen mixture to increase the stability of the arc, the hydrogen content should not exceed 20%. Copper cutting is usually performed using hydrogen-containing mixtures. Brass needs a nitric oxide mixture or nitrogen. After cutting, copper must be cleaned to a depth of 1-1.5 millimeters. But this requirement is not at all necessary for brass.
Laser cutting of metal
Laser cutting is a fundamentally new type of metal processing, which is characterized by extremely high accuracy and productivity. Such cutting machines have revolutionized the world of metalworking, making it possible to create complex metal structures simpler, faster and more affordable. Laser cutting is now confidently replacing other types of processing of metal workpieces and is becoming increasingly popular.
The essence of technology
Do-it-yourself metal laser cutting technology today is one of the most advanced technologies in creating various parts from sheet materials. The procedure is good for its versatility, because it allows you to work with any materials - metallic and non-metallic in origin.
The laser beam is a narrowly directed light beam of small diameter, which has high intensity. If the laser beam is aimed at metal surface or other solid object, the product will heat up to high temperature. It is enough for the metal to begin to melt at the point of contact. But at the same time, the surface areas that are adjacent to the beam remain hot, but are not damaged.
By moving the beam along the surface, you can create a very thin, high-quality line of cutting metal with perfectly thin edges, despite the thickness of the metal being processed. The area of the laser beam that hits the plane is literally calculated in square microns. But at the same time, during laser cutting, the energy density that is directed to the metal is excessively high, which causes the appearance of a heating area.
As a result, the metal melts locally, which is accompanied by the removal of molecules of the substance. Laser cutting machines are conventional coordinate tables, which interface with the head, which is controlled by the microprocessor of the machine and which moves according to a given program over the surface of the sheet being processed.
Laser cutting machines for special purposes can be produced; for example, laser cutting machines for pipes have become popular recently, which are suitable for any profiles. In this case, you can carry out processing along the entire length of the part at once. That's enough effective method, which provides tight control of cutting geometry when using a laser machine.
Advantages of laser technology
To the undoubted advantages laser technology include:
- complete absence of physical deformations and defects during operation of the machine;
- the ability to operate the machine with ductile metals;
- absence on the surface finished product microcracks;
- precision processing accuracy of a laser machine;
- high speed;
- small cutting thickness;
- waste-free machine;
- high level of automation of the laser cutting process;
- reasonable cost of metal cutting.
Using laser cutting
Work for laser machine occurs by burning sheet material through a laser beam. Due to the absence of direct contact between the part and the cutting head, the equipment allows you to safely process fragile products, successfully cope with carbide material, and easily provide high-speed cutting of thin sheet steel.
The technology is also considered beneficial in situations where products are produced in small batches, because the costs of producing expensive casting molds are eliminated. The equipment is capable of handling steel of any condition and quality; it works well with aluminum, aluminum alloys, copper, and brass.
A very significant nuance of this technological process simplicity in relation to working with flat and volumetric parts, as well as complex contours.
Laser cutting is one of the technologies in which the cost of the product when creating complex products almost does not depend on the size of the batch that is processed by the machine. That is why laser cutting technologies are widely used in private construction and household, while the time until the final result is obtained is minimal.
Guillotine metal cutting
For high-quality and fast cutting of metal, special sheet shears - guillotines - are used. The name of such metal-cutting machines comes from the similarity of the work of scissors with medieval weapon executions. But today guillotine shears are used for harmless purposes.
Selecting sheet shears
The main criteria for choosing a guillotine are the type of production: piece or serial, the thickness of the metal sheet, the length of the metal slitting line and mechanical strength. Consumers, depending on their goals, can choose simple manual or electromechanical guillotines. Many models of sheet metal shears are additionally equipped with industrial electronics and options that increase metal cutting productivity.
Despite the abundance of drive types, all guillotine models have the same operating principle. To begin with, the sheet to be cut is placed on the work table along the set stops between the lower and upper knives. It is first necessary to press a sheet of metal against the guillotine table using a pressure beam. Then the upper knife moves and the metal is cut. The finished parts can then be transported from the metal cutting area.
The precision of cutting metal sheets using guillotine shears is ensured by the sheet pressing mechanism. Cutting, as a rule, is carried out according to markings or a stop: it is customary to install precise back rulers on guillotines, which allow achieving high precision of the cutting procedure. Some models are equipped with a return tray to collect cut metal.
When choosing a specific model of scissors, you need to carefully think through the list of required functions, because the advantages of the work do not always consist in a large number of them, while the price of such a machine depends on this indicator directly. For work at home, a guillotine with a set of only the necessary functions is quite suitable; multifunctional scissors are required in large industries.
Types of guillotines
According to the principle of the device, sheet shears can be manual, pneumatic, hydraulic, mechanical, automatic, and also combine several combinations at the same time. Manual and pneumatic guillotines are among the simplest and are used for straight cutting of metal sheets.
Hydraulic shears with electromechanical drive are easy to operate and high level labor, which can be noted in the video about metal cutting. Cutting accuracy is ensured by adjusting the position of the knives. Hydraulic guillotine shears with automatic or manual adjustment of the gap that forms between the knives are extremely popular.
Using guillotine shears
Guillotines are designed for cutting in transverse and longitudinal directions metal sheets, which have different thicknesses. Some types of sheet metal shears are capable of cutting round, square or corner metal. The main characteristics of guillotines, which are used for cutting metal, are the length and maximum thickness of the cut.
The use of guillotines allows you to obtain an accurate cut of the material without nicks or dents, and does not damage the equipment polymer coating and metal coloring. Depending on the technical capabilities, guillotine shears are used in mass and individual production.
After reading our article, you have become familiar with the main types of sheet metal cutting. Recalling once again - guillotine, laser, plasma and gas cutting. Each of them has its own advantages and disadvantages. Remember that each type of metal cutting involves the use special equipment and tools, which requires the consumer to have certain skills and strict adherence to safety precautions.