Expandable Dummy Block Structure for Higher Extrusion Pressure
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Solution Overview
Problem
Existing dummy blocks for metal extrusion presses face challenges in efficiently transferring force to the billet and maintaining high extrusion pressures, often resulting in reduced operational efficiency and increased wear.
Innovation Solution
A dummy block design featuring a plunger disc and plunger shaft as separate components, with a plunger disc that elastically deforms outwardly and a collar that expands to accommodate the deformation, allowing for efficient force transfer and increased extrusion pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a traditional dummy block design is used, then the structure is simple, but the ability to transfer force directly to the billet is reduced and extrusion pressures are limited
Solution Approach 1:
The dummy block is divided into separate components: a plunger shaft, a plunger disc, and a collar. This segmentation allows each component to be optimized for its specific function - the plunger shaft for force application, the plunger disc for elastic deformation and force transfer, and the collar for containment and support.
Solution Approach 2:
The plunger disc is designed to elastically deform outwardly during operation, transitioning from a static component to a dynamic one. This elastic deformation enables the plunger disc to conform to the billet surface and transfer force more effectively, while the collar expands to accommodate this deformation.
2Productivity
If high extrusion pressures are applied, then productivity increases, but wear on the dummy block increases
Solution Approach 1:
The dummy block components are designed with specific material properties and geometric parameters that allow them to withstand high extrusion pressures. The plunger disc's elastic modulus and thickness are optimized to provide the right balance of flexibility and strength, while the collar's internal diameter and thickness are designed to accommodate deformation under pressure without excessive wear.
Solution Approach 2:
The plunger disc is designed as a replaceable component that can be worn or damaged during high-pressure operation. When wear occurs, only the plunger disc needs to be replaced rather than the entire dummy block, allowing for cost-effective maintenance and continued productivity.
3Ease of manufacture
If the plunger disc and plunger shaft are integrated, then manufacturing is simpler, but maintenance and replacement are more difficult
Solution Approach 1:
The plunger disc and plunger shaft are manufactured as separate components that assemble together. This segmentation simplifies manufacturing of each individual part while enabling easy replacement of the plunger disc when worn, as it can be removed and replaced without replacing the entire dummy block assembly.
Solution Approach 2:
The plunger shaft is inserted through the plunger disc, creating a nested arrangement where the plunger disc is positioned on the plunger shaft. This nested configuration allows the plunger disc to be easily removed and replaced while retaining the plunger shaft and other dummy block components.
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 design enhances the ability to transfer force directly to the billet, enabling operation at higher extrusion pressures while reducing wear and allowing for easier maintenance by enabling replacement of the plunger disc.
Implementation Method 1
a plunger disc that elastically deforms outwardly
Data Source
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AI summary
A dummy block for a metal extrusion press includes: a generally cylindrical base having a forward surface and an outwardly extending circumferential flange; an expandable collar coupled to the base, the collar having an inwardly extending circumferential rib abutting the circumferential flange; a plunger disc seated against the forward surface of the base and accommodated by the collar; and a plunger shaft extending through the plunger disc and coupled to the base.