Hydraulic Maintenance for Flying Shears in Roll Forming Machines | Guide

Hydraulic Maintenance for Flying Shears in Roll Forming Machines

1. Introduction

Flying shears are one of the most important cutting systems used in roll forming machines. Unlike stationary cutting systems that stop production during cutting, flying shears move with the material while cutting, allowing the machine to maintain continuous production speed.

Flying shear systems are commonly used in high-speed roll forming lines producing products such as:

• Roofing panels
• Structural deck panels
• Purlins and structural profiles
• Metal studs and tracks
• Trim and flashing products

Because flying shears operate while the roll forming line continues to run, they require precise synchronization and reliable hydraulic power.

Hydraulic systems are typically used to power the cutting action of the flying shear. The hydraulic system provides the force necessary to drive the cutting blade through the formed metal profile while maintaining accurate cut lengths.

If the hydraulic system supporting the flying shear is not properly maintained, it may cause several problems including:

• Incomplete cuts
• Burr formation
• Cut length inaccuracies
• Blade misalignment
• Production downtime

Flying shear systems operate under high loads and rapid cycle speeds. This means hydraulic components within the system are exposed to significant pressure, vibration, and mechanical stress.

Proper hydraulic maintenance ensures that the flying shear continues to operate efficiently and maintain accurate cutting performance.

Factories that implement regular flying shear hydraulic maintenance programs often experience:

• More accurate cutting performance
• Reduced machine downtime
• Longer hydraulic component lifespan
• Improved production efficiency
• Lower maintenance costs

Hydraulic maintenance for flying shears includes inspection of pumps, cylinders, valves, hoses, and hydraulic pressure settings.

This guide explains the hydraulic components used in flying shear systems and outlines maintenance procedures technicians should follow to maintain reliable flying shear operation.

These procedures apply to many types of roll forming machines including:

• Roofing panel roll forming machines
• Structural deck roll forming machines
• Purlin roll forming machines
• Metal stud roll forming machines
• Trim and flashing roll forming machines

Although flying shear designs may vary between machines, the hydraulic maintenance principles remain consistent across most roll forming equipment.

2. Components Involved

Hydraulic maintenance for flying shears involves several key components.

Hydraulic Pump

The hydraulic pump supplies pressurized oil to the flying shear system.

Pump efficiency is critical for maintaining cutting force.

Hydraulic Cylinder

The hydraulic cylinder drives the cutting blade through the metal profile.

Cylinder wear may affect cutting performance.

Hydraulic Valves

Control valves regulate the movement and pressure of the hydraulic cylinder.

Valve malfunction may affect cutting timing.

Hydraulic Hoses and Lines

Hydraulic hoses transport oil between system components.

Leaks or restrictions may affect cutting performance.

Hydraulic Reservoir

The reservoir stores hydraulic oil and helps regulate system temperature.

Hydraulic Filters

Filters remove contaminants from the hydraulic oil to protect system components.

3. Causes of Wear or Failure

Hydraulic problems in flying shear systems may occur due to several factors.

Hydraulic Oil Contamination

Contaminated oil may damage valves, pumps, and cylinders.

Seal Wear

Cylinder seals may wear due to repeated cutting cycles.

Hydraulic Pressure Problems

Incorrect pressure settings may affect cutting performance.

Hose Damage

Hydraulic hoses may degrade due to vibration or pressure.

Pump Wear

Pump inefficiency may reduce cutting force.

4. Inspection Procedure

Routine inspection helps maintain flying shear hydraulic performance.

Step 1 – Hydraulic Pressure Inspection

Technicians should verify that the system pressure meets manufacturer specifications.

Step 2 – Cylinder Inspection

Hydraulic cylinders should be inspected for leaks or seal wear.

Step 3 – Hose and Fitting Inspection

Hoses and fittings should be inspected for leaks or damage.

Step 4 – Valve Operation Inspection

Hydraulic valves should be checked for proper operation.

Step 5 – Oil Condition Inspection

Hydraulic oil should be inspected for contamination or degradation.

5. Maintenance Procedure

Several maintenance procedures help maintain flying shear hydraulic performance.

Replace Hydraulic Filters

Filters should be replaced regularly to maintain clean oil.

Maintain Hydraulic Oil Quality

Hydraulic oil should be replaced according to maintenance schedules.

Inspect and Replace Seals

Cylinder seals should be replaced if leakage occurs.

Repair Hydraulic Leaks

Leaks should be repaired immediately to maintain system pressure.

Maintain Proper Pressure Settings

Hydraulic pressure should be maintained within recommended limits.

6. Preventative Maintenance Tips

Preventative maintenance helps protect flying shear hydraulic systems.

Monitor Cutting Performance

Changes in cut quality may indicate hydraulic problems.

Inspect Hydraulic Components Regularly

Routine inspections help detect developing problems.

Maintain Clean Hydraulic Oil

Clean oil helps protect pumps and valves.

Replace Worn Components Early

Early replacement helps prevent production downtime.

7. Common Mistakes

Maintenance mistakes may lead to flying shear hydraulic problems.

Ignoring Hydraulic Leaks

Leaks may reduce cutting pressure.

Using Incorrect Hydraulic Oil

Incorrect oil may affect system performance.

Skipping Pressure Inspections

Pressure changes may affect cutting quality.

Delaying Seal Replacement

Worn seals may cause hydraulic pressure loss.

8. FAQ Section

Why are hydraulic systems used in flying shears?

Hydraulic systems provide the force required for high-speed cutting operations.

What causes flying shear hydraulic problems?

Common causes include contamination, seal wear, pressure problems, and pump wear.

How can hydraulic maintenance improve flying shear performance?

Proper maintenance helps maintain cutting accuracy and system reliability.

Can hydraulic leaks affect flying shear cutting?

Yes. Leaks may reduce pressure and affect cutting performance.

How often should flying shear hydraulic systems be inspected?

Inspection should be performed during routine roll forming machine maintenance.

9. Machine Matcher Support

Flying shear hydraulic systems are critical for maintaining continuous roll forming production. Proper hydraulic maintenance helps ensure accurate cutting, reliable system performance, and reduced machine downtime.

Machine Matcher provides technical support services for roll forming equipment worldwide including:

• Machine inspections
• Hydraulic system diagnostics
• Maintenance program development
• Remote troubleshooting
• Spare parts sourcing

Machine Matcher works with manufacturers worldwide to maintain reliable roll forming production and extend machine lifespan.