What Cutting Systems Are Used in Roll Forming Machines? Full Guide
Roll forming machines use different cutting systems to cut the continuous profile into required lengths. The choice of cutting system affects speed, accuracy, cost, and production efficiency.
The main cutting systems used are:
- Hydraulic stop-start cutting
- Flying shear cutting
- Pre-cut systems
- Post-cut systems
1. Hydraulic Stop-Start Cutting (Most Common)
This is the most widely used cutting system, especially for standard machines.
How it works:
- The machine stops briefly
- Hydraulic shear cuts the profile
- Machine restarts
Key features:
- Simple and reliable
- Lower cost
- Good accuracy
Typical speed:
- 10 – 25 m/min
Best for:
- Roofing panels
- Basic profiles
- Small to medium production
2. Flying Shear Cutting (High-Speed System)
This is the most advanced and efficient cutting system.
How it works:
- The cutter moves with the material
- Cuts without stopping the machine
- Continuous production
Key features:
- No stop-start delays
- High-speed production
- Higher output
Typical speed:
- 30 – 60+ m/min
Best for:
- High-volume production
- Industrial operations
- Automated lines
3. Pre-Cut System
Cutting is done before the material enters the roll forming machine.
How it works:
- Flat sheet is cut to length first
- Then formed into profile
Key features:
- No cutting after forming
- Simpler cutting system
- Less wear on cutting blades
Best for:
- Simple profiles
- Thin materials
- Certain structural applications
Limitations:
- Less flexibility for variable lengths
- Not ideal for all profiles
4. Post-Cut System (Most Common Setup)
Cutting is done after the profile is fully formed.
How it works:
- Continuous forming
- Cut to length at the end
Key features:
- Most common method
- Flexible for different lengths
- Works with most profiles
Best for:
- Roofing panels
- Purlins
- General roll forming products
5. Die Cutting / Punching + Cutting Systems
Some machines combine punching and cutting.
Features:
- Holes and slots punched during production
- Cutting integrated into the system
Used for:
- Purlins
- Framing systems
- Structural components
Types of Cutting Blades
Different materials require different cutting tools:
- Straight shear blades (most common)
- Crank or scissor-type cutters
- Die-based cutting systems
Blade quality affects:
- Cut finish
- Burr formation
- Maintenance frequency
What Determines the Best Cutting System?
1. Production Speed
- Low speed → hydraulic stop-start
- High speed → flying shear
2. Product Type
- Roofing → usually post-cut
- Structural → often punching + cutting
- Simple profiles → pre-cut possible
3. Budget
- Lower budget → hydraulic cutting
- Higher budget → flying shear
4. Accuracy Requirements
- High precision → flying shear or servo systems
Common Problems with Cutting Systems
If not set correctly, issues include:
- Burrs on cut edges
- Incorrect length
- Deformation at cut point
- Blade wear
Proper setup and maintenance are critical.
Best Cutting System for Starting
If you are starting a roll forming business:
👉 Recommended:
- Hydraulic post-cut system
Why:
- Lower cost
- Reliable
- Easy to maintain
- Suitable for most products
When to Upgrade
Upgrade to flying shear when:
- Production demand increases
- You need higher speed
- You want continuous production
Frequently Asked Questions
What is the most common cutting system?
Hydraulic post-cut systems.
What is the fastest cutting system?
Flying shear cutting.
Is flying shear worth it?
Yes, for high-volume production.
Can one machine have multiple cutting systems?
Usually no, but systems can be upgraded.
Final Answer (Simple)
👉 The main cutting systems are:
- Hydraulic stop-start (most common)
- Flying shear (high-speed)
- Pre-cut (before forming)
- Post-cut (after forming – most widely used)
👉 For most businesses:
- Start with hydraulic post-cut
- Upgrade to flying shear as production grows