1. Overview of Hydraulic Billet Cutting Shear

The Hydraulic Billet Cutting Shear is a specialized metallurgical machine designed to cut steel billets into fixed lengths using hydraulic force as the main driving source.
It is a critical component in the continuous casting and rolling production line, mainly used for cutting hot or cold billets of square, rectangular, or round cross-sections.

Unlike traditional mechanical Crank Shears, the hydraulic billet shear uses hydraulic cylinders to generate and control the cutting force, offering smooth motion, high precision, low vibration, and strong adaptability to different billet sizes and hardness levels.

It is widely applied in steel mills, forging plants, rebar production lines, and metallurgical material preparation workshops, playing an essential role in ensuring billet quality and cutting efficiency.

2. Working Principle

The Hydraulic Billet Cutting Shear operates based on hydraulic pressure transmission.
When the billet reaches the predetermined cutting position, the hydraulic system activates one or more hydraulic cylinders to drive the upper blade downward, shearing the billet against the fixed lower blade.

The cutting process consists of four stages:

1. Positioning Stage:
   Sensors and encoders measure the billet length and send signals to the control system.

2. Pressurizing Stage:
   The hydraulic pump builds up pressure within the cylinder, converting hydraulic energy into mechanical force.

3. Cutting Stage:
   The piston drives the upper blade downward to shear the billet cleanly, completing one cycle.

4. Return Stage:
   The hydraulic cylinder reverses, returning the blade to its initial position for the next cut.

Because of the closed-loop hydraulic control, the shear achieves stable force output and smooth operation, even under continuous heavy-duty conditions.

3. Structural Composition

A typical Hydraulic Billet Cutting Shear consists of the following main components:

1. Main Frame:
   A heavy-duty welded steel structure designed for rigidity and vibration resistance.

2. Upper and Lower Blades:
   Made from high-strength alloy tool steel (H13, Cr12MoV) with heat treatment to enhance hardness and wear resistance.

3. Hydraulic Cylinders:
   Core actuators that drive the upper blade to move linearly for cutting.

4. Hydraulic Station:
   Provides oil pressure, including pump, motor, valves, oil tank, and cooling unit.

5. Oil Supply System:
   Includes pipelines, filters, and pressure regulators to maintain clean and stable hydraulic flow.

6. Control System (PLC + HMI):
   Controls billet feeding, cutting synchronization, blade movement, and fault diagnostics.

7. Feeding and Discharging Roller Tables:
   Ensure smooth billet transport and positioning.

8. Cooling and Lubrication System:
   Prevents blade overheating and minimizes wear during long-term operation.

9. Safety Devices:
   Includes protective covers, emergency stops, limit switches, and overload protection systems.

4. Technical Performance and Advantages

1. High Cutting Force:
   Hydraulic systems provide adjustable pressure up to 25–40 MPa, suitable for billets up to 300×300 mm.

2. Smooth Operation:
   No impact loads or mechanical shock during operation.

3. High Cutting Precision:
   Positioning error within ±1.5 mm under automatic mode.

4. Strong Adaptability:
   Suitable for various billet shapes (square, round, rectangular).

5. Low Noise and Vibration:
   Hydraulic motion minimizes mechanical impact noise.

6. Automatic Control:
   Equipped with PLC and servo systems for synchronization with rolling line.

7. Easy Maintenance:
   Fewer mechanical parts and wear components than crank shears.

8. Safety and Reliability:
   Overload, oil temperature, and pressure monitoring ensure safe operation.

5. Control and Automation System

Modern hydraulic billet shears are equipped with intelligent control systems, typically based on PLC + HMI touch screen architecture.

Key control functions include:

• Automatic billet measurement and length control

• Real-time monitoring of hydraulic pressure and temperature

• Fault detection and alarm display

• Synchronization with Rolling Mill speed

• Manual, semi-automatic, and fully automatic operation modes

Advanced systems may integrate servo-hydraulic proportional valves to achieve precise motion control, improving cutting consistency at high speeds.

6. Application Fields

The Hydraulic Billet Cutting Shear is widely used in:

• Continuous casting and rolling production lines

• Rebar and wire rod processing plants

• Billet storage and length cutting workshops

• Steel forging and forming lines

• Metallurgical test and research facilities

It can handle both hot billets (up to 900°C) and cold billets, ensuring high-quality, smooth-cut sections.

7. Maintenance and Operation

To ensure long-term stability and precision, operators should follow these maintenance guidelines:

1. Regularly check and replace hydraulic oil every 6–12 months.

2. Clean oil filters and inspect for leakage.

3. Monitor oil temperature (should remain below 60°C).

4. Inspect blade wear and resharpen or replace when dull.

5. Check for air in the hydraulic circuit and remove it promptly.

6. Regularly calibrate sensors and position encoders.

7. Ensure emergency stop switches function properly.

Conclusion

The Hydraulic Billet Cutting Shear represents a modern, efficient, and precise solution for billet length cutting in the steel industry.
Its combination of hydraulic power, electronic control, and automation technology ensures excellent performance, long service life, and operational safety.
As intelligent and energy-efficient designs continue to develop, the hydraulic billet shear will remain a key component in advanced steel production systems.