Views: 0 Author: Site Editor Publish Time: 2025-11-10 Origin: Site
Cutting metal sheets may look simple, but precision takes skill. A shearing machine can slice steel cleanly — if operated correctly. Improper use leads to dull blades, wasted materials, and serious safety risks. In this guide, you’ll learn how to operate a shearing machine safely and efficiently, covering setup, cutting steps, and maintenance tips.
Before switching on the shearing machine, take time to prepare. A few simple checks can prevent damage, delays, and safety risks. This stage ensures the equipment runs smoothly and every cut is accurate.
Inspect the machine carefully before use. Look for loose bolts, unusual noise, or visible wear. Check all moving parts — gears, shafts, and the blade mechanism. They must move freely without obstruction.
Lubricate the required points using clean oil. A dry joint increases friction and shortens machine life. Confirm that the hydraulic oil level stays above two-thirds of the tank. Low oil can cause unstable pressure and cutting errors.
Remove leftover tools, metal scraps, or debris from the worktable. Keep the area clean. Finally, check all protective covers and fences. They should be firmly in place before the machine starts.
| Inspection Area | What to Check | Why It Matters |
|---|---|---|
| Lubrication Points | Apply clean oil regularly | Reduces wear and overheating |
| Electrical Wiring | Secure, no loose connections | Prevents power failure or sparks |
| Hydraulic System | Oil level ≥ 2/3 tank | Maintains stable cutting pressure |
| Worktable Area | No debris or tools present | Keeps operation safe and steady |
Safety starts before the first cut. Always work as a team — two or three operators under one leader’s direction. Everyone should know their role: one feeds, one measures, another retrieves the cut piece.
Keep your fingers and hands at least 200 mm away from the blade. Never reach near the pressing device while cutting. Wear goggles, gloves, and protective shoes to prevent injuries from sharp edges or flying scraps.
Avoid cutting quenched or hardened steel. It may break the blade or cause machine vibration. Most importantly, stay alert. A moment’s distraction can cause an accident.
Before cutting, inspect the material closely. Check its thickness, texture direction, and surface flatness. A warped sheet will not cut evenly. Make sure the plate matches the machine’s rated capacity. Don’t exceed the maximum thickness. Never cut mixed materials together — for example, stainless steel and mild steel — as this dulls the blade quickly. Label each batch clearly. Stack sheets neatly by size and type. It keeps your workflow organized and prevents mix-ups. A well-prepared workspace makes every shearing operation faster, safer, and far more precise.
Setting up the shearing machine properly ensures clean cuts, longer tool life, and safer operation. A few careful adjustments before you start can make all the difference.
Every material needs its own blade gap. The thicker the sheet, the wider the clearance. Too narrow, and the blade wears fast. Too wide, and you’ll see burrs or uneven edges. Use the control panel or manual knobs to set the gap according to the plate’s thickness. For thin stainless steel, a small gap gives a cleaner finish. For thicker carbon steel, increase it slightly to avoid tearing.
Check the blade condition before each shift. A dull edge causes rough cuts and more vibration. If it looks worn, replace or resharpen it before operation.
| Material Type | Typical Thickness (mm) | Recommended Clearance (mm) |
|---|---|---|
| Stainless Steel | 1.0 – 3.0 | 0.05 – 0.10 |
| Mild Steel | 3.0 – 6.0 | 0.10 – 0.25 |
| Aluminum Sheet | 1.0 – 4.0 | 0.08 – 0.20 |
Always test a short cut first. It confirms your gap is correct before large-scale shearing begins.
Next, set the back gauge, which controls how far the sheet extends under the blade. It determines the cutting length. Move the gauge slowly until it reaches the target position shown on the display. Lock it securely before starting. Use a ruler to double-check both ends of the sheet. Each cut should be square — no angle difference between left and right. If one side is off, adjust the gauge alignment. A small error in the gauge setting multiplies across hundreds of cuts, wasting material and time. So, take a few minutes to measure carefully.
Before powering the machine, verify all electrical connections. It must be linked to a stable three-phase supply. Check the voltage rating — it must match the machine’s requirement exactly.
Turn on the main breaker and inspect for loose wires or sparks. For hydraulic models, fill the tank with high-quality anti-wear hydraulic oil until it reaches two-thirds of the tank. It keeps pressure steady and reduces wear on seals.
If your machine includes pneumatic rear supporters, connect the air line firmly. Test for leaks by listening for escaping air. Install a regulator and filter to keep airflow clean and constant.
| System | Check Item | Required Condition |
|---|---|---|
| Electrical Power | Voltage / Phase Sequence | Stable, Correct Order |
| Hydraulic Oil | Tank Level | ≥ ⅔ of Tank Capacity |
| Air Pressure Line | Connection Tightness | No Leaks, Stable Flow |
Now it’s time to start the control system. Turn on the main power and key switch — the indicator light should come on. Make sure all emergency stop buttons are released; otherwise, the system won’t start. Press and hold the Reset button for a few seconds. The screen will show initialization progress. Then long-press the Pump-Start key to activate the hydraulic system. You’ll hear the pump running steadily when pressure builds up.
Watch the indicator lamps carefully. If only one light appears, it means a phase-sequence error. Swap two power lines and try again. When both lights glow, the wiring is correct and the machine is ready for operation. Each step takes less than a minute but guarantees smooth, safe shearing once production begins.
Once everything is set and calibrated, it’s time to run the machine. Operating a shearing machine isn’t just pressing a button — it’s about rhythm, observation, and control. Let’s walk through the steps.
Before cutting, make sure the system is fully loaded and ready. Look at the control panel; the screen should display normal status with no error codes. Listen closely to the motor. It should start smoothly without grinding or rattling sounds. Check the hydraulic pressure gauge — it must reach the rated range before operation.
If the system feels sluggish or makes a humming noise, stop immediately and recheck the oil level or wiring sequence. Stable pressure and quiet motor sound mean the machine is in good working order.
| Startup Check | Expected Condition |
|---|---|
| Display Panel | No warning or error message |
| Hydraulic Pressure Gauge | Stable, within rated range |
| Motor Sound | Smooth, steady operation |
| Emergency Stop Switch | Released and functional |
Now position the metal sheet carefully. Slide it along the back gauge until it touches the stopper. Keep the sheet straight — any tilt causes uneven cuts. Use both hands for larger plates, but stay clear of the blade area. Once aligned, the pressing plate should hold it firmly before shearing begins.
Avoid vibration or rebound during clamping. If the plate moves slightly, readjust before you press the pedal. A steady sheet ensures a precise, clean edge after cutting.
Pro Tip: For thin sheets, lower the pressure slightly to prevent bending. For thicker plates, tighten the clamping pressure for stability.
Start cutting only after the plate is secured. Use the foot pedal or the control button for single or continuous operation. Keep an eye on the pressure gauge during cutting. For 1 mm stainless steel, it should stay below 1.5 MPa. If pressure spikes, stop immediately — it could indicate overload.
Never exceed the rated thickness of the machine. Cutting sheets thicker than 6 mm can damage the blade or stress the motor. Watch the blade move — it should descend smoothly without jerks or hesitation. If you notice irregular motion, check the oil flow or valve pressure.
| Material Thickness | Max Recommended Pressure (MPa) | Cutting Mode |
|---|---|---|
| ≤ 1 mm (Stainless Steel) | ≤ 1.5 | Single |
| 2–4 mm (Mild Steel) | 2.0 – 2.5 | Continuous or Single |
| 5–6 mm (Carbon Steel) | 3.0 – 3.5 | Single |
Use the foot pedal lightly — pressing too hard doesn’t speed the process, it only wears components faster.
Stay alert while cutting. If you hear an odd noise, vibration, or see oil leakage, hit Stop right away. Keep the worktable clear — never wipe it or place tools there when the machine is active. Loose objects can slide into the cutting zone and cause damage. Observe the clutch, brake, and pedal switch. They should feel firm and responsive, not sticky or delayed. If something feels off, pause the operation and inspect before continuing. Check the cut quality every few sheets. Straight edges mean all systems are aligned and performing well.
Precision is the heart of good shearing work. Even a tiny misalignment can cause material waste and rework. Measuring and calibrating accuracy keeps every sheet within tolerance and ensures smooth production.
After cutting, always measure the finished piece. Start by checking the length and width — for example, a sheet might read 145.5 mm instead of 146 mm. That 0.5 mm difference matters in industrial cutting. Use reliable measuring tools like digital calipers, steel rulers, or a tape scale. Avoid flexible or worn instruments. Keep the tool flat against the sheet and check both sides to confirm uniformity.
| Measurement Tool | Accuracy Level | Best For |
|---|---|---|
| Digital Caliper | ±0.01 mm | Small sheets, precision cuts |
| Steel Ruler | ±0.1 mm | Quick manual inspection |
| Vernier Caliper | ±0.02 mm | Long sheets, edge alignment |
If the measured length differs from the target, note it immediately. Consistent readings tell you whether it’s an operator issue or a calibration problem.
A 0.5 mm deviation might seem small, but in mass production, it can cause hundreds of rejects. When this happens, stop cutting and find the cause. Check the blade gap first — too wide a gap can pull the metal and distort size. Then check the back gauge. If it’s misaligned or loose, every sheet will be off by the same amount. Once you’ve made adjustments, perform a test cut and re-measure the piece. Make sure both the left and right edges match your target dimension.
If the new reading is accurate, lock the settings firmly before resuming operation.
| Error Type | Possible Cause | Adjustment Needed |
|---|---|---|
| Oversized Cut | Back gauge too far back | Move gauge closer |
| Undersized Cut | Blade clearance too tight | Loosen clearance slightly |
| Uneven Diagonal Edge | Sheet not aligned properly | Realign before pressing start |
A few minutes of correction can save hours of rework later.
Once you confirm accurate measurements, input the value into the controller. Enter the actual measured length — say 145.5 mm — into the length calibration field.
The controller automatically adjusts internal parameters to match your true cut size. Watch the display carefully; it should show the updated setting immediately. If the numbers don’t update, press Reset and re-enter the data.
Afterward, perform one more trial cut. Compare the new result with your measurement tools. When both values align, your calibration is complete and the system is ready for full production.
Keeping your shearing machine in good condition saves time, reduces wear, and ensures every cut stays precise. Regular checks, quick responses to alerts, and careful testing all help prevent costly downtime.
Maintenance doesn’t take long — just a few minutes after each shift. Start by lubricating all moving parts like the gears, guides, and blade slides. It prevents friction, reduces heat, and extends machine life.
Wipe the worktable clean. Metal dust or offcuts can scratch the surface and affect sheet alignment. Remove leftover scrap immediately instead of letting it pile up. Next, check hydraulic lines and air hoses for leaks. A small drip today can lead to pressure loss tomorrow.
Inspect all bolts and nuts once a week. Tighten any that feel loose. Replace worn seals early — they’re cheap compared to a damaged pump.
| Maintenance Task | Frequency | Purpose |
|---|---|---|
| Lubricate moving parts | Daily | Reduce friction, extend component life |
| Clean worktable & remove scrap | Every shift | Maintain alignment and safety |
| Check hydraulic oil level | Weekly | Ensure stable pressure during cutting |
| Inspect air hoses & lines | Weekly | Prevent leaks and loss of pressure |
A clean, well-oiled machine always performs better and runs quieter.
Modern shearing machines, like those using DAC-360T controllers, detect problems automatically. When something goes wrong, the screen flashes an error code — don’t ignore it.
Common alerts include:
Phase-sequence error: The power lines are reversed; swap two wires to fix it.
Hydraulic pressure drop: Low oil level or clogged filters can cause this. Refill or clean the system.
Overload warning: The material might be too thick or too hard for the current setting.
If a fault or emergency stop occurs, follow these steps:
Turn off the power immediately.
Check for obvious causes — leaks, blockages, or overheating.
Wait until the motor cools, then press the Reset button.
Restart the system and watch the indicator lights.
| Alert Type | Cause | Quick Fix |
|---|---|---|
| Phase-Sequence Error | Incorrect wiring order | Swap two incoming power lines |
| Hydraulic Pressure Drop | Low oil or blocked filter | Refill, clean or replace filter |
| Overload / Overheat | Excessive thickness or jam | Stop, cool, and reset the system |
A fast response prevents minor alerts from becoming major mechanical failures.
Before large-scale production, always make a test cut. It’s the easiest way to confirm that all settings — blade clearance, pressure, and back gauge — are correct.
Use a scrap piece of the same material you’ll be cutting. Run a short shearing cycle, then inspect the edge quality. Smooth edges mean the setup is right. Rough or curled edges mean you need adjustment.
Check burrs and dimensional consistency. Measure the test piece to ensure the width and length match the target.
If everything looks good, proceed to full operation confidently.
Performing this step every time saves material, avoids rework, and ensures reliable cutting quality for every batch.
Finishing a shift doesn’t mean the job is done. How you shut down the shearing machine affects safety, machine life, and the next operator’s setup. Take a few calm minutes to do it right.
When cutting is complete, press the red Stop button firmly. It immediately halts all blade and back gauge movement. Don’t rush this step — wait for the system to respond fully before turning off power.
Next, switch the main power to the OFF position. Watch the control panel to ensure all indicators fade out. For hydraulic machines, give the pump a few seconds to release pressure naturally.
If the machine won’t be used for a while, disconnect it from the main supply. This prevents accidental restarts or electrical surges during idle periods.
Always secure the foot pedal or control switch to avoid unintentional activation.
| Step | Action | Purpose |
|---|---|---|
| Stop Cutting Operation | Press red Stop button | Instantly halts moving components |
| Power Off Machine | Turn main switch to OFF | Prevents accidental restart |
| Disconnect Power Source | Unplug for long idle periods | Saves energy and protects circuitry |
| Secure Controls | Lock pedal or switch | Avoids unintended engagement |
A proper shutdown ensures the system stays stable and safe for the next use.
After stopping the machine, wait until all motion completely stops. Don’t try to grab or move cut sheets while the blade is still descending. It’s easy to underestimate the remaining inertia.
Once everything is still, carefully remove any leftover metal pieces from the table. Use gloves to avoid cuts from sharp edges. Clean the blades using a soft cloth — remove oil residue or metal dust that could cause corrosion. Wipe the work area and check the floor for debris or spilled oil.
Return all tools to their storage rack and cover the control panel if required. These small actions protect equipment and create a tidy, safe workspace for the next operator.
Operating a shearing machine demands attention and discipline. Most accidents happen because someone ignores basic safety habits. These simple rules protect both the operator and the machine — follow them every time.
A shearing machine is not a one-person job. Always work in pairs or small teams. One operator controls the cut, another handles feeding or collecting sheets. Teamwork keeps operations smooth and prevents risky moves. If something goes wrong, there’s always someone nearby to press the stop button or call for help. Agree on clear signals before starting so everyone knows when to feed or retrieve material.
Not every metal is safe to shear. Hardened or quenched steel can crack the blade or overload the motor. Always check the plate’s thickness and hardness before cutting. If it’s near or above the machine’s limit, switch to another cutting method — like plasma or saw cutting. Exceeding rated capacity doesn’t save time; it shortens the machine’s lifespan and risks serious damage.
| Material Type | Max Thickness (mm) | Action |
|---|---|---|
| Mild Steel | 6.0 | Safe to cut |
| Stainless Steel | 3.0 – 4.0 | Reduce feed speed |
| Hardened Steel | — | Do not shear |
The area beneath the moving blade — the falling zone — is one of the most dangerous spots. Always install safety fences or guards to block access. They keep hands, clothing, and tools away from the descending blade. Never reach under the cutting area to grab waste or small pieces. Wait until the cycle stops completely, then remove debris safely.
Before every shift, test the emergency stop switches. Press each one and make sure the system shuts down instantly. Reset them afterward to resume normal operation. Inspect all mechanical guards — especially around gears, belts, and flywheels. They must fit tightly and show no cracks or movement. If a cover feels loose or missing, stop using the machine until it’s repaired. Safety barriers are only effective when fully secured.
| Safety Item | Inspection Frequency | Check For |
|---|---|---|
| Emergency Stop Buttons | Daily | Proper function and reset |
| Blade Guards and Covers | Weekly | Cracks, looseness, wear |
| Pedal Switch & Cables | Weekly | Damage or slow response |
A moment’s distraction can lead to serious injury. Keep phones and personal devices away from the work area. Focus on the blade, material position, and signals from your teammates. Avoid talking or multitasking during operation. If you feel tired, stop and take a short break. A focused operator is a safe operator — that’s the golden rule in any workshop.
Even experienced operators make small mistakes that affect cut quality and machine life. Knowing these issues — and how to fix them — keeps production safe, clean, and consistent.
If the cut edges look jagged or torn, the blade clearance is likely too wide. The sheet bends before it shears, leaving rough burrs behind. Tighten the gap according to material thickness. For thin stainless steel, use a smaller clearance; for thicker plates, widen it slightly.
Always test on a scrap sheet first. The edge should come out smooth and straight, without tearing. Keep both blades sharp and aligned — a dull edge exaggerates the problem.
| Material | Ideal Blade Gap (% of Thickness) | Edge Result |
|---|---|---|
| Stainless Steel | 6–8% | Clean, smooth edge |
| Mild Steel | 8–10% | Minor burrs (acceptable) |
| Aluminum Sheet | 5–7% | Fine, no tear marks |
When the sheet doesn’t separate completely, check the hydraulic or clamping pressure. Low pressure can leave uncut sections or force you to redo work. Watch the pressure gauge during operation — for 1 mm stainless steel, it should stay below 1.5 MPa, but not too low.
If pressure drops suddenly, refill the hydraulic oil or check for leaks. Consistent pressure ensures the blade runs at full strength and cuts cleanly every time.
Skipping lubrication is one of the quickest ways to damage a shearing machine. Dry parts rub, overheat, and wear out faster. Apply clean oil to slides, gears, and guides before each shift. Avoid over-oiling; it attracts dust that can cause scratches on the sheet.
Well-lubricated blades move smoothly, require less power, and maintain sharper edges longer.
If the finished sheets vary in length or angle, the machine needs calibration. A small 0.5 mm deviation per cut adds up over dozens of pieces. Recheck the back gauge alignment and blade clearance, then run a test cut. Measure the result and input the corrected value into the controller.
Regular calibration keeps accuracy high, reduces waste, and ensures every batch matches specification.
Trying to cut plates thicker or harder than the rated capacity strains every component — motor, pump, and blade. It might work once, but repeated overloading causes cracks, leaks, and motor burnout. Always check the machine’s maximum rated thickness before cutting.
When in doubt, use another cutting method such as plasma or laser. Staying within capacity keeps your shearing machine reliable and long-lasting.
| Common Mistake | Effect on Machine | Prevention Tip |
|---|---|---|
| Excessive Load | Blade chipping, motor strain | Stay within rated capacity |
| Poor Lubrication | Overheating, noisy operation | Oil key points daily |
| Ignored Calibration | Size inaccuracy | Recalibrate weekly |
| Loose Blade Gap | Uneven cutting, rough edges | Adjust before every shift |
A: Adjust the blade clearance before each shift or whenever you change material thickness. Proper clearance prevents burrs and extends blade life.
A: Use high-quality anti-wear hydraulic oil, such as 46# or equivalent. Keep the level above two-thirds of the tank for stable pressure and smooth operation.
A: If the indicator light shows a phase-sequence error, swap any two power lines. Restart the system and check that both indicator lamps illuminate.
A: A sudden stop usually signals low hydraulic pressure, overload, or an active emergency switch. Check oil levels, release all stops, and reset the controller.
A: Recalibrate the back gauge and blade clearance, then perform a test cut. Enter the new measured value into the DAC-360T controller for automatic correction.
A: No. Always operate as a team of at least two people. One handles feeding, another monitors cutting — teamwork reduces accidents and ensures accuracy.
A: Calibrate the machine weekly or anytime you notice deviation greater than 0.5 mm. Regular calibration ensures consistent, high-precision cutting results.
Safe, precise shearing starts with proper setup and careful monitoring. Routine maintenance prevents breakdowns and keeps blades sharp. Following each step reduces downtime and extends equipment life. Continuous training builds confidence and promotes safe operation. Mastering shearing machine control means better productivity, accuracy, and lasting protection.
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