ET 2004 seminar presentation front loading

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ET 2004 seminar presentation front loading

  1. 1. 1 EIGHTH INTERNATIONAL ALUMINUM EXTRUSION TECHNOLOGY SEMINAR AND EXPOSITION Front-loading Technology With Tandem Cylinder Design For High Precision Extrusions Tecalex
  2. 2. 2 INDEX 1. Introduction 2. Front loading principle 3. Advantages of front loading 4. Specific features of front loading 5. Tandem cylinder design 6. Advantages of the Tandem cylinder design 7. Conclusions
  3. 3. 3 Introduction • Front loading = charging of billet between stem and die and then moving container over billet. • Advantages but as well: problems that had to be resolved. • Tandem cylinder design = 2 pistons (main + auxiliary) on the same axis. • Precise extrusions + surface quality.
  4. 4. 4 General press design • 1100 – 2800 MT • Front loading + tandem cylinder • Variable hydraulic flow • Rotational die changer • Lubricated butt shear • Forged front plate • (…)
  5. 5. 5 Front loading principle Step 1: Hot shear cuts billet
  6. 6. 6 Front loading principle Step 2: Billet lubrication
  7. 7. 7 Front loading principle Step 3: Move billet to waiting position
  8. 8. 8 Front loading principle Step 4: Container and stem move backwards
  9. 9. 9 Front loading principle Step 5: Butt shear removes butt
  10. 10. 10 Front loading principle Step 6: Move billet to extrusion axis
  11. 11. 11 Front loading principle Step 7: Clamp billet between die and stem
  12. 12. 12 Front loading principle Step 8: Close container and extrude
  13. 13. 13 Advantages of front loading Comparison back loading vs. front loading • Compact design with 50% less cylinder stroke • Reduced dead cycle times • No need of high speed movements • Less oil volume Back loading Front loading
  14. 14. 14 Advantages of front loading Symmetrical upsetting of billet Front loading Back loading • Front loaded billet in the center line = no perpendicular stresses. • Less clearance between container and billet. • Symmetrical billet deformation, no press bending or die uplift. • Higher precision of the extruded profile.
  15. 15. 15 Special features of front loading Loading 2 pieces is tricky ! 2-piece billet waiting Clamping 2 piece billet
  16. 16. 16 Special features of front loading Optimized warm shear to remain original section . • 2-piece billet from billet rest management is easy to load
  17. 17. 17 Special features of front loading Feeder with movable shell to support different billet length.
  18. 18. 18 Tandem cylinder design 2 pistons (main + auxiliary) working on the same axis. Main Piston (Forged Steel F125) Auxiliary Piston (Forged Steel F125) Billet clamp Pre-fill valves Shaft (Forged Steel F125) Nut Bushing Bodies (Forget steel St52.3)
  19. 19. 19 Tandem cylinder design Video clip: Working principle.
  20. 20. 20 Advantages of Tandem Cylinder Forged steel plate flexion: Finite element analysis. 0,253 0,222 0,19 0,158 0,126 • Two cylinders on the main axis = reduced cylinder diameter and reduced front plate dimensions and distance of tie rods, compared to conventional cylinder design. • Due to the less distance between the tie rods, a tandem system press has 24% less flexion than standard presses.
  21. 21. 21 Advantages of Tandem Cylinder Alignment of the stem. • The additional bearing points from the auxiliary cylinder improve the alignment of the stem = more precise stem movement = more precise extrusion.
  22. 22. 22 Conclusions The combination of front-loading technology with tandem cylinder design helps to improve the precision and surface quality of extrusions because: • Front loading = The billet is loaded exactly and symmetrically onto the extrusion axis. • Due to the tandem design, the bending of the front plate is reduced and the die movement as well.
  23. 23. 23 Thank you for your attention! www.tecalex.com

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