380V - 415V Aluminium Extrusion Press Machine 1500T Strength

(1) Technical Parameters

• Dimensions of aluminium ingot
• Aluminium ingot diameter:(Determined by Customer) Ф152mm(6inch)
• Inner hole diameter of container Ф158 mm
• Diameter deformation of aluminium ingot after using the hot shearing shall not exceed +2 mm
• Length of aluminium ingot maximum 900 mm
• Minimum 400 mm
• If using two aluminium ingots for extrusion at the same time, the minimum length of each aluminium ingot shall be 300 mm.
• Aluminium ingot curvature 2mm/m

(2) Extrusion capability

• Extrusion force of the complete machine 25Mpa 1542T
• Side cylinder forwards 25Mpa 130T
• Side cylinder retreat 25Mpa 62T
• Container sealing 16Mpa 130T
• Container opening 16Mpa 82T
• Main shearing force 16Mpa 40T
• Shearing force of sliding mould base 16Mpa 24T

(3) Stroke

• Extrusion stem 1200 mm
• Container 400 mm

(4) Speed (Maximum speed during manual operation)

• Extrusion speed (adjustable) 0.2-14.5mm/s
• Fast forward speed of crosshead 350 mm/s
• Reverse speed of crosshead 380 mm/s
• Sealing speed of container 170 mm/s
• Opening speed of container 250 mm/s
• Decline speed of main shear: 400 mm/s
• Return speed of main shear 600 mm/s

(5) Hydraulic system parameters

a, Oil pump

• Primary oil-pressure pump: A15VSO175 variable plunger pump Rexroth 31Mpa 3 sets
• Auxiliary oil pump: SQP43-60-38 vane pump Tokyo relay 17Mpa 1 sets
• Auxiliary oil pump: SQP43-60-21 vane pump Tokyo relay 17Mpa 1 sets
• Auxiliary oil pump: SQP40-60 vane pump Tokyo relay 17Mpa sets
• Cooling filter pump: 558 L/min quantitative centrifugal pump Guangyi 7 kg/cm² 1set

b, The master cylinder, quick cylinder, container cylinder, shears and sliding mode cylinder adopt the logical valve integration control,and the retainer support, etc. adopt the three-position four-way electro-hydraulic reversing valve integration control.

c, Main hydraulic components: Rexroth applied for reversing-face valve and overflow-face valve of the main cylinder, and Jeou Gang applied for other low pressure valves

(6) Electrical system:

• AC contactor: Schneider
• Button switch: Schneider
• Intermediate relay: Schneider
• PLC: Siemens
• Operation interface: Floor-standing control cabinet ,15 inch industrial screen and industrial computer
• Proximity sensor: Omron
• Displacement sensor: MTS

Motors:

Manipulator motor: servo motor 7 KW 1 set (INOVANCE)

Total installed power: 270KW

(7) Die base

Die base dimensions Φ350 mm (diameter) x 350 mm (thickness)

Die base cylinder Φ140XΦ80

(8) Dimensions of die platen discharge hole: Φ200X240

1. Main oil cylinder

• Main cylinder plunger: Φ840mm
• Auxiliary cylinder: Φ180mmXΦ120mm quantity: 2 sets
• Stroke: 1200mm

(10) Container

• Cylinder: Φ150 mm x Φ80 mm Quantity: 4
• Stroke: 400 mm
• Tight locking force: 160T (adjustable)
• Container dimensions: Φ650mmX930mm
• Heating temperature setting: 420℃
• Heating mode: Electrical heating tube heating
• Heating power: 32Kw

(11) Shearing system

• Shearing cylinder: Φ180mmXΦ140mm
• Shear force: 40T

(12) Cooling system

• Plate heat exchanger: 25m² 1set
• Working pressure: 0.1-0.2 MPa

(13) Hydraulic operating oil (self-prepared by customer)

• Required amount 6000 L
• Viscosity N68# dust-free wear-resistant hydraulic oil

Part II:

Structure:

The extrusion press is composed of main cylinder components, die platen components and four heavy tie rods and four heavy prestressing pipe sleeves connecting these two parts, crosshead including extrusion stem and with sliding mechanism, container, ingot-carrying device, box-type die replacement device, shears including residual pressure knocking device and hydraulic units. The extrusion press is supported by the base in the welded steel structure.

1. Prestressing equipment structure:

Four heavy steel bushings apply 1.2 times of the pre-tensioning stress of the design tension of the tie rod between the die platen and main cylinder rack.

The prestress design has the following advantages:

• The main tie rod is tensioned by the prestress within the range of the whole length, enables the movement of the die platen to the minimum level under the pre-tensioning stress by the prestressing pipe sleeves and makes the alignment precision deviation of the equipment to the minimum level under the extrusion force.
• After the die platen and main cylinder rack are tightly connected, the equipment structure becomes quite rigid and firm

2. Main cylinder components:

• The main cylinder and side cylinder are respectively equipped with the suitable single-acting main cylinder.
• The V-shaped seal ring is used for the main cylinder as sealing and guiding for the tin bronze bushing.
• The spacer shim is applied between the seal ring cylinder and flange for adjustment to ensure the sealing precision.
• The back end of main cylinder is equipped with the prefill valve in mass flow to ensure that the working oil can freely flow into the main cylinder from the fuel tank during the fast shutdown of the primary plunger. Meanwhile, the main cylinder rack is equipped with four container cylinders.

3. Die platen components and box-type die replacement device:

• The die platen is cast by35# cast steel with high quality, and the central part of the die platen has the discharge hole in the dimensions and shape meeting the largest production requirements to make the extruded products pass through.
• The hole is equipped with the die platen hard pad manufactured by hard steel to support the pressure applied in the die platen.
• The extrusion press is equipped with two die boxes, which are driven by double acing hydraulic cylinder. Sliding inside the die platen will realize the fast replacement of the die pre-installed, effectively reduce the shutdown time of loading and unloading during the replacement of die. If necessary, the sliding formwork hydraulic cylinder can also be used as shearing.

4. Main crosshead and extrusion stem components

• The material of main walking beam is 35# cast steel. It is installed at the front end of the primary plunger and uses the main tie rod sleeve as the supporting and guiding for the X guide rail. It is used to balance the partial gravity of the primary plunger and driven by the main cylinder and side cylinder.
• The extrusion stem is firmly installed on the extrusion stem base at the front end of the crosshead by a clamping device with easy assembly and disassembly, which can move vertically up and down to leave space for the manipulator to enter the rod.

Container components:

• The container components contain the container, thermal insulation base, resistance heater, etc.
• The thermal insulation base has X-shaped support and six points for guiding.
• The lower sliding spacer is guided within the whole stroke along the guide rail of the base in 2 directions, namely vertical and horizontal directions.
• The upper sliding spacer is guided by the wear plate contacting the upper prestressing pipe to make the thermal insulation base move stably.
• The thermal insulation base is driven by four thermal insulation base cylinders on the main cylinder rack, and equipped with the adjustable positioning bolts, and plays a role in regulating the alignment of the container support.
• The container is heated by the directly inserted resistance elements. These heating elements are distributed in the area of the extrusion barrel jacket and are automatically controlled in SSR mode to maintain the required working temperature of the extrusion barrel.
• At the same time, a locking device is provided to ensure the alignment precision of extrusion stem and container.

5. Main shears:

• The vertical shears are installed inside the die platen and manufactured by #45 forged steel.
• The guiding part of the shears is the rectangular design, which will adjust the gap between the shear blade and die. Besides, the compensation for the wear of guiding plate will be realized through the adjustment for the block gap in use, to make the swing of the shearing stem to the minimum level during the shearing and maintain the best shearing effect for a long time.
• The residual pressure knocking device is installed on the main shear components and plays a role in knocking the residual pressure out from the shears.
• During the shearing, the die base is fixed by the locking device to ensure the shearing precision. Such locking device system is composed of longitudinal and transverse die assemblies.

6. Ingot-carrying device:

• The ingot-carrying device is driven by servo motor and composed of gear wheels, gear racks, linear guide rail, encoder, etc. and moves in straight line under the fixation and support by the linear guide rail, to ensure that the aluminium ingot is fast and stably conveyed to the extrusion center line of the container with accurate positioning during the loading.
• In case of the changes in the aluminium ingot diameter and dimensions, the center of aluminium ingot can be conveniently adjusted to the center of container through adjusting the support location fo the movable pulley.
• When the ingot carrier moves the aluminum ingot into the extrusion cylinder .

7. Hydraulic system:

• Hydraulic power for the operation of press: the high-precision variable delivery capacity electro-hydraulic proportional valve control plunger piston pump of REXROTH A15VSO series is used as the main pump, with Vane pump of Tokyo relay series as the secondary oil-pressure pumps.
• The oil throughput rate of the Primary oil-pressure pump is controlled by the pre-set oil pump electronic regulating unit, PLC central processor, main cylinder displacement sensor, etc.
• The Primary oil-pressure pump and the secondary oil-pressure pump are installed vertically behind the main cylinder through the vertical motor and connect the bottom of the fuel tank through the large drift diameter seamless steel tube, anti-shock stainless steel soft connection, switch valve, etc., to ensure that the oil suction end of the Primary oil-pressure pump maintains the role of positive oil pressure for a long time and will not generate such phenomena as empty suction or cavitation during the oil absorption damaging the oil pump and enable the oil pump to generate small noise with more stable working pressure and long service life.
• The vertical installation can save space for the oil pump motor unit and make the equipment more compact and beautiful.
• The logical valves like directional valve, pressure relief valve and safety valve are installed on the integrated oil-way valve station for use, so as to form the simple pipelines and prevent the oil leakage to the greatest extent.
• The logical valve is characterized by high pressure control, large flow and no impact.
• The sealed pump of container is used to maintain the sealing pressure inside the locking cylinder of container before and during the extrusion.
• All high-pressure pipelines are welded by seamless steel tubes and welding neck flanges, and the face-to-face flanges with O-rings are applied at the connected places or the deep thread connection is applied for connection.
• The incoming and outgoing oil pipes are installed with the anti-shock connections.
• The suction valve (butterfly valve) of the main cylinder is installed outside the fuel tank, and can be closed during the maintenance. There is no necessity to empty the hydraulic oil inside the fuel tank.

Operation:

1. Pipe extrusion/profile extrusion
2. Extrusion circulation

For the control of the extrusion press, the repeated full-automatic circulation or semi-continuous automatic circulation is allowed.

The extrusion press will realize the following circulating actions:

• Circulating action based on the control mode selection
• Manual
• Single circulating automation (from the container forward)
• Full automatic (continuous)

3. Extrusion speed

• The extrusion speed can be regulated to the maximum speed value from the zero stepless speed by the pre-set device on the operation cabinet. When starting the constant speed extrusion, the speed floating difference value shall be controlled within ±0.2 mm/s.
• In the full-automatic circulation, the extrusion speed can be controlled by program so as to determine the filling speed, extrusion speed and speed reduction ratio.

4. Temperature control of container

The heater in the extrusion cylinder uses a ring-shaped heating tube. According to the thermocouple signal display, the thyristor power controller inputs appropriate electrical energy into the heater to control the temperature.

5. Safety control

The extrusion press is controlled by the interlocking device to prevent the equipment damage possibly due to the mis-operation. For example, only after the ingot-carrying device is returned to the safe position, the primary plunger will run forwards. Overpressure limit protection and alarm and oil overtemperature alarm of main cylinder.

Part III

Detailed descriptions for all parts of extrusion press

1.Technical parameters

1.1 Mechanical equipment

1.1.1 Equipment base

• Material type
• Material Welded stee
• Technical Specification
• The equipment base is manufactured by the welded steel plate, and supports the whole structure from die platen to main cylinder rack.
• Before the machining and after the welding, the whole structural members will be quenched.
• The main cylinder rack is supported by the equipment base, and its amount of movement in the axial direction is limited by the fixed pins and tie rod.
• The die platen is fixed and supported by the equipment base through sliding rack.
• The die platen will move along with the flexible deformation of the tie rod on the sliding rack.

1.1.2 Main cylinder base and main cylinder

• Material type
• Material of main cylinder base casting steel (#35)
• Material of main cylinder Forged steel (#35)

Technical Specification:

• The main cylinder and side cylinder (two) are embedded in the main cylinder base. 35# casting steel is selected for the main cylinder base. During the casting, it has high mobility and therefore has the super high stability.
• The main cylinder is composed of two or three parts, welded by 35# forged steel by special electrowelding mode and then tempered.
• The primary plunger fast forwards and its return stroke are driven by two side cylinders on the main cylinder base.
• During the extrusion, the primary plunger and side cylinder work at the same time.

1.1.3

• Primary plunger
• Technical data
• Diameter Φ840 mm
• Pressure stem stroke 1200mm
• Working pressure 25Mpa
• Material type Chilled cast iron
• Technical description
• The primary plunger is made of chilled cast iron and finely polished on the surface by a special process, and the surface hardness may reach HRC46-49.
• The main cylinder moves inside the main cylinder along the direction of extrusion through copper casing and returned by two side cylinders driving the primary plunger during the return stroke.
• The main cylinder and copper casing are automatically lubricated by the hydraulic oil inside the main cylinder.
• The speed and location of primary plunger are monitored and controlled by the absolute encoder

1.1.4 Main crosshead

Material type:

Material 35# casting steel

Technical Specification:

The main crosshead is the 35# casting steel with high quality and is firmly placed on the primary plunger. The base of the extrusion stem drives the extrusion stem to move from the left to the right.

The crosshead is connected with the side cylinder.

The extrusion stem is firmly installed on the base at the front end of the crosshead by a clamping device with easy assembly and disassembly.

At the same time, a locking device is provided to ensure the extrusion stem and container in the same horizontal line. Within the whole stroke, the main crosshead is supported and guided on the smooth guiding base.

Two-way guide rail - vertically and horizontally - is equipped in the lower part of the main crosshead and adjusted by adjusting bolts.

The crosshead is equipped with the following parts:

1. The sliding and locking devices of the extrusion stem ensure the accurate support of extrusion stem
2. Clamping and connecting bolts of supporting extrusion stem

1.1.5 Die platen

Material: 35# casting steel

Thickness: 680mm

Technical Specification

The die platen is manufactured by the high-quality35# casting steel, and aims at reducing the pressed conditions, deformation and curvature of the die platen and die after the application of extrusion force to the minimum level.

The holes with suitable dimensions and shapes are determined in the center of die platen to make the extruded products through.

The die box is driven by double acing hydraulic cylinder and slides inside the die platen.

If necessary, the sliding formwork hydraulic cylinder can be used for shearing.

1.1.6 Double die base replacement device

Material type Die base 45# forged steel

Technical Specification:

The sliding formwork hydraulic cylinder is installed inside the die platen and operated by double acting hydraulic cylinder and can be used as auxiliary shears.

The vertical adjustment for the die box will be realized by placing the spacer shim outside the equipment, and the horizontal adjustment will be realized by setting the stopper.

The die replacement device is the two-position box type, and the die replacement location is one side of operation of the extrusion press die platen. It will fast replace the die and facilitate the operation and maintenance around the die platen of extrusion press.

1.1.7 Ingot-carrying device

Technical data

Type Linear moving type

Drive mode Driven by servo motor

Structure Welded steel

Technical Specification

The ingot-carrying device is driven by motor and moves in straight line under the support of roller, to ensure that the aluminium ingot is supported to the center of extrusion press during the loading.

In case of changes in the aluminium ingot dimensions, the replacement for the lining of roller support will easily load the aluminium ingot to the center of extrusion press.

1. 2 Extrusion tools

The extrusion tools of the extrusion press include the following elements:

1. 2.1 Container

Technical data:

inside diameter………………………………………………………Φ158 mm(Determined by Customer)

Length 930 mm

Material:

Liner of container Forged steel (H13 alloy tool steel)

Out sleeve of container Forged steel (5CrMnMo alloy tool steel)

Technical Specification:

The container is located inside the thermal insulation base and composed of two parts: liner and out sleeve of the container

During the extrusion, these two parts of the container will shrink to bear the thermal pressure and thermal tension.

Within the contact region at one side of the die platen, the lining stretches to about 20 mm from the liner surface of container, to ensure the correct sealing between the die and container during the extrusion, so as to avoid the metal overflow.

There is no cotterway in the middle of outside surface of the container liner to prevent the concentration of stress and heat and prolong its service life.

Only the two-end surface of the container out sleeve has the cotterway.

1. .2.2 Extrusion stem and fixed extrusion pad

Technical data:

Stem outer diameter Φ158 mm (Determined buyer)

Material:

Extrusion stem Forged steel (H13 alloy tool steel)

Connecting rod Forged steel (H13 alloy tool steel)

Fixed extrusion pad Forged steel (H13 alloy tool steel)

Technical Specification:

The extrusion stem transfers the extrusion force to the aluminium ingot by the fixed extrusion pad:

The extrusion stem components include extrusion stem and connecting rod. The connecting rod and extrusion stem are tightly connected.

The fixed extrusion pad is screwed into one end of the connecting rod, and the rest part is tightly connected with the head of extrusion stem.

Another tail end of the connecting rod is tapered to maintain the centrality.

1.2.3 Oil pump motor unit

The Primary oil-pressure pump and the secondary oil-pressure pump are installed behind the main cylinder and connect the bottom of the fuel tank through the large drift diameter seamless steel tube, anti-shock stainless steel soft connection, switch valve, etc., to ensure that the oil suction end of the Primary oil-pressure pump maintains the role of positive oil pressure for a long time and will not generate such phenomena as empty suction or cavitation during the oil absorption damaging the oil pump and enable the oil pump to generate small noise with more stable working pressure and long service life.

3. Overall dimensions of extrusion press:11000mm×6500mm×4100mm

Weight: extrusion press weight is about 80MT

Material of main parts of press