Rotating Die Tube Extrusion with Continuous Small-Billet Feeding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional extrusion processes for manufacturing 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 continuous start-up and shut-down of equipment for each billet, limiting the amount of tubing produced per run and causing system component wear.
Innovation Solution
A continuous extrusion method that allows for the use of smaller billets by continuously loading and extruding multiple billets through a rotating die, with gripping and cooling elements to secure and cool the billets, and a quenching system to rapidly cool the extruded material, reducing equipment size and operational costs while maintaining production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If large billets are used in conventional extrusion processes, then the manufacturing cost of metal tubing is reduced, but the equipment size and start-up costs increase significantly
Solution Approach 1:
The continuous extrusion process divides the extrusion operation into multiple segments, with each segment processing a smaller billet. The system uses multiple extrusion presses working in sequence, allowing each press to handle a manageable-sized billet while collectively producing large quantities of tubing. This segmentation enables the use of smaller, more cost-effective equipment while maintaining high production output.
2Productivity
If conventional extrusion processes are used with separate billets, then manufacturing flexibility is maintained, but continuous start-up and shut-down cycles cause system component wear and reduce productivity
Solution Approach 1:
The system maintains continuous operation by having multiple extrusion presses work in sequence, where each press processes a billet without requiring the entire system to shut down. The first press begins extrusion, and subsequent presses follow in sequence, creating a continuous production flow. This eliminates the repeated start-stop cycles of conventional single-press systems, reducing component wear and maintaining consistent production rates.
Solution Approach 2:
The system prepares multiple billets in advance and positions them for sequential processing. Each press is pre-loaded with a billet before the previous press completes its cycle, ensuring that no idle time occurs between extrusion operations. This preliminary preparation of materials and equipment maintains continuous productive action across the entire system.
3Weight of stationary object
If smaller billets are used in continuous extrusion, then equipment size and costs are reduced, but the ability to maintain consistent extrusion quality across multiple billets must be ensured
Solution Approach 1:
The system uses identical extrusion presses for each station, ensuring that each press has the same capabilities and precision characteristics. This universality means that quality standards are consistent across all presses, as they operate with the same tooling, parameters, and control systems. Each press is a duplicate of the others, guaranteeing uniform extrusion quality regardless of which press processes which billet.
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 continuous extrusion method enables the production of a desired quantity of extruded material with smaller billets, reducing equipment size and costs, improving manufacturing efficiency by minimizing start-up and shut-down cycles and extending equipment lifespan.
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
Implementation Method 3
a quenching system to rapidly cool the extruded material
Data Source
AI summary
One or more hollow billets are loaded onto an elongate mandrel bar for extrusion. The billets are 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.