What is Shearing?

When steel service centers receive their products from their suppliers, they often need to perform further processing on the material before delivering those products to their customers or end users. One of the many processes performed by steel service centers is called metal shearing. This article describes some details about the metal shearing process, and some of the benefits associated with it.

Shearing is a fundamental process in the metalworking industry, used to cut or slice sheet metal along straight lines without forming chips or using burning or melting processes. It's highly efficient for producing clean cuts in metal sheets and plates and is commonly employed for cutting large quantities of material to size.

Shearing is performed on sheet metal to trim an unwanted area off the sheet, or to form the sheet into a desired shape. One of the most common types of machines used in this production process is called a bench shear. The shearing process is carried out on the bench shear by placing the sheet metal onto a flat table, and then using a blade to slice through the material.

Shearing involves the use of a shearing machine or shear to apply a high force to a metal workpiece positioned between two blades—one fixed and one moving. The metal is positioned so the blades are slightly offset from each other, creating a shearing action when the upper blade moves downward. This action results in a straight cut across the metal.

Once the steel sheet has been loaded onto the machine properly, the operator will use what is called a squaring arm to perform precise cuts.

Types of Shearing Machines

Guillotine Shear: The most common type, which uses a moving upper blade and a fixed lower blade to create straight cuts. Also known as a power shear. These types of shearing machines are powered by mechanical or hydraulic components, and they offer faster and more effective cuts than a bench shear.
Bench Shear: A bench shear is a mechanical tool used to cut sheet metal and other materials with precision. It's also known as a lever shear.
Swing Beam Shear: This type of shear is similar but uses a pivoting blade for smoother, faster cuts.
Hydraulic Shear: Powered by hydraulic pressure, offering greater force for thicker materials when looking at what is shearing and its methods.
Mechanical Shear: These machines use mechanical flywheels to create the necessary shearing force and are often faster but less flexible than hydraulic shears.

Shearing vs. Saw Cutting

Shearing and saw cutting are two distinct methods used to cut metal, each with its advantages and limitations. The choice between these processes depends on factors such as material type, thickness, precision, and desired finish.

Shearing is ideal for cutting large sheets or plates of metal into smaller sections or strips. The process is fast and efficient, particularly for high-volume operations, but it is limited to straight-line cuts. Saw cutting, on the other hand, can create more intricate cuts, including curves and complex shapes.
Saw Cutting uses a blade with teeth to cut through metal. Unlike shearing, saw cutting generates chips or metal shavings, which can be less efficient for material conservation but more flexible in terms of cutting shapes. Saw cutting is slower than shearing but allows for more complex geometries and better edge finishes.

Thicknesses Sheared vs. Saw Cut

What is shearing versus saw cutting when it comes to what thickness of metal can be processed? The thickness of metal that can be sheared depends on several factors, including the strength of the material, the type of shear used, and the blade's strength.

Shearing is typically used for sheet metal, ranging from very thin materials (such as aluminum sheets) up to around ¼ inch (6 mm) for mild steel. High-strength shearing machines, especially hydraulic shears, can handle thicker materials, up to ½ inch (12.7 mm) or more, depending on the machine's capacity.
- Materials such as stainless steel, due to their strength and hardness, may have lower maximum thicknesses for shearing compared to softer metals like aluminum.
- Beyond these thicknesses, shearing becomes less effective as the blades may deform or struggle to maintain a clean cut, leading to burrs or rough edges.
Saw Cutting is better suited for cutting thicker materials. Bandsaws and cold saws, for instance, can cut through metals that are several inches thick, including materials like steel plates over 1 inch (25.4 mm) in thickness. For extremely thick materials, saw cutting is often the go-to method because of its ability to maintain accuracy and edge quality, even in heavy-duty applications.

Benefits of Shearing Metal

There are many benefits that make shearing attractive for organizations who process steel. One of the most important is the fact that the cuts are clean and precise, while also producing little to no waste. The shearing process is carried out when the steel is either cold or at room temperature; this means that this process results in no heat-affected areas as some of the other metal processing techniques do.

The shearing process is generally performed cold (without the application of heat), allowing it to be efficient and cost-effective for various industrial applications, including automotive, construction, and fabrication industries. Shearing is used to cut flat metal stock into smaller pieces or into different shapes.

Edge Quality: Shearing can produce a clean, straight edge, but for thicker materials, it may leave slight deformations or burrs, which often require secondary processes like deburring or sanding.
Cutting Capacity: The shearing machine's tonnage and blade type determine the maximum thickness and material type that can be efficiently sheared.
Material Type: Softer metals like aluminum can be sheared in thicker gauges compared to harder metals like stainless steel. The material's tensile strength directly impacts shearing capabilities.
Speed and Efficiency: Shearing is much faster than saw cutting, especially for high-volume production of straight cuts, making it an efficient option for simple shapes.

Another key benefit of steel shearing is that it is cost effective for high-volume operations. This is especially true for steel service centers who may process tons of steel each week. Shearing is one of the fastest metal processing techniques, as it is usually carried out in a matter of seconds. Shearing can be performed on multiple metal materials other than steel including bronze, iron, aluminum, and copper.

Applications of Shearing

Shearing is widely used in industries where metal sheets and plates are processed into smaller, manageable parts for further fabrication or assembly. What is shearing used for in daily use? Common applications include:

Fabrication of metal components for construction, HVAC systems, and household appliances.
Automotive industry for producing vehicle body parts and structural components.
Aerospace industry for cutting lightweight aluminum sheets into parts.
Manufacturing of enclosures for electrical and electronic systems.

In the metal industry, shearing is a fast and efficient process for cutting sheets and plates of metal, particularly when straight-line cuts are required. While limited by material thickness and edge quality in comparison to saw cutting, shearing is the preferred method for high-speed production and processing of sheet metal up to around ½ inch thick. Saw cutting, on the other hand, is favored for thicker materials and intricate shapes, offering flexibility and precision where shearing might fall short.

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