BLANKING PRODUCTION LINE SOLUTIONS
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Blanking Production Line Solutions

Blanks for forging are usually black metal and nonferrous metal with the shape as rod, plate or pipe, before heating or
forging, the process of cutting the raw material into the required length or geometry size is called as blanking, it is the first
process of free forging and die forging.
Shearing and sawing are commonly used blanking method, our band saw, circular saw and rod shearing machine are also 
commonly used equipment. All kinds of equipment have their own characteristics, their blank quality, material using rate, 
processing efficiency, etc. are different. Our equipment characteristics are summarized as follows. We hope to help
customers understand our equipment better, and facilitate them to make the best choice. 
 
Principle and characteristics of bar shearing 
4The cutting principle of rod cutting is shown at right. The blade shape of shearing die is similar to section of the bar, the small size bars are mostly cut by For the alloy steel and the larger size carbon steel bars, it need to be heated  up to 350-550 ℃  to prevent  cracks happening on the section. 
The shearing method of blanking is high efficiency, has no material loss in cutting section, is suitable for mass production. It is mainly used for medium and large forging enterprises with over 10000 tons forgings. However, the shearing section quality is poor, easily accompanied with burrs and cracks. 
To adopt precision shearing process and equipment can improve the  flatness on shearing section and reduce the deviation of material weight . 
 
 
For example, using our ZQ42 series warm shearing equipment to cut Φ50mm GCr15 round bar, the section and axis perpendicularity can be less than 2 degrees, the weight deviation is +/-0.5%. 
For blanking by shearing method, it is usually to adopt special shearing equipment , while it can also be done on a general crank press.
The shearing blanking state is shown at right:
Under the action of the shearing blade force, the rod produces bending and stretching deformation, and fracture occurs when the stress exceeds the shear strength. 
 
 
The shearing process is divided into three stages, shown as below:
(a) The blade is pressed into the bar, the plastic deformation area is not big, owing to processing hardening, cracks first shows at blade side.
(b) the cracks continues to expand with the deepening of the blade;
(c) under the pressure of the blade, the metal between the upper and 
The quality of the shearing section is related to sharpness of blade, die clearance of the blades, the supporting condition and the shearing speed.
When the blade is blunt, the plastic deformation zone will be expanded, the crack at the blade edge happens lately, the shearing section is uneven. If the clearance between the blades is big, the blank is easy to bend, it causes the section not perpendicular to the axis; if the clearance between the blade is too small, the blade is easily damaged. If the blank is not supported well, two cracks on the direction of the upper and lower will not be parallel, the blade will tilt.

If the shearing speed is fast, the plastic deformation zone and the processing hardening are concentrated, the upper and lower cracks are in the same direction, smooth section can be obtained. When the shearing speed is slow, the situation is opposite.

In order to improve the shearing efficiency and quality, we often use high-speed shear blanking process and blue brittle* blanking process. The axial and lateral movement of cracks are eliminated by high speed shearing, and the crack growth along the circumferential direction is accelerated. The stress concentration at the tip of the cracks make the plastic zone is smaller, the brittleness of the material is increased, the plasticity is reduced.

Thus the inclination of the broken face is greatly improved. For normal medium strength carbon steel, shear speed should be controlled at 5m/s~7m/s according to the above theory.
The blue brittleness blanking is shearing rod at the blue brittleness temperature range 300℃~450℃. Shearing rod in blue brittleness temperature can get better shearing accuracy than that of the room temperature. The blue brittleness of the steel increases, the plasticity decreases, the section collapses small , the ellipticity keeps small and the heating energy consumption is greatly reduced, good blank quality and section quality can be obtained.
*Blue brittleness is steel mechanical properties change caused by deformation aging. The tensile strength and hardness of the steel are increased near 300 ℃, and the section elongation and shrinkage  are decreased. The tenacity of most alloy steels with ferrite pearlite structure decrease with temperature increasing at about 300 ℃. It occurs on the steel surface with a blue oxide film, so it is called blue brittleness. Blue brittleness occurs in low alloy steels with low alloying elements annealing or normalizing.
Our ZQ42 series Shearing Equipment and SJ45 series Horizontal Bar Shearing Machine can use blue brittleness blanking with good quality.
Performance And Characteristics Of Bar Shearing Machine
There are 3 series Rod Shearing Machine in SSET: ZQ42 series Mechanical Warm Shearing Machine, SJ45 series Horizontal Bar Shearing Machine, JD series Hydraulic Shearing Machine, its performance and characteristics are introduced as follows:


ZQ42 series Mechanical Warm Shearing Machine
Characteristics of ZQ42 series Mechanical Warm Shearing Machine
1. Shearing range: To shear medium carbon and alloy steel bar of diaΦ25-Φ145, under cold condition, and bearing steel after heating in blue brittleness condition.
2. Shearing precision high, the shearing section perpendicularity is less than 3 degrees, and the weight deviation is ±0.5%.
​3. The  body of  machine is whole  steel plate welded structure, it has enough strength and rigidity after aging treatment, .
4. The electrical control system adopts PLC,  which is of  high accuracy and high reliability.
5.The device can realize point adjustment, single stroke, manual operation, automatic shearing and other functions.

      
SJ45 Series Horizontal Shearing Machine 
Characteristics of SJ45 series Horizontal Shearing Machine
1. It is suitable for cold shearing carbon steel or low alloy steel bar Φ25-Φ90 or blue brittleness shearing after warming
2. The shearing accuracy is high, the section perpendicularity is ≤3° , and the weight deviation is 0.5%.
3. The high rigid steel body is cast in whole, strong and durable and keeps good accuracy. 
4. Adopt PLC control, helical gear four stage transmission, low noise.
5. Pneumatic clutch is flexible, reliable and easy to maintain.
6. Feeding system has material rack and feeding device, which can realize automatic lifting, feeding, counting and other functions.


    
JD Series Hydraulic Shearing Machine
Characteristics of JD series series Hydraulic Shearing Machine
1. It has an ideal effect for shearing medium carbon steel or low alloy steel bar Φ12-Φ50. 
2.The shearing accuracy is high, the section perpendicularity is ≤2°, and the weight deviation is ±0.25%.
3. It adopt Hydraulic transmission, hydraulic fittings, easy to operate and maintain,  low failure rate.
4.The hydraulic mechanism is stable and the die impact force small. So the service life is 3-4 times that of the mechanical shearing machine.
5. It adopt hydraulic transmission, the transmission is smooth and the noise is low.
6. Easy to install and does not require large concrete foundation. Just place the machine on flat ground.


     
Characteristics Of  Sawing Rod Blanking
Sawing  refers to cutting work piece or material a narrow slot or spit it with saw blade, circular saw blade, band saw or thin slice grinding wheels. Common sawing methods  is shown as  the right picture.
Sawing blanking can obtain accurate length, smooth section, good straightness, it the first choice blanking in precision forging process.
In recent years, some manufacturers all adopt sawing blanking in gear precision die forging, precision die forging for gear billet and closed-die forging.
Sawing can cut large cross section billets, can saw the metal in cold or hot state. The disadvantage is low productivity and the sawing blade loss. 
Cold sawing is usually used in forging production, and hot sawing is used more frequently in rolling mills.
The band saw and circular saw provided by SSET are very suitable for blanking procedures in forging production.

  
Performance And Characteristics Of Band Saw Machine
The structure of band saw machine of SSET is reasonable, performance stable and reliable, and precision high. It is suitable for supplying various black metal, nonferrous metal billet for cold and hot forging forming equipment like: extruder, roll forging machine and other 
Characteristics of SSET Band Saw Machine:
1. High cutting accuracy : length repeat   accuracy can reach +/-0.1mm. 
The section roughness can reach Ra6.3, the perpendicularity is not more than 0.2mm.The cross section smooth without any common defects such as bending, skew, collapse angle , etc.
2. Low energy consumption, high productivity, convenient operation. 
3. Narrow sawing slot, high material utilization .
Many kinds of automatic and semi-automatic machines for choice, can choose
automatic feeding devices and bundle sawing devices according to the customers
requirements.

       
Performance And Characteristics Of Circular Saw Machine
SSET high speed circular sawing machine is a high efficiency, high precision automatic cutting machine, it has easy operation interface, high rigid body, full closed cutting, high safety, is suitable for requirement of large quantity blanking in precision forging production.
Characteristics of SSET high speed circular sawing machine:
1.The blanking precision is higher than
that of the common  belt sawing machine.
2. Low energy consumption, high
productivity, cutting efficiency is five times
that of common band sawing machine.
3. Servo blade entering and feed system
ensure accurate cutting.
4. Hydraulic clamp and  lower press device ensure the work piece securely clamped. Prevent saw blade vibration and prolong the saw blade life.
5. High rigidity and  precision spindle gearbox cooperation, with gear space elimination mechanism, blade entering steady.
6. Dialogue operation interface, humanized operation simple and easy to understand.

     
If you want to know more details, please download our document.  
Blanking Equipment In Forging Production
Technical Scheme Of Warm Shearing For Bearing Steel Rod

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 E-mail:
larry@smartsmith.cn
Jenny@smartsmith.cn
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(Ms.Jenny Zhang)
  Add:Room 603,Building 18,Pan Asian Center, Duantang East Road, Ningbo, Zhejiang, China

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