Flying-Shear Roll Forming Machines

Flying-shear roll forming machines utilize a unique cut-to-length system to boost efficiency in roll formed profile production. The flying shear mechanism shears the moving strip just before it enters the roll forming section.

Key details about flying-shear roll formers:

  • Cut-to-length system integrated into roll former
  • Rotary shear cuts moving strip at high speed
  • Precise shear timing synchronized to line speed
  • Permits faster overall line speeds
  • Quick and easy size changes
  • Used for metals up to 4mm thickness
  • Ideal for producing parts in standard lengths
  • Commonly used to make roofing panels, decking, and panels

By removing the stop-and-start action of typical end shears, flying shears optimize the roll forming process.

Types of flying-shear roll forming machine

Machine TypeDescription
MechanicalShear timing via Geneva mechanism and servo drive
ElectronicShear controlled by PLC with encoder feedback
HydraulicHydraulic cylinder actuates shear at right moment

Mechanical flying shears precisely time the cut mechanically for a simpler, economical design.

Electronic flying shears offer more flexibility and speed control through the system’s logic controller.

Hydraulic flying shears generate high shearing force while maintaining accurate timing.

flying-shear roll forming machine
Flying-Shear Roll Forming Machines 4

Key Components of Flying Shear Roll Formers

DecoilerFeeds strip from coil into line under proper tension
Roll ToolingForming stations gradually shape the strip
Flying ShearRotary shear cuts moving strip at high speed
ConveyorReceives cut parts and discharges from line
PLC ControlCoordinates decoiler, shear, conveyor, and monitoring
Operator InterfaceTouchscreen to control and adjust forming parameters

Flying shears combine dynamic roll forming technology with synchronized high speed shearing for superior productivity.

Typical Applications of Flying Shear Roll Forming Lines

Roofing PanelsFor standing seam, concealed fastener panels
Siding and CladdingWall panels, architectural facades
DeckingRoof deck, flooring panels
Solar FramesFor solar panel mounting structures
ShelvingAdjustable shelves, support beams
Drainage SystemsCulverts, rain gutters, downspouts

Flying shear roll formers are ideal for producing roofing, siding, decking, and numerous profiles in standard lengths.

Design Standards for Flying Shear Roll Forming Machines

FrameRigid steel, stress-relieved welded construction
ToolingHardened rolls, machined shafts, bearings
Shear BladeHardened D2 steel, heat treated
Shear TimingPrecise Geneva or electronic control
DrivesHelical gearboxes or servo motors
ControlsPLC, color touchscreen HMI
FinishesPrimed then powder coated
SafetyFully enclosed guards, e-stops

Robust framing matched with high quality components and smart controls result in reliable, consistent performance and end product quality.

Specifications of Flying Shear Roll Formers

SpecificationTypical Values
Line Speed10 – 50 m/min
Max Strip Width1000 – 1300 mm
Thickness Capacity0.5 – 4 mm
Length Tolerance± 1 mm
Length RangeAny cut length
Power30 – 75 kW
Machine Weight5000 – 8000 kg

Speeds, widths, and power requirements vary across mechanical, hydraulic, and electronic flying shear machine models.

Pricing Details for Flying Shear Roll Forming Equipment

ManufacturerPrice Range
Metform$150,000 – $250,000
ETP$140,000 – $220,000
Samco$160,000 – $280,000
China manufacturers$80,000 – $150,000

Prices range from $80,000 to $280,000 depending on size, features, and precision. Installation and shipping add 10-20%.

Installation and Commissioning of Flying Shear Machines

Site PreparationClear space, anchor bolts to foundation
LiftingUse appropriate lifting gear to offload sections
AssemblyBolt frame together; install components
AlignmentPrecision align and level all sections
ElectricalWire motors, PLC, controls, and accessories
ConveyorBolt in feed and exit conveyors
Test RunCycle slowly, inspect operation and cut parts
OptimizationRefine shear timing, control parameters

Proper installation and thorough testing ensures smooth startup and quality output from the machine.

flying-shear roll forming machine
Flying-Shear Roll Forming Machines 5

Operation and Maintenance of Flying Shear Roll Lines

Safety ChecksPer shift
Coil LoadingAs needed
Parameter AdjustmentAs needed
Blade LubricationDaily
Blade InspectionWeekly
Bearing LubricationMonthly
Hydraulic ServiceQuarterly
Gearbox OilPer manual

Daily safety procedures must be followed. Careful operation and regular maintenance are vital for flying shear longevity and performance.

Selecting a Flying Shear Roll Former Manufacturer

ExperienceLook for extensive background with flying shears
CustomizationAbility to tailor machine to application needs
SupportInstallation help, training, manuals, service
ReputationChoose established brand known for quality
DeliveryManufacturer can deliver on required schedule
ValueBalance capabilities against price paid

Consider expertise with this specialized equipment along with customization, support, and fair cost.

Benefits of Flying Shear Roll Forming Lines

  • Faster production than standard roll former with end shear
  • Precisely cut parts immediately off the roll former
  • Quick and easy size changeovers
  • Increased throughput from uninterrupted strip flow
  • Ideal for producing profiles in standard lengths
  • Consistent cut tolerance and quality
  • Compact design minimizes space
  • Lower labor requirements
  • Ability to cut to length on the fly
  • Simpler material handling

Key advantages include speed, changeover ease, consistency, and labor savings versus typical stop-and-cut systems.

Limitations of Flying Shear Roll Forming Technology

  • Higher initial capital cost than standard roll formers
  • Requires more maintenance and skilled operation
  • Limited to thinner/softer material gauges
  • Not as easy to cut non-standard length parts
  • Precise alignment critical for smooth operation
  • Timing mechanisms can wear over time
  • Special tooling required for different profiles
  • Can increase roll changing time during size changes
  • Scrap generation during initial setup

The main limitations relate to higher cost and maintenance requirements versus basic roll formers.

Cost Comparison of Flying Shear vs End Shear Machines

Machine TypePrice RangeBenefitsDrawbacks
Flying Shear$150,000 – $300,000Faster speeds, easy length changesHigher cost, specialized maintenance
End Shear$100,000 – $200,000Lower initial cost, simple operationSlow cut-to-length method

Flying shears improve productivity but have higher capital and operating costs. Evaluate based on volume, changeovers, and budget.

Troubleshooting Issues with Flying Shear Roll Lines

Inaccurate shear timingAdjust/replace worn gears; check encoder
Blade wearRotate/replace shear blades
Strip marksIncrease blade/roll hardness; adjust guides
Hydraulic leaksReplace seals, hoses, cylinders
Excess vibrationCheck alignment, mountings; repair as needed
Electrical faultsCheck/replace wires, connections, drives

Proper blade maintenance along with swift repairs of leaks, looseness, or electrical problems prevents unplanned downtime.

flying-shear roll forming machine
Flying-Shear Roll Forming Machines 6


Q: What thickness of steel can flying shears accommodate?

A: Most machines can handle up to 4 mm thickness. Heavier models are available for thicker material.

Q: How fast can flying shear roll formers operate?

A: Speeds range from 10 to over 50 meters per minute depending on machine size.

Q: What length parts can be produced?

A: Any cut length can be produced, though typical lengths are from 1 to 7 meters.

Q: How accurate are the cut lengths?

A: Precision flying shears can achieve a tolerance of ± 1 mm or better.

Q: How long does it take to change to a new profile?

A: With quick change tooling, profile changeover takes 30-60 minutes in general.

Q: What safety features are included?

A: Full guarding, e-stops, access interlocks, and control reliability per prevailing standards.

Q: What is the typical production lifetime of a machine?

A: Approximately 15-20 years of productive life can be expected with proper maintenance.

Q: What types of warranty are offered by manufacturers?

A: Warranty periods range from 6 months to 1 year on most components. Extended warranties may be purchased.

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