Multi-Container Extrusion Die for Wide Sheet Welding
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Solution Overview
Problem
Existing methods for producing wide metal sheets or plates, such as rolling and conventional extrusion, are energy-intensive and costly, with limitations in achieving widths greater than 1500 mm due to high extrusion forces and pressures, and result in inconsistent mechanical properties and edge quality issues.
Innovation Solution
An apparatus with multiple small extrusion containers and a die set that includes a welding chamber, allowing for the extrusion of billets into wide sheets with reduced extrusion forces and costs, using pre-heated billets pushed through the containers and welded together for efficient production of wide metal sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional extrusion method is used to produce wide metal sheets, then the sheet width can be increased, but the extrusion force and pressure increase significantly making it impractical for widths greater than 1500 mm
Solution Approach 1:
The patent divides the extrusion process into multiple separate extrusion containers, each producing a narrower profile. These multiple extruded profiles are then welded together to form a wide sheet. This segmentation allows each container to operate at feasible force levels while achieving overall wide sheet production that would be impossible with a single container.
2Area of stationary object
If existing extrusion methods are used to produce wide sheets, then sheet width can be increased, but the mechanical properties become inconsistent across the sheet
Solution Approach 1:
By using multiple separate extrusion containers, each producing a narrower profile with consistent mechanical properties, and then welding them together with proper control of the welding process, the patent achieves overall consistency across the wide sheet that cannot be obtained through single-container extrusion of wide profiles.
3Area of stationary object
If expanding extrusion is used to produce wide sheets, then sheet width can be increased, but edge quality deteriorates with saw-tooth features requiring further processing
Solution Approach 1:
Instead of using expanding extrusion with a single large die, the patent uses multiple separate extrusion containers with controlled extrusion. This allows for better control of material flow and edge formation in each container, producing cleaner edges that do not require additional processing.
4Area of stationary object
If rolling process is used to produce wide metal sheets, then sheet width can be increased, but energy consumption and cost increase due to multiple passes and intermediate heating
Solution Approach 1:
The patent uses multiple extrusion containers working in parallel to produce wide sheets in a more direct process, avoiding the multiple rolling passes and intermediate heating required by conventional rolling methods, thereby reducing energy consumption.
5Area of stationary object
If magnesium alloy is processed by rolling to produce wide sheets, then sheet width can be increased, but cost increases significantly due to difficulty of deformation
Solution Approach 1:
The patent uses extrusion instead of rolling, which is more suitable for magnesium alloys with HCP crystal structure. By dividing the process into multiple extrusion containers, the patent makes wide sheet production of magnesium alloy economically viable.
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 apparatus significantly decreases the load requirement and cost, enabling the production of wide metal sheets up to 2200 mm or more with improved mechanical properties and edge quality, suitable for automotive and aerospace industries.
Implementation Method 1
one or more rams, wherein the one or more rams are aligned with the axes of the extrusion containers and are arranged to push the billets of material through the extrusion containers into the die set
Implementation Method 2
a lower die incorporating a welding chamber, wherein two or more extruded billets from each of said extrusion channels are welded together
Data Source
AI summary
An apparatus for extruding a material, the apparatus comprising: a block which includes two or more extrusion containers composed of heat resisting material, the containers being arranged to receive billets of the extruding material; a die set arranged downstream of the block including the two or more extrusion containers; and one or more rams, wherein the one or more rams are aligned with the axes of the extrusion containers and are arranged to push the billets of material through the extrusion containers into the die set; wherein the die set includes an upper die including two or more extrusion channels for extruding material from each of the extrusion containers, and a lower die incorporating a welding chamber, wherein two or more extruded billets from each of the extrusion channels are welded together and passed out through the exit of the die set.