i Table of Contents Table of Contents Table of Contents Table of Contents The Extrusion Press Maintenance Manual Introduction ...................................................................................................................................................... v Acknowledgments .......................................................................................................................................... vi References .....................................................................................................................................................vii Useful Tables: Conversion of Units ........................................................................................................................... x Temperature Conversion.................................................................................................................. xi Calculating Stretcher Capacity – English Units ................................................................................xii Calculating Stretcher Capacity – Metric Units ................................................................................. xiii Weight of Extrusion Billets .............................................................................................................. xiv Press Specific Pressure – English Units ......................................................................................... xv Press Specific Pressure – Metric Units ........................................................................................... xvi Millimeter Conversion ..................................................................................................................... xvii Time Limits for Tooling in Oven at Temperature ........................................................................... xviii Thermocouple Types..................................................................................................................... xviii Glossary of Terms for Press Components ...................................................................................... xix Diagrams of Press Components ..................................................................................................... xxi Routine Inspection and Maintenance Scheduled Maintenance ................................................................................................................. 1-1 Mechanical Maintenance................................................................................................................ 1-3 Lubrication...................................................................................................................................... 1-7 “Preventive Maintenance Program Recommendations” (The Voice of Experience), by David Turnipseed ........................................................................................................ 1-8 Daily Check Sheet Procedure ........................................................................................ 1-11 Daily Check Sheet (Sample) .......................................................................................... 1-15 Press Troubleshooting Chart ......................................................................................... 1-16 “Extrusion Press Maintenance – A Predictive Approach” (The Voice of Experience) by P. Gopalan Kutty, Gulf Extrusions, Dubai ................................................................. 1-23 Farrel Maintenance Training Course information: Press Installation............................................................................................................ 1-29 Mechanical Functions of an Extrusion Press ................................................................. 1-35 Mechanical Maintenance ............................................................................................... 1-38 Press Alignment ......................................................................................................................................... 2-1 Alignment Procedures .................................................................................................................... 2-3 Recommended Tools ..................................................................................................................... 2-3 Alignment and Leveling of the Fixed Press Components............................................................... 2-6 Alignment of the Moving Press Components ................................................................................. 2-8 Use of the Alignment Tool Stack .................................................................................................. 2-11 Quick Checks of Press Alignment ................................................................................................ 2.13 Modifying the Press for Easier Adjustment of Alignment ............................................................. 2-15 “Extrusion Press Alignment with Modern Technology,” by J.E.V. Mulder and G.J. Smith, University of Otago, New Zealand........................................................ 2-17 Tooling Fixed Dummy Blocks...................................................................................................................... 3-1 Loose Dummy Blocks .................................................................................................................... 3-4 Clean-out Blocks ............................................................................................................................ 3-4 Stem ............................................................................................................................................... 3-5 Container ........................................................................................................................................ 3-7 Container Liner ............................................................................................................................... 3-9 “Extrusion Container Care and Maintenance,” by James M. Pope, Special Projects Consultant to Lake Park Tool .............................................................. 3-11 Improvements to Container Design .............................................................................................. 3-15 “Preventive Maintenance of Extrusion Tooling,” by Gary Dion, Extrusion Consultant .................................................................................... 3-18 Minimizing the Occurrence of Flared Billets ................................................................................. 3-23 “Lubrication of Extrusion Press Tooling” by James Dyla, Amcol Corp ......................................... 3-27
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i
Table of ContentsTable of ContentsTable of ContentsTable of Contents
The Extrusion Press Maintenance Manual Introduction ...................................................................................................................................................... v Acknowledgments .......................................................................................................................................... vi References ..................................................................................................................................................... vii Useful Tables:
Conversion of Units ........................................................................................................................... x Temperature Conversion .................................................................................................................. xi Calculating Stretcher Capacity – English Units ................................................................................ xii Calculating Stretcher Capacity – Metric Units ................................................................................. xiii Weight of Extrusion Billets .............................................................................................................. xiv Press Specific Pressure – English Units ......................................................................................... xv Press Specific Pressure – Metric Units ........................................................................................... xvi Millimeter Conversion ..................................................................................................................... xvii Time Limits for Tooling in Oven at Temperature ........................................................................... xviii Thermocouple Types ..................................................................................................................... xviii Glossary of Terms for Press Components ...................................................................................... xix Diagrams of Press Components ..................................................................................................... xxi
Routine Inspection and Maintenance Scheduled Maintenance ................................................................................................................. 1-1 Mechanical Maintenance ................................................................................................................ 1-3 Lubrication ...................................................................................................................................... 1-7 “Preventive Maintenance Program Recommendations” (The Voice of Experience),
“Extrusion Press Maintenance – A Predictive Approach” (The Voice of Experience) by P. Gopalan Kutty, Gulf Extrusions, Dubai ................................................................. 1-23
Farrel Maintenance Training Course information: Press Installation............................................................................................................ 1-29 Mechanical Functions of an Extrusion Press ................................................................. 1-35 Mechanical Maintenance ............................................................................................... 1-38
Press Alignment ......................................................................................................................................... 2-1 Alignment Procedures .................................................................................................................... 2-3 Recommended Tools ..................................................................................................................... 2-3 Alignment and Leveling of the Fixed Press Components ............................................................... 2-6 Alignment of the Moving Press Components ................................................................................. 2-8 Use of the Alignment Tool Stack .................................................................................................. 2-11 Quick Checks of Press Alignment ................................................................................................ 2.13 Modifying the Press for Easier Adjustment of Alignment ............................................................. 2-15 “Extrusion Press Alignment with Modern Technology,” by J.E.V. Mulder
and G.J. Smith, University of Otago, New Zealand ........................................................ 2-17
Tooling Fixed Dummy Blocks ...................................................................................................................... 3-1 Loose Dummy Blocks .................................................................................................................... 3-4 Clean-out Blocks ............................................................................................................................ 3-4 Stem ............................................................................................................................................... 3-5 Container ........................................................................................................................................ 3-7 Container Liner ............................................................................................................................... 3-9 “Extrusion Container Care and Maintenance,” by James M. Pope,
Special Projects Consultant to Lake Park Tool .............................................................. 3-11 Improvements to Container Design .............................................................................................. 3-15 “Preventive Maintenance of Extrusion Tooling,” by
Gary Dion, Extrusion Consultant .................................................................................... 3-18 Minimizing the Occurrence of Flared Billets ................................................................................. 3-23 “Lubrication of Extrusion Press Tooling” by James Dyla, Amcol Corp ......................................... 3-27
Introduction
ii
Inspecting and Repairing Major Components ......................................................................................... 4-1 Procedure for Repairing Cracked Main Cylinder ........................................................................... 4-3 How Major Components are Designed and Tested ....................................................................... 4-5 “Adapting Extrusion Presses for a High Cycle Fatigue Load Environment,”
by J.O. Nøkleby, Det Norske Veritas ............................................................................... 4-7 In-Service Inspection, Repair, and Trouble-Shooting .................................................... 4-10 Failed Components – Repair or Replace? .................................................................... 4-12 Requirements for Replacement Components ............................................................... 4-13 “Catastrophic Failure: A 48 Hour Remedy,” by Rick Colden and Adam Cramlet,
Air Breather .................................................................................................................................... 5-5 Pumps ............................................................................................................................................ 5-5 Valves ............................................................................................................................................ 5-7 Piping ............................................................................................................................................. 5-7 Pressure Gauges ........................................................................................................................... 5-8 System Documentation .................................................................................................................. 5-8 Troubleshooting ............................................................................................................................. 5-9 “Proper System Maintenance to Avoid Contamination
and Cavitation,” by Jack Hayes, Oilgear ....................................................................... 5-13 Farrel Maintenance Training Course information:
Hydraulic Maintenance .................................................................................................. 5-21 Right and Wrong Ways to Install Hydraulic Tubing and Fittings ................................... 5-23 Troubleshooting Hydraulic Problems ............................................................................. 5-25 Glossary of Hydraulic Terms ......................................................................................... 5-29
ISO/CETOP Hydraulic Symbols ................................................................................................... 5-33 Oilgear Training Bulletins:
Hydraulic System Survival Techniques #90012 ............................................................ 5-37 Filtration Recommendations #90007-D ......................................................................... 5-41 Piping Information #90011-F ......................................................................................... 5-49 Resistance of Valves and Fittings to Flow of Fluids ...................................................... 5-53 Storage Recommendations #90006B ............................................................................ 5-54
Electrical & Controls .................................................................................................................................. 6-1 Maintenance of Control Equipment................................................................................................ 6-3 Container Heating .......................................................................................................................... 6-6 Electric Motors ............................................................................................................................... 6-6 “Extrusion Press Electrical Systems,” by David Turnipseed ....................................................... 6-10 “Tips for Successful Electrical Trouble Shooting of Extrusion Equipment,”
by David Turnipseed ...................................................................................................... 6-15
Billet & Log Infeed Systems Billet/Log Infeed Conveyors ........................................................................................................... 7-1 Billet/Log Heaters - Gas Fired ....................................................................................................... 7-3
Refractory and Insulation ................................................................................................. 7-4 Thermocouple Probes ..................................................................................................... 7-4 Combustion Systems ....................................................................................................... 7-9
Profile Handling Systems High Temperature Textile Materials ............................................................................................... 8-2 Lead-out Tables ............................................................................................................................. 8-4 Run-Out Conveyors ....................................................................................................................... 8-5 Water Quench Systems ................................................................................................................. 8-9 Air Quench Systems .................................................................................................................... 8-11 Saws and Shears for Hot Profile Cut-Off ..................................................................................... 8-13 Pullers .......................................................................................................................................... 8-18 Profile Transfer Systems and Lift-Overs ...................................................................................... 8-22
iii
Cooling Tables: Walking Beams .............................................................................................................. 8-25 Belt Conveyors ............................................................................................................... 8-27
Age Ovens ................................................................................................................................................... 9-1 Temperature Surveys ..................................................................................................................... 9-1 Basic Age Oven Configurations ..................................................................................................... 9-2 Combustion Systems ..................................................................................................................... 9-6 Routine Combustion System Maintenance .................................................................................. 9-20 Improving Age Oven Energy Efficiency ........................................................................................ 9-22
Die Ovens .................................................................................................................................................. 10-1
Spare Parts Recommended Spare Parts .......................................................................................................... B-1 Storage of Spare Parts ................................................................................................................ B-11
Modernizing Older Presses ...................................................................................................................... C-1 Specifying a New Press ................................................................................................................ C-5 Modernizing the Press Feed Line .................................................................................................. C-9 Modernizing the Handling System ............................................................................................... C-13 Downstream Material Handling ................................................................................................... C-17 Auxiliary Equipment ..................................................................................................................... C-17 Vendor Request form for Press Upgrades .................................................................................. C-19 “The Extrusion Press Line for 2024: A Forecast,” by Al Kennedy ............................................... C-21 Double-Length Run-out Systems ................................................................................................ C-30
Managing Extrusion Plant Maintenance .................................................................................................. E-1 The Maintenance Level Audit ........................................................................................................ E-1 Staffing and Required Skills .......................................................................................................... E-4 Maintenance Engineering.............................................................................................................. E-5 Equipment Information Files and History ...................................................................................... E-6 Spare Parts Inventory .................................................................................................................... E-6 “Ten High-Tech Tools for Extrusion Plant Maintenance,” by Al Kennedy ..................................... E-9
Sponsors’ Information .................................................................................................... Special Supplement
Albarrie Amcol Belco Butech BWF Tech COMPES Castool Dunaway, Inc. Granco Clark Lake Park Tool Marathon Belting Oilgear OMAV R.L. Best
Introduction
iv
Notes:
v
IntroductionIntroductionIntroductionIntroduction and Editor’s comments about the 3
nd Edition of
The Extrusion Press Maintenance Manual
Here it is --- the Third Edition, bigger and more detailed than ever before.
This Manual began as a project of the Aluminum Extruders Council Tech Services Committee. The idea was to provide a reference and training tool for newcomers to the extrusion industry --- especially anyone working with older presses where the original manuals have been lost and the original maintenance people aren’t around any more.
Since the 1st Edition in 1996, the available
information about extrusion equipment has grown substantially, so much so that we decided to redefine the Manual as “the essential reference for extrusion plant managers.” The goal is to bring together in one place all of the useful information we can find about extrusion equipment, to make it the first place that maintenance personnel, plant engineers, managers, trainees --- everyone in the industry --- can turn to for answers and instruction. We’ve touched on repairs, preventive maintenance, installation, modernization --- anything useful we could find about the subject.
If you look carefully you will find different recommendations by different contributors, for example, the frequency and procedures for press inspections. I have not tried to remove or resolve these contradictions, but left them in so that the reader will have the benefit of all available advice. Sometimes even the experts don’t agree, and you must choose between conflicting recommendations.
Please note that I claim to be the Editor (as opposed to Author) of this Manual, since most of the material has been gathered from other sources. I have compiled it, in many cases rewritten it for clarity and conciseness, formatted it, and commented on it. I’ve tried to give proper credit for all material used (please let me know if I failed to properly credit anyone), and tried to leave references so the reader can get additional information if necessary.
So, I want to thank everyone who has shared their know-how for this Manual, especially to those who have prepared technical papers and made presentations at seminars. You have helped to make our industry strong and competitive by passing along your experience and knowledge to those who will follow in your footsteps.
A final Thank You is due to the Manual’s Sponsors, who make the publication possible by sharing the costs of preparing and publishing the book and CD. Please visit their advertisements and give them a call.
Al Kennedy
Kennedy Eurotech, Inc. - 4 Oak Point - Newnan GA 30263 USA
AcknowledgmentsAcknowledgmentsAcknowledgmentsAcknowledgments Special thanks for help in preparing this manual are extended to: Ennio Alberti, of Metra Group, for assistance in recommended maintenance procedures and
schedules. Belco, Inc., for their assistance and for permission to use portions of their maintenance
instructions. Domenico Bertoli, of Sepal SpA, for information on Minimizing the Occurrence of Flared Billets. Phil Dibb of Oilgear, Inc., for permission to use his presentation material on Maintenance of
Electrical Motors. Gary Dion, formerly of Nova Tool and Die, Inc., for permission to reprint “Preventive Maintenance
of Extrusion Tooling.” Jim Dyla, of Amcol Corporation, for permission to reprint “Instructions for Installation, Start-Up,
and Maintenance of Precision Saw Lubricant Applicators,” and “Lubrication of Extrusion Press Tooling.”
Mario Gottardi, Erection Supervisor for OMAV SpA, for permission to use information from his Recommended Maintenance brochures for press feeding lines and handling systems.
Granco-Clark, Inc., for their assistance and for permission to use portions of their maintenance instructions.
Jack Hayes, of Oilgear, Inc., for permission to use portions of his paper “Proper System Maintenance to Avoid Contamination, Cavitation, and Over-Pressure.”
Steve James, of Aluminum Shapes, Inc., for assistance and sound advice. P. Gopalan Kutty, of Gulf Extrusions, Dubai, for his contribution to “The Voice of Experience,”
Chapter 1. Joseph E.V. Mulder, of the University of Otago, New Zealand, for permission to use his
information on “Extrusion Press Alignment with Modern Technology.” John O. Nøkleby, of Det Norske Veritas, for permission to reprint “Adapting Extrusion Presses for
a High Cycle Fatigue Load Environment.” North American Mfg., for permission to reprint maintenance and product bulletins for combustion
equipment, including portions of “Practical Pointers - Industrial Burner Control Systems.” The Oilgear Company, Inc., for permission to reproduce various brochures in Chapter 5. Ken Summerfield and Jim Bjerregaard of Oilgear for their help in revising and updating Chapter 5
– Hydraulics. David Turnipseed, for permission to reprint his paper on “Extrusion Press Electrical Systems,“ and
to him and his Maintenance Team at Cardinal Aluminum for new contributions on Routine Maintenance and Troubleshooting, used in Chapters 1 and 6.
Javier Valdez, of Cuprum Aluminio SA, for recommendations on many related subjects. Charles White, extrusion plant equipment designer and CAD drafter par excellence, for help in
preparing illustrations. And especially to: Ann Marie Fellom, Publisher of Light Metal Age, who, along with the entire staff of Fellom
Publishing, contributed to the design and “feel” of the manual, and who worked hard to make its publication possible.
We also thank the manual’s Sponsors, listed on page iii, for helping to make the preparation and publication of this manual possible.
vii
ReferencesReferencesReferencesReferences 1984 Saw Noise Report and 1987 Saw Noise Report. Aluminum Extruders Council, Chicago IL,
USA. Aluminum Extruders Council, “Extrusion Dies and Tooling Manual: Recommended Handling and
Maintenance,” www.aec.org. Allen-Bradley Division of Rockwell Automation, “Maintenance of Industrial Control Equipment,”
from Publication C-111, March 1995. 1201 South Second Street, Milwaukee WI 53204. American Society of Mechanical Engineers, “Graphic Symbols for Fluid Power Diagrams - USAS
Standard Y32.10,” Fairfield NJ 07007. Anthofer, E.J., “Press Alignment,” Proceedings of 2nd International Aluminum Extrusion
Technology Seminar, Vol. I, (1977), p. 169-173. Baldwin, M. Dana, “Extrusion Sawing: Tighter Tolerance at Quadruple Production,” Modern Metals
Magazine, January, 1996.
Bartelt, Alan, “Extrusion Hazards and Risk Reduction,” Proceedings of 8th International Aluminum Extrusion Technology Seminar, (2004).
Beer, Stefan, “Improved Operation of Single Billet Induction Heaters by Modern Plant Design and Modern Plant Technology,” Proceedings of the Eighth International Aluminum Extrusion Technology Seminar, (2004).
Bergman, John, “Press Alignment Using 3D Laser Technology,” presented at AEC Press Maintenance Seminar, (2002), Chicago.
Bessey, Guy, “Fixed Dummy Block Design,” Proceedings of 4th International Aluminum Extrusion Technology Seminar, Vol. II, (1988), p. 131-133.
Bugai, John, “Billet/Log Furnace and Shear Maintenance,” papers presented at AEC Press Maintenance Seminars, (1991 and 1995), Chicago.
Castle, Alan F., “Fixed Dummy Block Extrusion,” Proceedings of 4th International Aluminum Extrusion Technology Seminar, Vol. II, (1988), p. 134-134.
Castle, Alan F., “Improving Fixed Dummy Block Performance,” Proceedings of 6th International Aluminum Extrusion Technology Seminar, Vol. I, (1996), p. 301-304.
Colden, Rick, and Cramlet, Adam, “Catastrophic Failure: A 48 Hour Remedy,” Proceedings of 8th International Aluminum Extrusion Technology Seminar, (2004).
Conserva, M., Donzelli, G., and Trippodo, R., Aluminium and its Applications, Edimet SpA, via Corfu 102, 25124 Brescia, Italy.
Crosti, M., “’Thermal Alignment’: Temperature Control in Extrusion Technology,” presented at Aluminium 2000, Rome, March 2003.
Douglas, M., “High Temperature Textile Products for Aluminum Extrusion Handling Systems,” Proceedings of 6th International Aluminum Extrusion Technology Seminar, Vol. II, (1996), p. 287-292.
Dyla, James, “Protect Your Press Tools,” Proceedings of 7th International Aluminum Extrusion Technology Seminar, Vol II, (2000), p. 277-282.
Dyla, James, “Enhanced Tool Lubrication Systems,” Proceedings of the Eighth International Aluminum Extrusion Technology Seminar (2004).
Eidson, B., “Improving Equipment Effectiveness Through Total Productive Manufacturing,” Proceedings of 6th International Aluminum Extrusion Technology Seminar, Vol. II, (1996), p. 315-319.
Ferryman, Roger L., “Proper Handling of Hydraulic Oil in the Extrusion Press,” Proceedings of 5th International Aluminum Extrusion Technology Seminar, Vol. II, (1992), p. 583-585.
Fielding, Roger A. P. and A. J. Bryant, “The Quest for Optimal Extrusion Billet Heating,” Light Metal Age, Vol. 59, No. 8, August 2001, 24 – 36.
Freese, Howard W., “Alignment of the Extrusion Press,” Proceedings of 3rd International Aluminum Extrusion Technology Seminar, Vol. I, (1984), p. 105-111.
Freri, Enrico, “Advantages of a ’Special Nozzles’ Cooling Tunnel,” Proceedings of the Eighth International Aluminum Extrusion Technology Seminar (2004).
Gaube, Doris, “Technical Textiles for Handling Systems: Introducing High Tech While Avoiding Basic Mistakes,” Proceedings of 6th International Aluminum Extrusion Technology Seminar, (2004).
Introduction
viii
Gramaticopolo, F., “Flying Cut Puller Without Hand-off,” Proceedings of the Eighth International Aluminum Extrusion Technology Seminar (2004).
Gramaticopolo, F., and Kennedy, Al, “Modifications to the Extrusion Press and Handling System for Increased Reliability and Productivity,” Proceedings of 5th International Aluminum Extrusion Technology Seminar, Vol. II, (1992), p. 263-271.
Hahnel, Werner, and Herder, Manfred, “Tool Steel and Design of Modern Containers for Extrusion of Light Metal,” Proceedings of 8th International Aluminum Extrusion Technology Seminar, (2004).
Hayes, Jack, “Proper System Maintenance to Avoid Contamination and Cavitation,” presented at AEC Press Maintenance Seminar, (1991), Chicago.
Industrial Ventilation Manual, published by the Committee on Industrial Ventilation, PO Box 16153, Lansing MI 48901 USA. Sales: American Conference of Governmental Industrial Hygienists, 1300 Kemper Meadow Drive, Cincinnati OH 45240 USA. www.acgih.org/resources/press/vent25th.htm.
Jenista, David, “Practical Non-Contact Temperature Measurement for Gas-Fired Billet Heating Furnaces,” Proceedings of the Eighth International Aluminum Extrusion Technology Seminar, (2004).
Johnen, Willi, “Further Developments with Regard to Single-Billet Induction Heaters for Light Metal Extrusion Billets,” Proceedings of the Eighth International Aluminum Extrusion Technology Seminar (2004).
Jowett, Chris, “The Importance of Tooling Temperature Control,” Proceedings of the Eighth International Aluminum Extrusion Technology Seminar (2004).
Jowett, Chris; Johannes, Veikko; Langille, Al; Fraser, Warren; and Yoshimura, Hideki, “The Causes of Variation in Extruded Section Weight,” Proceedings of 7th International Aluminum Extrusion Technology Seminar, Vol. I, (2000), p. 1-16.
Kennedy, Al, “Modernizing the Extrusion Press and Handling System: Adapting New Technology to Older Plants,” Proceedings of 6th International Aluminum Extrusion Technology Seminar, Vol. I, (1996), p. 105-112.
Kennedy, Al, “Modernizing the Extrusion Press and Handling System,” presented at AEC Press Maintenance Seminar, (1991), Chicago.
Kennedy, Al, “Modernizing the Older Press and Related Equipment,” presented at AEC Press Maintenance Seminar, (1995), Chicago.
Kennedy, Al, “Ten High-Tech Tools for Extrusion Plant Maintenance,” presented at the Aluminium 2000 Conference in Rome, March, 2003.
Kennedy, Al, “The Extrusion Press Line for 2024: A Forecast,” Proceedings of 8th International Aluminum Extrusion Technology Seminar, (2004)
Laue, Kurt, and Stenger, Helmut, Extrusion, American Society for Metals, Metals Park, Ohio 44073.
Luscombe, Jon, “Billet Heaters and Log Shears: Servicing for Optimum Performance,” presentation at AEC Maintenance Seminar, (2002), Chicago.
MacGregor, Charles W., “Mechanical Properties of Materials,” Marks’ Mechanical Engineers’ Handbook, Sixth Edition, McGraw-Hill Book Company, Inc., New York, NY, p. 5-2.
Marinelli, M., “Building a Better Age Oven,” Proceedings of 7th International Aluminum Extrusion Technology Seminar, Vol. I, (2000), p. 469-472.
Mason, Bill, and Molitor, Mel, Session on Die Correction at 1989 Die Workshop, Aluminum Extruders Council, (October 1989), Chicago.
Maxon Corporation, “Maxon ‘400’ OVENPAK® Gas Burners – Installation and Start-Up Instructions,” www.maxoncorp.com.
Mulder, Joseph E. V., and Smith, Gavin J., “Extrusion Press Alignment with Modern Technology,” Proceedings of 7th International Aluminum Extrusion Technology Seminar, Vol. I, (2000), p. 455-463.
New York Blower Company, The, “Installation, Maintenance, Operating Instructions,” 7660 Quincy Street, Willowbrook IL 60521-5596, USA.
Nøkleby, J.O., “Adapting Extrusion Presses for a High Cycle Fatigue Load Environment,” presentation at AEC Maintenance Seminar, (1995), Chicago.
North American Combustion Handbook, 2nd
Edition, North American Mfg. Co., Cleveland OH 44105 USA, p. 296.
Milwaukee WI 53219. Oilgear Company, The, “Instructions – Storage Recommendations for Oilgear Units,” 90006B,
May, 1994. 2300 So. 51st. Street, Milwaukee WI 53219.
Pope, James M., “Extrusion Container Care and Maintenance,” presented at AEC Press Maintenance Seminar, (2002), Chicago.
Proceedings of the Workshop on the Control of Metal Sawing Noise in the Aluminum Industry, June, (1976). The Aluminum Association, Washington DC.
Parker Filter Division, “Parker Hydraulic Products and Total Systems Engineering,” Metamora OH. Catalog 0108, p. 179.
Ramanan, Ram, “How to Obtain the Most from Your Ageing Ovens,” Proceedings of 6th International Aluminum Extrusion Technology Seminar, Vol. I, (1996), p. 269-273.
Robbins, Paul, “Dummy Blocks, Clean Out Blocks, Lubrication and Film Coatings, and Alignment (the Enemy),” presented at AEC Press Maintenance Seminar, (1995), Chicago.
Robbins, Paul, “Superextruders: Improving Container Life Through Temperature Control,” Light Metal Age Magazine, April 2003, Page 44.
Rutkowski, Richard, “Upgrading Extrusion Presses with Variable Frequency Drives,” Proceedings of 8th International Aluminum Extrusion Technology Seminar, (2004).
Sant, Russell J., “Preventive Maintenance: If It Ain’t Broken, Don’t Fix It!” presented at AEC Press Maintenance Seminar, (1991), Chicago.
Spizzo, M., “Innovative F.T.S. Three Puller Automatic Stretcher System,” Proceedings of the Eighth International Aluminum Extrusion Technology Seminar (2004).
Stewart, John S., “Aluminum Extrusion Sawing Noise Reduction,” Proceedings of 4th International Aluminum Extrusion Technology Seminar, Vol. II, (1988), p. 423-427.
Stott, J.G. and B. Wilkins, “A Low Energy, Reliable, Electro-Hydraulic System for Extrusion Presses,” Proceedings of the Seventh International Aluminum Extrusion Technology Seminar, Vol. I, (2000), o. 465-468.
Van Dine, Dennis, “Thermal Control of the Extrusion Press Container,” Proceedings of 8th International Aluminum Extrusion Technology Seminar, (2004)
Wieser, Volker; Sommitsch, Christof; Haberfellner, Kurt; and Lehofer, Paul;” New Developments in the Design and Production of Container Assemblies, “ Proceedings of 8th International Aluminum Extrusion Technology Seminar, (2004).
Wirtz, Rodney, “A Lock Out/Tag Out Procedure that Works,” Proceedings of 4th International Aluminum Extrusion Technology Seminar, Vol. II, (1988), p. 421-422.
Wu, Benson, “The Competitiveness of the Chinese Extrusion Industry,” presented at Aluminium 2000, Rome, March 2003, sponsored by Interall SRL, Modena, Italy.
Disclaimer The Extrusion Press Maintenance Manual is provided AS IS. This book can only be considered a general guide.
Fellom Publishing and Kennedy Eurotech, Inc., will in no way be responsible or liable, financially or otherwise, for damages (both consequential and incidental) including but not limited to: damaged equipment, personal injury, loss of production, or damaged goods, resulting from the use or misuse of the Extrusion Press Maintenance Manual.
Introduction
x
Conversion of UnitsConversion of UnitsConversion of UnitsConversion of Units1111
1 Source: North American Combustion Handbook, Volume II, North American Mfg. Co., Cleveland
OH 44105 USA, p. 317 - 325.
Length 1 millimeter = 0.0394 inch 1 centimeter = 0.394 inch 1 meter = 39.4 inches 1 meter = 3.2808 feet 1 kilometer = 0.62137 mile 1 inch = 25.4 millimeters 1 inch = 2.54 centimeters 1 foot = 30.48 centimeters 1 foot = 0.305 meter 1 yard = 0.9144 meter 1 mile = 1.60935 meters
Area 1 square millimeter = 0.00155 square inch 1 square centimeter = 0.1550 square inch 1 square meter = 10.764 square feet 1 square kilometer = 0.3861 square mile 1 square inch = 6.452 square centimeters 1 square inch = 645.2 square millimeters 1 square foot = 0.0929 square meter 1 square yard = 0.8361 square meter 1 square mile = 2.590 square kilometers
Volume 1 cubic millimeter = 0.0006 cubic inch 1 cubic centimeter = 0.0610 cubic inch 1 liter = 0.26418 US gallon 1 liter = 1000 cubic centimeters 1 cubic meter = 1.3079 cubic yards 1 cubic meter = 35.313 cubic feet 1 cubic meter = 264.143 US gallons 1 cubic inch = 16.3872 cubic centimeters 1 cubic inch = 1638.72 cubic millimeters 1 US gallon = 3.78533 liters 1 cubic foot = 28.32 liters 1 cubic foot = 0.02832 cubic meters 1 cubic foot = 1728 cubic inches 1 cubic foot = 7.48 US gallons 1 cubic yard = 0.7656 cubic meter
Press Specific Pressure Press Specific Pressure Press Specific Pressure Press Specific Pressure –––– English UnitsEnglish UnitsEnglish UnitsEnglish Units To calculate Specific Pressure on the die face:
where Ps is in pounds/square inch and container ID is in inches (typically 3% larger than billet diameter. Billet Dia.-in. 6” 7” 8” 9” 10” 12” 14” Container I.D.
– in. 6.18 7.21 8.24 9.27 10.3 12.36 14.42
Container Area - sqin
30.00 40.83 53.33 67.49 83.32 119.99 163.31
Press Tons ↓↓↓↓ Press Specific pressure on Die Face – pounds/square inch
900 60,008
1200 80,010 58,783
1400 93.345 68,580
1600 106,680 78,377 60,008
1800 120,015 88,174 67,508
2000 133,350 97,971 75,009 59,267
2200 107,769 82,510 65,193
2400 117,566 90,011 71,120 57,607
2500 122,464 93,762 74,083 60,008
2750 103,138 81,492 66,008
3000 112,514 88,900 72,009
3250 121,890 96,308 78,010 54,173
3500 103,717 84,011 58,341
3750 111,125 90,011 62,508
4000 96,012 66,675
4250 102,013 70,842 52,047
4500 108,014 75,009 55,109
5000 83,344 61,232
5500 91,678 67,355
6000 100,013 73,479
6500 79,602
7000 85,725
Notes: 1. Many experts recommend operating with Specific Pressure (die face pressure) in the range of
85,000 to 115, 000 pounds/square inch. 2. Many North American extruders operate in the range 70,000 to 80,000 psi. 3. The optimum range of Specific Pressure will also depend on extrusion practices and the type
of profile or bar being extruded.
Introduction
xvi
Press Specific Pressure Press Specific Pressure Press Specific Pressure Press Specific Pressure –––– Metric UnitsMetric UnitsMetric UnitsMetric Units To calculate Specific Pressure on the die face:
where Ps is in kilograms/square millimeter and container ID is in millimeters (typically 3% larger than billet diameter. Billet Dia. – in. 6” 7” 8” 9” 10” 12” 14” Billet Dia,-mm 152 178 203 228 254 305 356
Container ID-mm
160 185 210 236 262 314 365
Container Area – mm2
20106 26880 34636 43744 53913 77437 104635
Press MTons ↓↓↓↓ Press Specific pressure on Die Face – kilograms/square millimeter
800 39.79
1000 49.74 37.20
1200 59.68 44.64
1400 69.63 52.08 40.42
1600 79.58 59.52 46.19 36.58
1800 89.52 66.96 51.97 41.15
2000 99.47 74.40 57.74 45.72 37.10
2200 81.84 63.52 50.29 40.81
2400 89.28 69.29 54.87 44.52
2600 96.73 75.07 59.44 48.23
2800 80.84 64.01 51.94
3000 86.61 68.58 55.65 38.74
3200 92.39 73.15 59.36 41.32
3400 98.16 77.73 63.06 43.91
3600 82.30 66.77 46.49
3800 86.87 70.48 49.07
4000 91.44 74.19 51.65 38.23
4500 83.47 58.11 43.01
5000 92.74 64.57 47.79
5500 71.03 52.56
6000 77.48 57.34
7000 90.40 66.9
Notes: 1. Many experts recommend operating with Specific Pressure (die face pressure) in the range of
60 to 80 kilograms/square millimeter. 2. Many North American extruders operate in the range 50 to 60 kg/mm2. 3. The optimum range of Specific Pressure will also depend on extrusion practices and the type
Recommended Time Limit for Tooling in OvenRecommended Time Limit for Tooling in OvenRecommended Time Limit for Tooling in OvenRecommended Time Limit for Tooling in Oven After Reaching TemperatureAfter Reaching TemperatureAfter Reaching TemperatureAfter Reaching Temperature
500
oF .................................................................. Unlimited
Type J: Iron-Constantan I/C one wire silver and one wire bronze in color Iron: Magnetic Positive White Constantan: Non-magnetic Negative Red
Type K:
Chromel/Alumel C/A both wires silver in color Chromel: Non-magnetic Positive Yellow Alumel: Magnetic Negative Red Note: Thermocouple lead wire must be located in a dry, grounded, steel conduit and separated from power wiring. Do not use wire-pulling lubricant.
xix
Glossary of Terms for Press Components
Press Base or Bedplate: a welded structure, it is designed to accurately position and support the press structure. It is precisely leveled, anchored, and grouted to the concrete press foundation.
Main Cylinder: the hydraulic cylinder, normally cast or forged steel, incorporates the Main Cylinder Flange, also sometimes called the Main Cylinder Platen; other Main Cylinder parts include the Main Cylinder Bearing Bushing and Main Cylinder Packing system.
Main Ram: the piston of the main hydraulic cylinder.
Crosshead (or Moving Crosshead): mounted on the Main Ram, the Crosshead is fitted with the Extrusion Stem, and with guide shoes to guide the main ram travel along the Guide Ways.
Crosshead Cylinders or Pullback Cylinders: for rapid pull-back of the main ram at speeds not possible using main cylinder action alone; mounted on the Main Cylinder housing or Platen.
Extrusion Stem or Ram Stem: pushes the billet through the Container. Various mounting designs are used to permit precise adjustment and alignment of the stem. To avoid sticking or “welding” to the billet, a Dummy Block is fixed to the nose of the stem. Older presses used Loose Dummy Blocks, mechanically fed into position with each bullet, then removed, separated, and recycled. Today almost all presses incorporate Fixed Dummy Blocks mounted on the Stem.
Guide Ways: for guiding the Moveable Crosshead and Container, although many presses use separate guide systems for each. Guide ways are usually mounted on the Press Frame or Bedplate, or on the Columns or Tie-Rods.
Tie Rods or Columns: operating in tension, these restrain the extrusion force between the Main Cylinder Platen and Front or Resistance Platen. The most common designs are: threaded tension rods with 4 nuts per rod (2 at each platen); threaded rods with fixed sleeves between platens; and laminated plates or bars.
Platen (also Front Platen or Resistance Platen): cast or forged steel, it provides support for extrusion tooling and so is designed for minimum deflection under load. It incorporates also the Pressure Ring, a replaceable precision segment designed for extremely precise support of the Tooling Stack.
Tooling Stack or Die Stack: includes the die, die backer, bolster, die ring, and other spacers as may be required to adapt a particular die to the standardized overall Tooling Stack dimensions for the particular press.
Die Changer: a device for rapid changing of dies. Common designs include:
• single die changer: the simplest system, it holds only one tooling stack at a time.
• double die slide: holds two tooling stacks, allowing advance set-up of the next set during extrusion and therefore faster die changes; but one pocket must be loaded from the far side of the press, away from the press operator’s position.
• unistation die changer: also allows advance set-up and quick changes, fully accessible from the operator side of the press; dies are exchanged in a “shuttle” motion.
• rotostation die changer: similar to unistation, except a turntable rotates for exchanging die carriers.
• gate lock: on very old presses, dies are removed and reinserted through the front platen, then locked in place with a “gate lock” device, which also absorbs the resistance forces.
Introduction
xx
Container: retains the extrusion pressure against the die by containing the billet; incorporates a replaceable Container Liner to accommodate wearing tendencies.
Container Holder: supports, guides, and transports the Container; connected to the Container Cylinders and mounted on Guide Shoes which slide on the Guide Ways. Also incorporates Container Heating Elements, and their flexible electrical connections; and locking devices to retain the container firmly and precisely in position.
Container Cylinders: move the container away from the Tooling Stack during butt shearing (also during “burp cycle” and die changing); and provide sealing pressure to retain the container firmly against the Tooling Stack during extrusion.
Billet Loader: most commonly a swing-arm device mounted to the press frame. However, on newer presses this loader may be a robot device or an overhead carrier for increased reliability and positioning accuracy.
Butt Shear: for removal of the remaining billet or “butt” at the end of the extrusion cycle, a hydraulically powered blade descends to shear away the remainder. To insure complete removal, a “Butt Knocker,” usually pneumatically actuated, may also be provided to sweep the blade area.
Diagram of Press Components
In order to provide a common reference of terminology, please see the extrusion press diagrams shown on the following pages. Terms used throughout this manual are defined according to this diagram and the Glossary of Terms for Press Components above.