DANIELI SERVICE
Training Center
I SO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
Mill Shears
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DANIELI SERVICE
Training Center
I SO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
Most rolling mills run with an over speed on the shears, this is
normally done to ensure the nose and tail crops are thrown into
the disposal chute and not left in the path for the next bar, and
on the divide shear that the nose end is straight.
The amount of over speed will be determined by the size of the
crop end disposal problem for each shear, we may well find
different amounts of over speed for different shears in just one
rolling mill.
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DANIELI SERVICE
Training Center
I SO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
What factors determine the amount of over speed required for a shear?
size of bar to cut
temperature of bar
steel grade
condition of blades
shear drive & gear ratio
type of shear (flywheel, clutch, stop/start)
efficiency of shear brakes
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DANIELI SERVICE
Training Center
I SO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
Can we determine over speed by observing the effect on the bar?
a) If the shear is too slow and the bar is being driven faster than the shear
speed, the bar will ripple or buckle behind the shear blades. The nose crop
will drop or fall away after the cut without too much momentum.
b) If the shear is too fast we will see the nose crop thrown with great
momentum far away from the shear. On the tail end when the bar has left
the previous stand, the bar will ripple and buckle severely into the
following stand.
Both situations increase the load placed upon the shear, shear lead speed
or over speed needs to be kept within the manufacturers guidelines a
nominal figure of 12% would normally cover the range of operating
conditions.
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DANIELI SERVICE
Training Center
I SO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
In many mills the shear over speed is adjusted as a solution to some other
problem. It has to be said that for every problem there is a best solution, shear
over speed is not the best.
What is the effect of a mismatch in speed between the shear and the stand?
a) High torque to the shear unit in both under speed and over speed.
b) Damage to troughs, guides etc as the rippled bar enters the following stands.
What about the divide shear at the cooling bed in relation to speed?
a) If the shear is too slow then the front end cut will be bent
b) If the shear is too fast then the tail end cut will be bent
If both front end and back end are bent?
This is normally a combination of speed mismatch, entry guide height, plus
poor blade condition/alignment
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DANIELI SERVICE
Training Center
I SO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
The blades or knives of the divide shear are more important than say snap shears
blades, the setting has to be more precise and the grade of steel used for the blades
much higher to deal with continual cutting especially on quenched bar. For these
reasons the divide shear blades will need changing much more frequently, the actual
frequency will depend on the grade of the blade, the grades of steel, the size mix, etc
So with our shears and blades we have these aspects:
* the blade overlap 2-5 mm* is normal (depends to the size of the shear)
* the blade clearance is set to between 0.2 and 0.5mm.* See the following
slide for backlash and setting. It is important that the blade arms are turned by
hand to ensure that the blades do not clash.
* the blade bolts should be tightened with lock nuts to ensure that the blades
remain secure throughout service
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DANIELI SERVICE
Training Center
I SO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
• the condition of the blade, should be sharp, well ground, cutting on
quenched bar will causing severe bruising and perhaps even some local
breaking of the cutting edge, change blades when in doubt, experience
suggests twice per week when rolling quenched bar.
• cleanliness is important, in and on the blade fixing seat may be
compacted grease and spots of rust, therefore the blade seating should be
scraped clean, shims and packers spotless, not broken or creased, bolts and
holes should be clean and well fitting especially that the threads are in good
condition. The next area demanding attention is the base of the shear where
over time oil and grease will accumulate and compact on the floor, in this
situation fire is only moments away!!!
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DANIELI SERVICE
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I SO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
* Different shear manufacturers will give their own
clearances and these should be followed.
Blade Overlap
2 - 5mm*
Blade Clearance
0.2 - 0.5mm*
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DANIELI SERVICE
Training Center
I SO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
Blade clearance is sometimes misunderstood by people especially non-
engineering. A shear is operated via a power unit (a motor) through a gear
box and pinions to the shear blade arms and then to the shear.
With all these interconnecting and related features the shear blades will have a
certain amount of horizontal movement which we refer to as ‘backlash’.
A shear blade gap it is the gap plus the backlash, this means to say that if a
screwdriver is forced between the blades movement will be evident.
The amount of backlash in a new shear should be about 0.5mm this will grow
over the coming years. The amount of backlash should be no greater than 1.0mm,
if the shear has more than this then corrective action should be taken.
So when setting shear blades the pair of blades are freely set to the figure
without exerting any horizontal force. The blade gap is the gap plus the
backlash.
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