Shear Brake Roll Forming User Guide

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Shop Area: Metal Shop

Tool: Shear, Brake, Roll Bender 

Requires in-person training: Yes 

Procedure Number

UG 130-09, Rev. 1

Date

2/20/2021

 

GENERAL

3 in 1 Combination Shear, Brake, Roll - Baileigh Industries SBR-5216

Shear Brake.png

SAFETY

  • Always wear approved safety glasses or face shield while operating the equipment.
  • Wear suitable hearing protective devices such as ear muffs or earplugs to protect against objectionable or uncomfortable loud noises.
  • Before operating equipment, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.
  • Non-slip footwear or anti-skid floor strips are recommended.
  • Closed toe shoes are required when working in a shop area.
  • Never place your hand or any part of your body in this machine.
  • Never place your hands, fingers, or any part of your body in the die area of this machine.
  • Always be aware of the position of the clamp handle and the counterweight. They are heavy and can swing back suddenly causing serious body or head injuries.
  • Keep hands and fingers away from the rolls when the machine is in operation.
  • Never place your hands, fingers, or any part of your body in the die area of this machine. Keep hands and fingers away from the shear blade and the punching and notching dies when the machine is in operation.
  • Keep hands and fingers clear from under the blade. Never place your hand or any part of your body in this machine.
  • Remove any adjusting tools. Before operating the machine, make sure any adjusting tools have been removed. Keep work area clean.
  • Do not overload the machine, may cause injury from flying parts. Do not exceed the specified machine capacities.
  • Do not overreach. Maintain proper footing and balance at all times. DO NOT reach over or across a running machine.
  • Check for damaged parts. Carefully check any part that appears damaged. Check for alignment and binding of moving parts that may affect proper machine operation.

REFERENCE

PROCEDURE

General

  • Make sure guards are in place and in proper working order before operating machinery.
  • Dress material edges. Always chamfer and deburr all sharp edges.
  • Always keep blades sharp and properly adjusted for optimum performance.

  SHEARING

The shear section has blades that can be reversed to provide a sharp edge as needed and are capable of shearing up to 16 gauge (1.519mm) mild steel sheet x 52” (1321mm) wide. An adjustable upper blade assembly passes by a fixed lower blade resulting in a precise shearing action. If necessary, the back gauge can be adjusted to accommodate repeat pieces.

Shearing Tips

• Keep the blade gap to the smallest distance possible.

• When shearing, the work should be squared against a guide.

• The pressure plate should be adjusted approximately 0.125" (3.175mm) above the table when the shear blade is in the up position. As the blade is moved downward, the pressure plate should immediately rest against the workpiece and hold it in place.

• To prevent distortion when shearing, snap the handle assembly quickly to pierce the workpiece, then continue with steady even pressure to complete the cut.

• After shearing, metal parts will have a sharp edge on them. These edges may cause cuts when handled. Deburr the workpiece to remove the edge before handling.

• Have the shear blades sharpened by a professional. This will lead to accurate, quality results.

• To avoid rolling over the edge of the sheet metal and pinching it between the two blades, Never cut any piece narrower than eight times the thickness of the material.

Shearing

1. Adjust the rear stop (#48) to accommodate the length of the cut.

Shear Brake rear stop.png

2. Adjust the handlebars within the hubs to full extension to provide as much leverage as possible to assist in the cut.

3. Using the handle assembly, raise the upper blade to the highest position.

4. Have at least one square edge of the material against the side guide or the adjustable rear stop for accurate cuts.

5. Lay the sheet metal on the work apron against the left side guide. Push the sheet under the hold down until it bumps up to the adjustable stop.

6. In a coordinated fashion, both operators should rotate the handlebar to begin the cut. The shearing action begins at the left side of the piece part and continues to the right until the cut is complete. a. The pressure plate (#63) should make contact with the sheet before the blade (#46) does. If it does not, adjust the two hex bolts (#17) on the pressure plate brackets to lower the pressure plate. When fully open the gap should not exceed 0.125” (3.175mm).

Share Brake Pressure Plate.png

7. Carefully lift the cut piece from the rear of the machine if it does not fall to the tabletop or floor on its own.

BRAKE OVERVIEW

The Combination SBR has adjustable and removable fingers to offer a wide variety of bending brake options. The brake section is capable of bending up to 16ga. (1.519mm) x 52” (1321mm) wide mild steel sheet.

To start a bend, the operator places a piece of sheet metal on the blade brake die. By turning the handlebar, the brake die is raised up until the tips of the brake blades line up with a line scribed on the sheet metal. If necessary the back gauge can be adjusted to accommodate repeat pieces. By continuing the upward travel of the brake die, the brake blades push the sheet metal down into the “V”-groove of the brake die. The thinner the material the further it will enter the groove for a slight overbend. This is helpful when the material experiences some springback. To remove the piece part, the operator lowers the brake die and removes the piece from the front of the machine.

Bending Allowance

In order to bend sheet metal accurately, you will need to consider the total length of each bend. This is referred to as bend allowance. Subtract the bend allowance from the sum of the outside dimensions of the piece part to obtain the actual overall length or width of the piece. Because of differences in sheet metal hardness, and whether the bend is made with the grain or against it, exact allowances must sometimes be made by trial and error. However bend allowances for general use can be obtained from metal working books or from the Internet.

When using the Combination SBR as a manual box and pan brake, the brake blades can be removed and setup to allow all four flanges of the box or pan to be bent upward.

Basic Bend Operation

1. Install the back gauge assembly to be on top of the rods as shown.

2. Adjust the stop to the required depth. It can also be mounted on the front of the brake. Or. Scribe a line on the sheet metal to indicate where the bend is to be made.

3. Adjust the handlebars within the hubs to full extension to provide as much leverage as possible to assist in the cut.

4. Using the handle assembly, raise the fingers on the brake until there is enough gap to fit the work piece.

5. Make sure the material is against the back stop or that the scribe mark is lined up to where the brake blade will come down.

6. While the sheet metal is being held firmly, both operators should rotate the handlebar to make the bend to the desired angle.

7. Raise the brake blade die and remove the piece part.

Note: The brake die is designed to bend material up to 90°.

Adjust the fingers for box and pan bending:

1. Place a thin and flat piece of spacer material (A) over the notch of the brake die. This flat surface will help you obtain equal finger length.

2. With the handle assembly, lower the fingers so they are just touching the top of the spacer on the brake die.

3. Loosen, but do not remove, the six cap screws (#20).

4. Slide the fingers horizontally to the desired position or rearrange them to get the desired width combination for your project.

5. Using the handle assembly, lower the fingers to apply light pressure. Check to make sure each finger has continuous contact with the spacer.

6. Tighten the six cap screws.

Shear Brake Fingers Adjustments.png

SLIP ROLL OVERVIEW

The slip roll section can be used to roll up to 16ga. (1.519mm) x 52” (1321mm) wide mild steel. It consists of 3 hardened rolls. The rear roll is adjustable to control the radius of the piece part as it is being formed. The closer the rear roll is brought to the front upper roll, the tighter the radius. The two front gear driven rolls pinch the material and pull it against the rear roll, forcing it up towards the front upper roll. The top front roll has two adjustment knobs, one on each end of the machine, to control the upper and lower roller spacing for different material thicknesses. When removing the formed piece part, the top front roll can be slipped out.

• When the slip roll section is not being used, the operator can cover the rolling mechanism with the formed steel pivoting cover / guard.

• The rear roll can be adjusted to a raised or tilted position on one end to roll cones or left flat to roll cylinders or arcs.

• Located on the end of the upper and lower rolls are three wire or forming grooves. These can be used for forming small diameter tubing or wire into rings or curved shapes.

• To prolong the life of the rolls, always keep them clean and well lubricated. Remove burrs from the edges of any sheet metal being processed through the rolls.

• DO NOT exceed the rated capacity on this slip roll. It has been tested at the factory to roll 16ga. (1.519mm) x 52” (1321mm) wide mild steel.

• Because material springback varies with the kind of material being formed, only by test forming several pieces can the correct adjustments be made.

Share Brake Slip Roll.png

OPERATING THE SLIP ROLL

Determining Length of Material

LENGTH OF MATERIAL necessary to form the desired size circle is the first consideration in circle forming. To determine the approximate length of material needed use the formula: C = I x D, Where C is the circumference, I is the value of π or 3.1416, and D is the diameter. For example, to find the length of material (C or Circumference) to form a 4” (101.6mm) diameter circle, multiply (3.1416 x 4). The result is 12.5664 or the approximate length of material needed. Cut a few pieces of material to this length for test forming. Material may have to be lengthened or shortened depending upon results of the test forming run.

Pre-Bending and Finish Rolling

PRE-BENDING is the operation where the ends of the material are bent to the same radius as that of the finished piece. This principle is used to get the best results in full circle bending.

Before bending, follow these steps:

• Clean the material and rolls of any dust or grease.

• Make sure the edges of the piece part are free of chips and burrs.

• Check that the material is flat.

• Have a template of the finished diameter to compare with.

• Always work in the center of the rolls.

Rolling Operation

1. Back off the idler roll by turning the two adjustment bolts counterclockwise (ccw) as in view “A” below.

2. Unscrew the top roll adjustment bolts until there is enough gap between the top and bottom rolls to allow the piece part to fit between.

3. Rotate the handlebar to advance the piece part about 1” (25.4mm) beyond the rolls.

4. Tighten the top roll adjustment bolts to hold the piece part firmly.

5. Raise the idler roll enough to get the material started in an upward direction against the top front roll as shown in view “B.

Shear Brake roll adjustment.png

6. Rolling the initial edge slightly will give it a pre-bend.

7. Back the piece out, turn the piece part and repeat the sequence for the other end. See view “C” below.  

CAUTION: Have an assistant support the top roll when removing finished cylinders from the top roll. Failure to adequately support the top roll may result in the roll falling, and causing personal injury.

8. Now that you have a pre-bend on both ends, it is time to roll the final diameter.

9. Back down the rear idler roll and start rolling the piece forward and reverse as shown in view “D”.

10.Start raising the idler roll gradually and continue rolling the piece forward and reverse until you have reached the finished diameter.

Shear Brake C and D adjustment.png

Note'': To achieve a cone configuration, adjust the idler roll on one end only.

11.To remove a finished piece part from the top roll, loosen both top roll adjustment bolts (#24).

12.With the help of an assistant, lift the left end of the top roll, up and out, keeping the right end gears meshed as much as possible. The other person will slide the finished cylinder off. The roll is heavy, so DO NOT attempt this alone.

Shear Brake Roll Adjustment Bolts.png

Rolling Round Shapes

There are three wire or forming grooves located on the right end of the upper and lower rolls (25” .31” .37”). They can be used to form solid wire, rods, and small tubing. To make rings, follow the “Determining Length of Material” procedure to calculate the actual length. Then proceed with the rolling operation.

Shear Brake forming grooves.png

BENDING ALLOWANCE

In order to bend sheet metal accurately, you will need to consider the total length of each bend. This is referred to as bend allowance. Subtract the bend allowance from the sum of the outside dimensions of the piece part to obtain the actual overall length or width of the piece. Because of differences in sheet metal hardness, and whether the bend is made with the grain or against it, exact allowances must sometimes be made by trial and error. However bend allowances for general use can be obtained from metal working books or from the Internet.

UNDERSTANDING SPRINGBACK

Springback, also known as elastic recovery, is the result of the metal wanting to return to its original shape after undergoing compression and stretch. After the bending leaf is removed from the metal and the load is released, the piece part relaxes, forcing the bent portion of the metal to return slightly to its original shape. The key to obtaining the correct bend angle is to over bend the metal a little and allow it to spring back to the desired angle. All metals exhibit a certain amount of spring back.

MATERIAL SELECTION

When selecting materials keep these instructions in mind:

• Material must be clean and dry. (without oil)

• Material should have a smooth surface so it processes easily.

• Dimensional properties of material must be consistent and not exceed the machine capacity values.

• Chemical structure of material must be consistent.

TROUBLESHOOTING

Shear Brake Troubleshooting.png

                                               END OF THE PROCEDURE