1. Overview of High-Speed Billet Cutting Shear

The High-Speed Billet Cutting Shear is a critical piece of metallurgical equipment used to cut steel billets to specific lengths during continuous casting or rolling production.
Unlike conventional mechanical or hydraulic billet shears, this type is designed for high-speed continuous operation, capable of synchronizing perfectly with modern high-output Rolling Mills.

The equipment utilizes high-response hydraulic or servo-driven systems, precise motion control, and robust structural design to achieve fast, accurate, and reliable billet cutting without interrupting production flow.
It is widely used in steel mills, forging plants, bar and wire production lines, and continuous rolling systems where billet cutting speed, precision, and durability are crucial.

2. Working Principle

The High-Speed Billet Cutting Shear operates through a synchronized motion system that matches the billet’s linear speed during rolling or conveying.
When the billet reaches the cutting position, sensors and encoders provide feedback to the control system, which triggers the shear movement.

There are typically two operating modes:

1. Flying Cutting Mode (On-the-Fly Shear):
   The cutting head moves together with the billet during the shear operation, maintaining speed synchronization.

2. Stationary Cutting Mode:
   For intermittent processes, the billet stops momentarily for cutting before being transported onward.

In the flying mode, the high-speed shear uses a servo or electro-hydraulic actuator to drive the upper blade in perfect synchronization with the billet, completing the cut precisely while the billet continues to move.

This principle ensures non-stop production, eliminating downtime and increasing the overall throughput of the rolling line.

3. Structural Composition

A typical High-Speed Billet Cutting Shear consists of the following major components:

1. Main Frame:
   A high-rigidity welded steel structure with excellent vibration resistance and stability.

2. Cutting Mechanism:
   Comprising upper and lower blades, sliding guides, and blade holders. The blades are made from high-alloy tool steel (H13, Cr12MoV) with heat treatment for wear resistance.

3. Drive System:
   Can be hydraulic, electro-hydraulic hybrid, or servo-electric, providing the required acceleration and synchronization.

4. Hydraulic or Servo Actuator:
   Provides linear motion for the blade during the cutting stroke.

5. Positioning and Measuring Unit:
   Includes optical or laser sensors, encoders, and limit switches for billet length detection.

6. Control System (PLC + Servo Controller):
   Coordinates billet speed, cutting timing, and blade synchronization.

7. Cooling and Lubrication System:
   Ensures temperature control and minimizes blade wear during long production runs.

8. Safety System:
   Includes overload protection, emergency stop circuits, and mechanical guards.

4. Technical Characteristics and Performance

1. High Cutting Speed:
   Capable of cutting billets at speeds up to 15–25 m/s, synchronized with high-speed rolling lines.

2. Precision Synchronization:
   Speed difference between billet and blade less than ±0.1 m/s, ensuring clean, burr-free cuts.

3. High Reliability:
   Designed for continuous 24-hour operation, with reinforced bearings and low-maintenance components.

4. Smooth Operation:
   Servo control ensures soft start, acceleration, and deceleration, minimizing impact forces.

5. Flexible Adaptability:
   Suitable for hot or cold billets, with automatic adjustment of cutting force and speed.

6. Energy Efficiency:
   Advanced hydraulic circuits and servo control reduce energy consumption by 20–30%.

7. Compact Structure:
   Modular design simplifies installation and maintenance.

5. Control and Automation

The control system of the High-Speed Billet Cutting Shear adopts advanced PLC, servo control, and HMI technology, providing a fully automated cutting process.

Key features include:

• Real-time billet length measurement

• Automatic speed matching with rolling mill

• Servo synchronization of cutting motion

• Data recording and production tracking

• Remote diagnostic interface via industrial Ethernet

Through servo-proportional control, the system achieves precise motion coordination even at high speeds, ensuring the shear performs each cut at the exact moment required.

6. Application Fields

The High-Speed Billet Cutting Shear is used primarily in:

• High-speed continuous casting and rolling lines

• Steel bar and wire rod production plants

• Billet length trimming and preparation lines

• Forging billet feeding systems

It is particularly suited for high-output, automatic steel plants that demand both speed and precision.

7. Maintenance and Safety

To ensure reliable long-term operation, regular maintenance should include:

1. Monitoring hydraulic oil temperature and pressure;

2. Cleaning filters and checking for leaks;

3. Regular lubrication of bearings and guide rails;

4. Checking blade wear and replacing as necessary;

5. Verifying synchronization calibration between shear and billet transport;

6. Testing emergency stops and safety locks.

Conclusion

The High-Speed Billet Cutting Shear represents the pinnacle of modern metallurgical cutting equipment.
With precise synchronization, high speed, and robust construction, it ensures efficient, continuous, and safe billet cutting in large-scale steel production lines.
Its integration with intelligent control and servo-hydraulic systems makes it an indispensable component of future smart steel manufacturing.