1. Overview of Flying Shear

A Flying Shear is a type of high-speed cutting equipment widely used in continuous production lines such as steel Rolling Mills, metal plate processing, pipe mills, and bar or wire production. Unlike traditional fixed shears, a flying shear can cut materials while they are moving, without stopping the production line. This enables continuous operation, high efficiency, and precise length control, making it an essential component of modern metal processing systems.

The core principle of a flying shear is that the cutting blade moves synchronously with the material for a short period during cutting. This synchronized motion ensures that the material is cut to the desired length without interrupting its movement, which is particularly important in high-speed rolling and continuous casting processes.

2. Working Principle of Flying Shear

The working principle of a flying shear is based on synchronous motion and precise timing control. During continuous material feeding, the machine continuously monitors the material’s speed and position. When the preset cutting length is reached, the control system commands the flying carriage (which holds the shear blades) to accelerate and match the line speed of the material.

At that moment, the upper and lower blades close rapidly to cut the moving material. After the cut, the shear carriage decelerates and returns to its initial position to prepare for the next cut. The entire process is completed in milliseconds, ensuring both accuracy and high-speed performance.

Modern Flying Shears often adopt Servo Motors and PLC (Programmable Logic Controllers) for accurate synchronization and cutting length control. Some high-end systems are equipped with CNC (Computer Numerical Control) and optical encoders for real-time feedback and error correction, ensuring exceptional precision even at high line speeds.

3. Structure and Main Components

A typical flying shear machine consists of the following main parts:

1. Frame (Body): Provides structural stability and supports all moving components.

2. Flying Carriage (Slider): The moving platform that carries the cutting blades and executes synchronized motion.

3. Cutting Blades: Upper and lower shear blades made of high-strength alloy steel to ensure sharpness and durability.

4. Drive System: Usually powered by servo motors, hydraulic actuators, or mechanical linkages, ensuring fast acceleration and precise motion.

5. Measuring System: Includes encoders and sensors to measure the material length and line speed in real time.

6. Control System: Based on PLC or CNC, responsible for synchronization, timing, and error correction.

7. Transmission Mechanism: Includes gears, couplings, and guide rails that ensure smooth and stable motion.

8. Cooling and Lubrication System: Reduces heat and friction during continuous operation.

9. Safety and Protection Devices: Include guards, limit switches, and emergency stop mechanisms.

4. Classification of Flying Shear Machines

Flying shears can be classified according to different criteria:

1. By Driving Mode:

• Mechanical Flying Shear: Driven by gears and cams; reliable but less flexible.

• Hydraulic Flying Shear: Uses hydraulic cylinders; offers strong cutting force, suitable for thick materials.

• Servo Flying Shear: Uses servo motors for precise synchronization; ideal for high-speed lines.

2. By Function:

• Cold Shear: Used for cutting materials at normal temperature.

• Hot Shear: Used in hot rolling lines, cutting materials while they are still hot.

3. By Application:

• Bar Flying Shear: For cutting long steel bars.

• Plate Flying Shear: For cutting continuous metal plates or strips.

• Pipe Flying Shear: Used in tube mills for cutting pipes at high speed.

5. Performance Features and Advantages

• Continuous Operation: Enables nonstop cutting during production, improving efficiency.

• High Precision: Servo synchronization ensures consistent length accuracy.

• High Speed: Suitable for rolling speeds exceeding 30–100 m/s.

• Flexible Adjustment: Cutting parameters can be quickly modified through the control interface.

• Durability: High-quality materials and precision machining ensure long service life.

• Reduced Downtime: Quick blade replacement and automatic error detection minimize production interruptions.

• Intelligent Control: Equipped with PLC or CNC system for data recording, fault alarm, and remote monitoring.

6. Application Fields

Flying shears are used in many industrial sectors, including:

1. Steel Rolling Mills: For cutting bars, rods, and billets in continuous casting lines.

2. Pipe Mills: Online cutting of steel pipes or tubes during high-speed production.

3. Sheet Metal Processing: Cutting metal plates to fixed lengths in coil lines.

4. Automotive and Aerospace: Processing structural components with precise length control.

5. Construction Industry: Producing standardized rebar and beams for building materials.

7. Maintenance and Operation

To ensure stable performance, the following practices are recommended:

• Regularly inspect blade wear and replace when necessary.

• Check lubrication and cooling systems for proper function.

• Keep sensors and encoders clean to maintain accuracy.

• Verify synchronization between shear and line speed frequently.

• Follow safety protocols and perform preventive maintenance.

Conclusion

The Flying Shear is a cornerstone technology in modern continuous metal production. By enabling high-speed, accurate, and uninterrupted cutting, it dramatically enhances production efficiency and material utilization. With advancements in automation, control algorithms, and smart systems, flying shears will continue to evolve—offering greater precision, reliability, and integration within the intelligent manufacturing ecosystem.