<p>Rotary shear machines are widely used in metal cutting and sheet processing industries due to their ability to achieve precise and high-speed cutting of moving metal sheets without stopped or repositioned. The selection and design of an appropriate mechanism based on kinematic analysis directly influence the machine’s performance and durability. High speed rotary shear machine requires kinematically optimized mechanisms to maintain smooth operation without compromising cutting quality. This study focuses on the kinematic modeling and parametric sensitivity analysis of 5-bar double crank mechanism. A detailed kinematic analysis was performed using analytical method and multi-body dynamic simulation to evaluate position, velocity and acceleration profiles of various linkages. The parametric sensitivity study investigates the influence of critical parameters such as crank angular velocity, link lengths, and phase angles on the overall system behavior. Additionally, a metal shearing force calculation was conducted to determine optimal force requirements. The results provide valuable insights for designers to enhance the efficiency, reliability, and longevity of rotary shear machines by selecting optimal geometric and operational parameters for mechanism. This research offers a structured methodology for kinematic analysis, serving as a foundation for future advancements in dynamic performance optimization and energy efficiency improvements in high-speed cutting technologies.</p>