Flying-shear roll forming machines utilize a high-speed flying shear to cut profiles after forming them from metal coils. This guide provides a detailed overview of flying-shear technology in roll forming covering working principles, shear types, machine specifications, advantages, manufacturers, installation, operation and maintenance guidelines, and FAQs.
Introduction to Flying-Shear Roll Forming Machines
Flying-shear roll formers continuously form metal strips into various structural profiles which are then cut to length by a high speed rotating shear.
Key features:
- Flying shear achieves faster, cleaner cuts
- Higher accuracy of cut lengths
- Suitable for high production roll forming lines
- Integrates with other in-line processes
- Automated using speed and position sensors
Flying-shear technology enhances roll formed profile quality and productivity.
Working Principle of Flying-Shear Roll Forming Machines
- Coil material is fed into the roll forming section to shape the desired profile
- Formed profile enters the cutting zone at the same speed as the rotating shear blades
- Shear blades cut the profile “on-the-fly” at a tangent point with minimal interruption
- Top and bottom blades are mounted on rotating cylinders or shafts
- Precise blade alignment and synchronization ensures clean shearing action
- Sheared lengths are collected on a conveyor or stacked via grabber
Main Types of Flying Shears
| Type | Operation | Characteristics |
|---|---|---|
| Rotary shear | Circular blade motion | Simple, economical, medium speeds |
| Gantry shear | Linear blade motion | Very high speeds, expensive |
| Oscillating shear | Oscillating blade | High precision, clean cuts |
Rotary flying shears are most commonly integrated into roll forming lines. Gantry and oscillating shears offer faster linear blade speeds.
Specifications of Flying-Shear Roll Forming Machines
| Parameter | Typical Values |
|---|---|
| Line speed | 10 – 120 m/min |
| Feed thickness | 0.5 – 3 mm |
| Shear length | 2 – 6 m |
| Cut length tolerance | ± 0.5 mm |
| Blade gap adjustment | 0.1 – 1 mm |
| Motor power | 5 – 15 kW |
| Stroke rate | 5 – 15 cuts/min |
| Control | PLC with HMI |
Specifications depend on application requirements like cut length, material thickness, and production volumes.
Components of Flying-Shear Roll Forming Machines
| Component | Function |
|---|---|
| Decoiler | Feeds metal coil strip |
| Roll forming stands | Gradually forms profile |
| Shear blades | Cuts profiles on-the-fly |
| Hydraulic power pack | Powers blade cylinders |
| Infeed/outfeed tables | Guides strip into shear |
| Conveyor/stacker | Collects sheared lengths |
| Sensors | Detect position, speed |
| Controls | Automates process parameters |
Applications of Flying-Shear Roll Formed Profiles
| Industry | Typical Profiles |
|---|---|
| Construction | Wall studs, roofing panels, framing sections |
| Automotive | Inner/outer door frames, pillars, roof channels |
| Appliances | Washing machine drums, refrigerator panels |
| Furniture | Table frames, storage racks, shelves |
| Infrastructure | Highway crash barriers, traffic sign poles |
| Logistics | Racking systems, conveyor support frames |
Common materials: Galvanized steel, stainless steel, aluminum
Benefits of Flying-Shear Roll Forming
- High speed precision cutting minimizes burrs
- Consistent cut lengths improve product quality
- Automated synchronization for speed, accuracy
- Lower scrap generation compared to stop-and-cut shearing
- Compact design fits inline with other processes
- Enables heavy and thick profile cutting
- Minimal material deformation or cracks
- Lower maintenance than rotary or guillotine shear systems
Installation Guidelines for Flying-Shear Machines
- Rigid flat foundation for securing equipment
- Leveling and alignment of shear shaft parallel to roll former
- Calibration of blade gaps and proof testing
- Guarding for rotating shear blades
- Service access for maintenance and adjustments
- Overhead lifting equipment for coil loading
- Trial production runs to fine tune settings
Operation and Maintenance Guidelines
| Activity | Guidelines |
|---|---|
| Setup | Check lubrication, power, material, safety devices |
| Running | Monitor sensors, line speed, shear RPM, cut lengths |
| Inspection | Check blade wear/damage, hydraulic leaks, loose parts |
| Maintenance | Lubricate bearings, inspect/replace worn parts |
| Adjustment | Adjust blade gaps, position sensors, stroke rate |
| Safety | Use proper lockout procedures during service |
| Troubleshooting | Verify sensors, hydraulics, electrical systems |
Follow manufacturer’s instructions manual for procedures, schedules, troubleshooting and safety.
Selection Criteria for Flying-Shear Roll Forming Machine
- Shear design type suited for production volumes
- Capability to achieve desired cut lengths and speeds
- Precision and automation features
- Built quality and reliability
- Integration with upstream and downstream equipment
- Maintenance requirements and response time
- Manufacturer’s experience and technical support
- Overall cost considerations
- Production scalability for future growth
- Compliance with all required safety standards
Pros vs Cons of Flying-Shear Roll Forming Machines
| Pros | Cons |
|---|---|
| Fast and clean on-the-fly cutting | Higher cost than stop-type shearing |
| Minimal burrs and deformation | Complex design and synchronization required |
| Consistent cut lengths and precise tolerances | Needs greater maintenance attention |
| High productivity and speeds | Limited thickness capacity versus guillotine shears |
| Less scrap generation and downtime | Not suitable for small batch or short length cutting |
| Automated precision alignment | Requires highly skilled personnel |
| Compact and safe design | Significant capital investment |
FAQs
Q: What types of profiles can be roll formed and cut using flying shear?
A: Flying shears can cut various structural profiles like wall studs, roofing panels, door frames, racking posts, highway guardrails, solar frame sections etc.
Q: What are the limitations of flying shear technology?
A: Limitations include thickness capacity upto 3 mm normally, higher maintenance needs, not economical for short length cutting requirements.
Q: What safety aspects are important for flying shear operation?
A: Proper guarding, emergency stop circuits, lockout/tagout procedures during maintenance, electrical safety systems, avoiding speed/position sensor issues, and using PPE.
Q: What regular maintenance is required for flying shear roll formers?
A: Key maintenance includes lubricating bearings, inspecting/replacing worn shear blades, hydraulic system inspection, checking sensors and gaps, testing emergency stops, and cleaning scrap buildup.
Q: How does flying shear help improve roll formed profile quality?
A: The high speed cutting minimizes burrs and deformation marks associated with stop-type shearing. It improves profile dimensions and functional performance.
Conclusion
Flying-shear technology provides distinct advantages for high productivity roll forming lines producing metal profiles requiring precise cut lengths. This guide covered the working principles, types, specifications, components, applications, benefits, selection factors, installation and maintenance guidelines, pros and cons, and common FAQs regarding flying-shear roll formers to support engineers, technicians, and buyers in understanding and adopting this technology. With rapid advances in speed, precision, and automation, flying-shear roll forming machines are positioned to transform profile manufacturing across industries.