Continuous Billet Extrusion Press With Rotating Die Heating
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Solution Overview
Problem
Conventional extrusion processes for manufacturing seamless metal tubing require large billets and extensive machinery, leading to high start-up and maintenance costs, as well as manufacturing inefficiencies due to the need for large facilities and limitations in the amount of tubing produced per run.
Innovation Solution
A continuous extrusion system that allows for the continuous loading and extrusion of multiple smaller billets, using a rotating die and mandrel bar with gripping and cooling elements to secure and heat the billets, reducing the size of the equipment needed and improving manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If large billets are used for conventional extrusion, then the manufacturing cost per unit is reduced, but the equipment size and facility requirements increase significantly
Solution Approach 1:
The continuous extrusion system divides the extrusion process into multiple segments, processing smaller billets sequentially through a rotating die assembly. This segmentation allows the use of smaller, more manageable billet sizes while maintaining production efficiency, eliminating the need for extremely large equipment required for single large-billet extrusion
Solution Approach 2:
The system implements continuous extrusion by loading multiple smaller billets in sequence through a rotating die, maintaining uninterrupted production flow. This continuous action achieves the same productivity as large-billet extrusion but with smaller equipment footprint and reduced facility requirements
2Productivity
If large-scale machinery is used to process large billets, then the production capacity per run increases, but the start-up and maintenance costs increase
Solution Approach 1:
The die assembly rotates during the extrusion process, creating dynamic friction heating that eliminates the need for separate pre-heating equipment. This dynamic mechanism integrates multiple functions (heating, extrusion, shaping) into a single moving assembly, reducing overall equipment complexity while maintaining high production capacity
Solution Approach 2:
The system combines the heating function with the extrusion die itself through friction-generated heat during rotation, rather than using separate heating equipment. This merging of functions reduces the number of components and simplifies the overall system while maintaining productivity
3Reliability
If separate extrusion runs are performed for each billet, then the extrusion process can be completed, but manufacturing efficiency decreases due to constant start-up and shut-down
Solution Approach 1:
The system loads and processes multiple smaller billets in continuous sequence through the rotating die assembly, eliminating the start-stop cycles of conventional single-billet extrusion. This continuous operation maintains constant friction heating in the die, ensuring reliable process completion while dramatically improving manufacturing efficiency
Solution Approach 2:
The rotating die assembly periodically engages with each billet in sequence, creating a rhythmic continuous process. This periodic action across multiple billets achieves the same reliability as single-billet completion but without interruption, maintaining efficient continuous production
4Adaptability or versatility
If conventional extrusion equipment is used, then the process can handle large billets, but system component wear increases due to constant start-up and shut-down
Solution Approach 1:
By processing multiple smaller billets through sequential loading rather than one large billet at a time, the system reduces mechanical shock and thermal cycling stress on components. This segmentation approach maintains adaptability to handle various billet sizes while significantly reducing wear and improving component durability
Solution Approach 2:
Continuous operation with sequential billet loading eliminates repeated start-stop cycles that cause thermal expansion/contraction and mechanical stress on components. The continuous friction heating in the rotating die maintains stable operating conditions, reducing component wear while maintaining versatility for different billet sizes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables the production of seamless tubing with reduced equipment size and costs, increasing efficiency by allowing continuous operation with smaller billets and minimizing system component wear, while maintaining product quality and compliance with standards like ASTM-B88 and NSF/ANSI-61.
Implementation Method 1
The rotating die heats the billet as the billet advances through the rotating die
Implementation Method 2
transporting the first billet along the mandrel bar and through cooling elements that clamp to the mandrel bar and deliver cooling fluid to the mandrel bar
Data Source
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AI summary
The invention relates to an extrusion press system. In certain embodiments, one or more hollow billets are loaded onto an elongate mandrel bar and transported along the mandrel bar to a rotating die. The billets are transported through fluid clamps, which engage the mandrel bar and provide cooling fluid to the mandrel bar tip, and through mandrel grips, which engage the mandrel bar and prevent the mandrel bar from rotating. One or more press-rams advance the billets through a centering insert and into the rotating die. A quench assembly is provided at an extrusion end of the extrusion press to quench the extruded material. A programmable logic controller may be provided to control, at least in part, operations of the extrusion press system.