1. Ensure Safety Precautions

• Turn off the power to the roll forming machine.
• Wear protective gear such as gloves and safety glasses.
• Lockout/Tagout procedures should be in place to prevent accidental machine activation.

2. Check Blade Condition

• Inspect the shear blades for wear, nicks, or damage. If the blades are dull or damaged, replace them before proceeding with adjustments.

3. Adjust Blade Clearance

• Blade clearance is crucial for accurate shearing. The clearance between the upper and lower blades should be checked and adjusted according to the thickness of the material being cut.
• Procedure:
  • Use a feeler gauge to check the gap between the blades.
  • Loosen the adjustment bolts on the shear assembly.
  • Adjust the blade gap by moving the blades closer or farther apart based on the material thickness. A typical gap is between 5% to 10% of the material thickness.
  • Retighten the adjustment bolts after setting the gap.

4. Align the Blades

• Proper blade alignment ensures that both the top and bottom blades are parallel, avoiding angled or incomplete cuts.
• Procedure:
  • Visually inspect the alignment of the blades from the side.
  • Use a straight edge or dial indicator to verify that both blades are level.
  • If misaligned, adjust the blade holders by loosening the mounting bolts and realigning the blades.
  • Retighten the bolts after achieving proper alignment.

5. Set Blade Stroke (Optional)

• Some roll forming machines have adjustable shear stroke lengths depending on the material length or profile.
• Procedure:
  • Locate the stroke adjustment mechanism (usually a knob or lever).
  • Adjust the stroke so that the blade travels just enough to complete the cut without excessive movement.
  • Test the stroke by manually cycling the machine to verify the length is appropriate.

6. Check and Test

• Once the adjustments are made, manually rotate the machine through a cycle to ensure the blades do not bind or interfere.
• Perform a test cut on a sample of the material to verify the shear operation is clean and accurate.
• Make additional fine adjustments if needed based on the test results.

7. Maintenance

• Regularly check and lubricate moving parts of the shears to reduce wear.
• Periodically inspect blade sharpness and overall shear performance.

Following these steps will help you achieve precise shearing results and prolong the life of your roll forming machine.