Purpose
The objective of this document is to standardize the work behavior of operators and guarantee human-machine safety, avoiding rework and product scrap due to human negligence. It also aims to promote standardized and standardized operations.
Scope
This document is applicable to the operation control of cutting machine in the production department of our company.
Working principle
The cutting machine applies cutting force to metal plates of various thicknesses, using a reasonable blade gap between the movable upper blade and the fixed lower blade, causing them to break and separate according to the required size.
The cutting machine can be divided into pedal (manual), mechanical cutting machine, hydraulic cutting machine, etc.
Shearing machines are commonly used to cut blanks with straight edges.
The shearing process must ensure the straightness and parallelism of the sheared surface of the material and minimize plate distortion to obtain high-quality parts.
Our company uses QB11-4×2000 cutting machine.
Responsibilities
Relevant production personnel are responsible for material confirmation, quality assurance and reporting during the production process.
Procedures
5.1 Material Selection
Related personnel select the necessary materials according to production requirements: when selecting, they must pay attention to the color, grade, coating type, thickness, width and strength of the materials and whether they are consistent with the requirements of the production order. Use the remaining materials first.
5.2 Machine startup and shutdown
When starting the machine, the main control power supply lock on the electrical cabinet must be opened first, the switch must be turned to the “ON” position, and then the power switch on the main control panel must be turned in the “ON” position. "Position. When turning off, first turn the main control switch to the “OFF” position, then turn the electrical cabinet power switch to the “OFF” position and lock the cabinet.
5.3 Precautions when using the cutting machine:
- Operate the cutting machine without load for several cycles to ensure that under normal conditions it cuts plates of different thicknesses, from thin to thick. Make sure the operator is familiar with the performance of the cutting machine.
- When testing cutting with different sheet thicknesses, adjust the corresponding blade clearance. If the corresponding blade clearance is not adjusted, it will affect the durability of the blade.
- Maintain a balanced sound level during operation. If there is abnormal noise from the cutting machine, stop the machine and check it.
- The oil temperature during operation should not exceed 60 degrees. If it exceeds, turn off and rest.
| Model | Max Cutting Thickness.（mm） | Max cutting width (mm) | Cutting angle | Backgauge range（mm） | Stroke frequency (times/min) | Main engine power（kw） | Weight (kg) | Dimensions (mm) |
| QB11-4×2000 Hydraulic Cutting Machine | 4 | 2000 | 2°30' | 500 | 27 | 5.5 | 3300 | 3200×1300×1610 |
7.4 Operating Procedures
7.4.1 Preparation before Operation
(1) Before operating, the operator must wear tight-fitting protective clothing, tighten the cuffs, and not wear loose clothing or wrap anything around the body near the conveyor belt to avoid being caught by the machine. Safety helmets must be worn and hair must be placed inside the helmet. Skirts and sandals are not permitted.
(2) The operator must be familiar with the main structure, performance and use of the cutting machine.
(3) This machine is suitable for cutting various steel plates, copper plates, aluminum plates and non-metallic material plates with a thickness equal to the nominal value of the machine, as long as they are free from hard marks, slag, burrs, and welds . Excessive thickness is not permitted.
(4) Lubrication of each part of the machine must be maintained regularly. The operator should add lubricating oil once per shift, and the machine repairman should add lubricating oil to the bearing part once every six months.
7.4.2 Operating Procedures
(1) Operators must be familiar with the general structure and performance of the equipment and strictly prohibited from using the equipment beyond its performance limits.
(3) Before starting the machine, add lubricating grease according to the equipment lubrication requirements, check the oil level and quality, and cover the oil cup hole cover.
(4) Before working, the blade must be kept sharp. If the blade becomes dull or cracks, it must be sharpened or replaced immediately. The blade plate must be securely fixed, the blade must be close to the plate, and the upper and lower surfaces of the blade plate must be kept parallel. After adjustment, manual rotation of the steering wheel should be used to check for accidents.
The blade clearance should be determined according to the thickness of the steel plate to be sheared, generally between 5-7% of the sheared plate thickness. Each time the clearance is adjusted, the handwheel must be turned manually to make the upper and lower blades move back and forth once, and an auxiliary measuring tool must be used to check whether the clearance is appropriate for avoid breaking the spring or damaging the blade.
(5) It is not allowed to cut two different specifications or different sheet metal materials at the same time or cut stacked materials. The cut sheet must have a smooth surface and the edge of the deburred material must not be trimmed. It is not permitted to cut narrow or short materials that are not well pressed.
(6) Adjust the stop or accessory according to the cutting requirements of the workpiece. Loosen the positioning material stop screw, adjust the position of the positioning material plate, and fix it firmly. Before working, operate the machine without material 2 to 3 times to confirm good lubrication and normal operation before starting work.
(7) The feed must be straight, flat and stable. Fingers should not be close to the cutting blade or pressure plate. When feeding, pay attention to finger safety, especially when cutting the last piece of material, do not place your fingers under the material or on the cutting edge. If the last piece of material is less than 200 mm, manual cutting is not allowed and auxiliary tools must be used for cutting.
(8) It is not allowed to repair or clean the machine tool during operation, and tools or other objects cannot be placed on the machine table to avoid damaging the blade when entering the cutting edge.
(9) During cutting, the material pressing device must firmly press the metal sheet, and cutting is not allowed in the loose pressing state.
(10) A protective fence should be installed on the shear trigger to prevent the operator's hand from entering the cutting area. The protective fence must not block the operator's eyes from seeing the cutting position. It is strictly prohibited to collect waste on the ground during work to avoid injuries caused by falling work pieces. After operation, the operator must clean up the residue with sharp edges in time to avoid stabbing or cutting.
(11) The moving parts of the belt, flywheel, gear and scissor shaft must be equipped with protective covers.
(12) Pay attention to whether the clamping mechanism, clutch and brake have any abnormal defects. Concentrate while cutting. If there is any abnormal phenomenon in the equipment, immediately stop cutting, turn off the power supply, and notify relevant personnel for inspection.
(13) To ensure production safety and improve work efficiency, in the event of personnel or equipment accidents, the site must be maintained and reported to the relevant departments.
(14) Before leaving work, the power supply must be cut off, the equipment must be cleaned, and the inspection log must be completed.
7.4.3 Precautions
(1) It is prohibited to cut materials that are too long or too thick and materials such as high-speed steel, tool steel and cast iron that have been hardened or tempered.
(2) Before starting the machine, disengage the clutch and do not start the engine under load.
(3) Before starting the machine, make a test cut without the workpiece. Only after the test is successful can you begin processing.
(4) It is prohibited to cut explosive materials, bars, very thin materials and non-metallic materials.
(5) Pay attention to the clutch to ensure it is working properly. Check that fasteners are secure and keep fingers away from the cutting area while feeding. It is strictly prohibited for two people to cut two pieces of material at the same time on the same machine, and it is not allowed to remain on the cutting table after cutting.
(6) The equipment must be operated by a dedicated person and must not be used without permission. It is necessary to ensure that the machine is stopped when people are absent.
(7) Adjustment, repair and cleaning of equipment must be carried out with the machine stopped.
(8) It is prohibited to loosen or tighten the material clamping device or adjust the blade clearance by tapping. When adjusting the blade clearance, the machine must be stopped first.
(9) It is prohibited to reach into the cutting area with your hands or use your hands to feed or pick up materials during operation.
Security
When operating the cutting machine, all safety rules must be followed:
- Under no circumstances should hands or any part of the body reach the cutting blade or other rotating parts.
- It is not permitted to operate under the cutting rack.
- It is not permitted to remain within the machine's protection or danger zone.
- No one can be at the rear of the machine or under the cutting rack before the machine is started.
- When adjusting the uniformity of the machine's blade clearance, the engine must be turned off.
- If any abnormal noise or other unusual situation is discovered during operation of the machine, the machine must be stopped immediately until the problem is resolved before continuing to use the machine.
- In the case of multiple operators, it is necessary to ensure that there are no dangerous factors before pressing the pedal or button.
Maintenance methods for the cutting machine
The maintenance and upkeep methods of the cutting machine are as follows:
- Strictly follow operating procedures.
- Before each start-up, add lubricating oil according to the lubrication table requirements, with clean, sediment-free oil.
- Keep the machine clean by applying rust-preventing grease to unpainted areas.
- Regularly replace and add lubricating oil to engine bearings and frequently check electrical components for safe and reliable operation.
- Regularly inspect the machine and surrounding area to maintain cleanliness and good insulation of electrical cables.
- Regularly check the triangle strap, handle, knob and button for damage, and replace worn parts in a timely manner, reporting and supplementing spare parts as necessary.
- Regularly check the repair switch, fuse and handle to ensure their reliable operation.
- Before leaving work each day, lubricate and clean the machine for 10 minutes.
- Undesignated personnel are strictly prohibited from operating the equipment. Always keep people away from the machine when not in use.
Cleaning
- Adjustment and cleaning must be done with the machine stopped.
- Keep the workplace and machine clean at all times. Do not accumulate workpieces or debris.
- After work is completed, store the finished products properly, turn off the power supply, clean the machine, clean the workplace, and lock the distribution box.
