BENDING & CUTTING TECHNOLOGIESCollection 2013

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BENDING & CUTTING TECHNOLOGIESCollection 2013

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Shearing is a metal fabricating process used to cut straight lines on sheet metal. Material is cut (sheared) between the edges of two opposed cutting tools. It works by first clamping the material with hold down cylinders. During the shearing process, a moving blade comes down across a fixed blade with the space between them determined by a required offset.The moving blade may be set at an angle in order to shear the material progressively from one side to theother; this angle is referred to as the shear angle and this decreases the amount of force required, but increases the stroke.As far as equipment is concerned, the machine consists of a shear table, work-holding device, upper and lower blades, and a gauging device. The gauging device is used to ensure that the workpiece is being cut where it is supposed to be.

Shearing angleinfluences slightly the cutting force; using two square edge blades requires higher cutting force than if the upper blade is ground at a slight angle; this shearing angle is typically 3°.Cutting angle has a heavy effect on cutting force and has an important effect on distortion which can occur when shearing thin strips. The cutting angle is less than 3°.Cutting clearanceis the perpendicular distance between the shearing blades. Exact cutting clearance depends on plate thickness and material strength. Accurate values must be determined for each case. If the cutting clearance is too small tool wear increase: tooling costs and cutting force will be higher. If the cutting clearance is too large, the material is drawn between the two blades. The result will be a cut edge with increased taper and larger plastic deformation. Cutting clearance is a key factor for edge quality.

When the depth of the plate to be cut is less than 10 times the thickness, the internal tensions caused by cutting make it take on a “helical” shape, in other words the plate tends to twist. This phenomenon is amplified when the cutting angle is open. To reduce this phenomenon to a minimum it is recommended to apply the anti-torsion device (optional). This accessory consists of a series of hydraulic cylinders fitted below the bottom blade which support the plate against the top blade. This contrasting action is carried out during the cutting phase. The cylinders exert a counter-pressure in proportion to the thickness cut. This device can be added also post machine installation.

SHEARING PROCESS

CUTTING CLEARINGS OR BLADE GAP (VARIABLE)•0.06mmforeachmmtocutuptoXCut-10•0.04mmforeachmmtocutoverXCut-10(i.e. XCut-16: 0.04x16=0.64 mm max)

LOWER BLADE

HOLD DOWN

UPPER BLADE

SHEARING ANGLE(TYPICAL 3°)

CLEARING ANGLE(FIXED =1.5°)

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To perform a perfect shearing you need a perfect guillotine that minimizes the effects that take place in the metal sheet during cutting action due to its inner composition, its accumulated inner stresses, its geometry. These natural effects, if not corrected and compensated, become defects in your sheet metal products, reducing their quality. Common shearing effects are: the torsion effect, the straightness effect, the bending effect and the cut edge defect.

STRAIGHTNESS ERRORThis effect results in a sheet metal bowed along its plan (the surface stays flat) at the end of cut action. It is related to strip width, its thickness, material strength and previous cold rolling direction (residual stresses). To reduce this effect it is recommended to use smaller cutting angle and to do pre cuts (scraps) along rolling direction.

TORSION EFFECTThis effect results in a sheet metal twisted along its axe at the end of cut action. This effect happens typically when shearing narrow strips. Shearing conditions that enhance this effect are related to sheet metal geometry (high thickness, thin width, short length), material characteristics (soft material, uneven stress distribution) and of course cutting parameters (big cutting angle, high cutting speed).

BENDING EFFECTThis effect results in a bowed sheet metal (the sheet metal is no more flat as its edges raises from the plan) at the end of cut action. This defect is related to cutting angle and workpiece strength.To reduce this effect it is recommended to use a smaller cutting angle and to support the sheet metal.

NOT STRAIGHT CUT EDGEThe material to be cut deforms plastically in a very small region that causes a residual deformation. The bright zone is where the upper blade penetrates the material before the formation of a crack that produces a rough and irregulars surface known as the fractured zone. This area extends into the edge burr which occurs during the final phase of shearing and depends on cutting clearance, workpiece strength and tools condition.

SHEARING PROCESS

FRACTURE ANGLE

NOMINAL SIZE

PLASTIC DEFORMATION

BRIGHT ZONE

FRACTURED ZONE

BURR HEIGHT

CUTTING CLEARANCEWORKPIECE STRENGHTTOOLS CONDITION

TOOLS CONDITIONCUTTING ANGLE

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The best cutting quality in the world: the exclusive Blade Pads system guarantees cutting linearity and accuracy in any conditions

New design: unique, technological, Italian. One look and feel for all product families

Delem DAC 360 CNC with internal material database

Gasparini Hydraulic project (diagram and mainfold)

LED lighting of cutting line

Scrap/small parts metal box (optional)

Independent hydraulic hold down pressure as standard feature

Milled monolithic bench with milled slots to

facilitate sheet movement

Back gauge:helical tooth rack and pinion hardened and

grinded

Stand By Function (optional)

Double blade life time with 4 cutting edges suitable also for stainless steel

No sheet metal twist with the optional Anti Torsion Device

Stripe feeder (optional)

Front supports with upper aluminum profile with encased balls and

disappearing gage, measuring rule, brushes

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X-CUT

The X-CUT is available in a wide range of models and powers, with a cut thickness up to 30 mm, a length between 1500 and 10000 mm.

With a wide range of accessories (pneumatic sheet metal support, setting of the cut start position, stripe feeder, scrap/small parts metal box, pneumatic front guard, stand by function, anti scratch device, etc.), with tailor made approach, we always guarantee the best solution for every production need and every set of technical and economical constraints.

BLADE PADS

The best cutting quality in the world: the exclusive Blade Pads system guarantees cutting linearity and accuracy in any conditions and places Gasparini shears at the top of the market. It consists of a series of adjustable pads that force accurate blade positioning every 200 mm throughout the entire length.

ANTI TORSION DEVICE

No sheet metal twist with the Anti Torsion Device.It consists of a series of hydraulic cylinders fitted below the bottom blade which support the plate against the top blade. This contrasting action is carried out during the cutting phase. The cylinders exert a counter-pressure in proportion to the cut sheet metal thickness. This device can be added also on existing machines of X-CUT series.

HIGH STIFFNESS FRAME

The bolted structure with milled junctions designed with Finite Element Analysis gives the X-CUT high stiffness, high stability, less vibrations, high accuracy.LENGHT / THICKNESS 4 6 10 12,5 16 20 25 30

10000 • • •6000 • • • • • • • •4000 • • • • • •3000 • • • • • •2000 • •

MAIN FEATURES

•PlanarupperbeamwithFerrozellguidesandadjustable pads distributed along the whole length

•Doublebladelifetimewith4cuttingedgessuitable also for stainless steel

•AutomaticCNCcuttingangleadjustmentaccordingto cut material

•AutomaticCNCcontrolledbladegapsettingaccording to cut material

•Milledmonolithicbenchwithmilledslotstofacilitate sheet movement

•Independenthydraulicholddownpressure

•Frontsupportswithupperaluminumprofilewith encased balls and disappearing gage, measuring rule, brushes

•LEDlightingofcuttingline

•DelemDAC360CNCwithinternalmaterialdatabase

•Automaticswitchoffwhennotinuse

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Scraps/small parts metal box

Micrometric disappearing gauge

Digital micrometric gauge with display

Front supports Ruled protractor

Pneumatic sheet metal support

Stripes feeder

X-CUT

SCRAP/SMALL PARTS METAL BOXScrap/small parts metal box.

BLADE ANTI-SCRATCH DEVICEThis option lifts the metal sheet on feed side while movable blade is returning up to start position eliminating the contact between blade and the sheet itself. The result is to reduce the scratches and flaws on the sheet border, improving the quality of the finished part.

PNEUMATIC SHEET METAL BACK SUPPORTUp to 4 movements (vertical, rotation, horizontal, tilting) combined in 3 versions: standard A version (movements 1 and 2: cutting with rear discharge), B version for small pieces (movements 1 and 3: support down and back to let the free fall of cut piece), C with return-to-sender mode (movements 1,2 and 4: cut piece is sent back to operator).

HEAT EXCHANGERA dedicated heat exchanger for the hydraulic oil is recommended, either for installation of the shear with heavy duty applications, such as within automated shearing lines, or for tropical environmental conditions.

FRONT SUPPORTFront supports can be supplied on demand in extended version +1000 mm, with Micrometric retractable gauge, Brushes, Additional measuring rule and Side stop.

HI-SPEED PACKAGEHigh speed package especially suitable for automated shearing lines, with high frequency and/ or fast sequential cuts. The actual speed of the shear (blade movements, feeding and back gauge positioning, etc.) can be then improved, assuring final higher productivity.

SENSOR IN THE BACKGAUGE

VOLTAGE STABILIZER

PNEUMATIC FRONT GUARD

STRIPES FEEDERAssures cutting very close to the blade area in accordance with CEN-EN13985:2003.

BACK GAUGE with increased 1500 mm stroke.

SPARE PARTS KIT The current option provides a kit of recommended spare parts and consumables (blades excluded) for safe production for 2,000/4,000 working hours. Cutting start square with pneumatic retractable Gauge.

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X-Cut 4

2004 4 3 2000 2050 24÷42 0.5÷2.5 1000 500 ± 0.05 ± 0.03 2150 2700 3650 4,5 7,53004 4 3 3000 3050 18÷37 0.5÷2.5 1000 500 ± 0.05 ± 0.03 1900 3700 3650 6,0 7,54004 4 3 4000 4100 14÷33 0.5÷2.5 1000 500 ± 0.05 ± 0.03 2050 4700 3650 9,0 7,56004 4 3 6000 6100 10÷22 0.5÷2.0 1000 300 ± 0.05 ± 0.03 2500 6700 3900 18,5 11

X-Cut 6

2006 6 4 2000 2050 17÷35 0.5÷2.5 1000 500 ± 0.05 ± 0.03 2300 2700 3650 6,5 113006 6 4 3000 3050 12÷30 0.5÷2.5 1000 500 ± 0.05 ± 0.03 1900 3700 3650 8,0 114006 6 4 4000 4100 10÷26 0.5÷2.5 1000 500 ± 0.05 ± 0.03 2050 4700 3650 11,5 116006 6 4 6000 6100 8÷23 0.5÷2.5 1000 300 ± 0.05 ± 0.03 2700 6700 3900 20,0 15

X-Cut 103010 10 7 3000 3050 11÷22 0.5÷2.5 1000 500 ± 0.05 ± 0.03 2050 3850 3800 12,0 18,54010 10 7 4000 4100 8÷20 0.5÷2.5 1000 500 ± 0.05 ± 0.03 2200 4850 3800 18,0 18,56010 10 7 6000 6100 6÷17 0.5÷2.5 1000 300 ± 0.05 ± 0.03 2850 6700 4050 30,0 30

X-Cut 123012 12,5 8 3000 3050 11÷22 0.5÷2.5 1000 300 ± 0.05 ± 0.03 2200 3850 3800 12,0 18,54012 12,5 8 4000 4100 8÷20 0.5÷2.5 1000 300 ± 0.05 ± 0.03 2200 4850 3800 18,0 18,56012 12,5 8 6000 6100 6÷17 0.5÷2.5 1000 300 ± 0.05 ± 0.03 2850 6700 4050 30,0 30

X-Cut 16

3016 16 12 3000 3050 10÷16 0.5÷2.5 1000 300 ± 0.05 ± 0.03 3050 3850 3800 20,0 304016 16 12 4000 4100 9÷15 0.5÷2.5 1000 300 ± 0.05 ± 0.03 3050 5050 3800 26,5 376016 16 12 6000 6100 7÷17 0.5÷2.5 1000 300 ± 0.05 ± 0.03 3050 7000 4050 52,5 44

X-Cut 204020 20 14 4000 4100 9÷15 0.5÷2.5 1000 300 ± 0.05 ± 0.03 3180 5100 3800 32,0 556020 20 14 6000 6100 7÷15 0.5÷2.5 1000 300 ± 0.05 ± 0.03 3180 7100 4050 63,0 55

X-Cut 253025 25 17 3000 3050 7÷14 0.5÷2.5 1000 300 ± 0.05 ± 0.03 3500 3850 4050 35,0 556025 25 17 6000 6100 4÷11 0.5÷2.5 1000 300 ± 0.05 ± 0.03 3750 7100 4050 65,0 75

X-Cut 30 6030 30 22 6000 6100 4÷11 0.5÷2.5 1000 300 ± 0.05 ± 0.03 4500 7100 4050 70,0 75

CUTTING CAPACITY MACHINE PERFORMANCE BACK GAUGE DIMENSIONS AND GENERAL DATA

Mod

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MAX

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mm mm mm mm strokes/min ° mm mm/s mm mm mm mm mm t kW

X-CUT - TECHNICAL FEATURES

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TAILOR MADE SOLUTIONS 1

GASPARINI INDUSTRIES is an Industrial Company, with the ambition to be recognized as the Leader in the development of bending and cutting technology. We develop ideas, design solutions and realize products, for Customers looking for the best Partner, as for skill, commitment, safety and service.

Our Team is capable to understand and even anticipate, the most sophisticated customer’s needs, providing outstanding “tailor made” solutions, supported by our differentiation factors: co-design attitude, adaptability, ecological approach.

The following examples are just some of the Projects developed recently.

PROJECT: PRESS BRAKES “TANDEM” 2X 200T-3M

Destination: RussiaCustomer Industry: Trucks equipment & road construction machinery

PROJECT: PLASMA ROBOTIC CELL

Destination: ItalyCustomer Industry: Pressure vessels

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PROJECT: SHEAR LINE 6 m - 10 mm, WITH SEMI-AUTOMATIC DOWN LOADING DEVICE

Destination: SwitzerlandCustomer Industry: Metal parts production.

PROJECT: SHEAR LINE 4m - 6 mm, WITH SEMIAUTOMATIC LOADING, DOWN LOADING AND STAKING DEVICES

Destination: SwitzerlandCustomer Industry: Multi-metal service centermachinery

TAILOR MADE SOLUTIONS 2

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Gasparini Industries Srl COLLECTION 2013This edition was printed in October 2012

All rights reserved and protected by industrial design rights. Gasparini Industries srl reserves the right to change or technically improve the products featured in this catalogue.

GASPARINI INDUSTRIES SRLvia F. Filzi 33 - 31036 Istrana - (TV) Italy

Ph: +39 0422 8355 - Fax: +39 0422 835 600info@gasparini.it - www.gasparini.it