鋁擠壓機培訓資料31

1、PAGE PAGE 24Chappterr3 MMachhineery andd Eqquippmennt ffor Dirrectt/Inddireect Hott ExxtruusioonTHE MACCHINNERYY ANND EEQUIIPMEENT reqquirred forr rood（桿桿，棒，竿竿） aand tubbe eextrrusiion is dettermmineed bby tthe speeciffic exttrussionn prroceess.Ideaallyy, tthe macchinneryy annd eequiipmeent shoouldd

2、 haave fleexibbiliity butt, aalsoo, pprovvidee sppeciificc exxtruusioon pproccesss wiith thee opptimmum（最最適宜的的） qquallityy annd eeconnomiic eeffiicieencyy. DDireect hott exxtruusioon iis tthe mosst wwideely useed pproccesss, aand thee teerm exttrussionn ussuallly refferss too thhis proocesss. Thee m

3、aachiinerry uusedd iss ussuallly bassed on so-callledd sttanddardd deesiggns.The othher exttrussionn prroceessees uusuaallyy reequiire speeciaallyy deevellopeed mmachhinees. Theey aare dessignned acccorddinggly andd buuiltt too meeet thee neeedss off thhe ooperratoor.注釋：rodrd桿，棒，竿竿optiimummptiimmm 最

4、適適宜的3.1 Macchinneryy foor DDireect ExttrussionnThe dessignn off a dirrectt-exxtruusioon ppresss iis ddeteermiinedd byy thhe ffolllowiing facctorrs： Prroduucta. AAlumminuum aand aluuminnum allloyss (llighht mmetaal) eassy tto eextrrudee annd/oor ddiffficuult to exttrudde. Wirre（金金屬絲制制的；金金屬網(wǎng)制制的）, baar

5、（木、金金屬等的的條）, seectiion, hoolloow ssecttionn, aand widde at secctioons b. CCoppper（銅銅） aand coppperr allloyys iinclludiing braass （黃銅銅） (heaavy mettal) eaasy to exttrudde aand/or diffficcultt too exxtruude. Wiire, baar, andd seectiionc. SSteeel aand higgh-sstreengtth ssteeel aallooys eassy tto eextrr

6、udee annd/oor ddiffficuult to exttrudde. Prroceess tecchnoologgya. EExtrrusiion witthouut llubrricaatioon （潤潤滑）aand witthouut aa shhelll （殼殼）b. EExtrrusiion witthouut llubrricaatioon aand witth aa shhelllc. EExtrrusiion witth llubrricaatioon wwithhoutt a sheell Toooliinga. CConttainner（擠擠壓筒）, stem（桿

7、）, dummy block（擠壓墊）, and dieThe widde rrangge oof ddifffereent dessignns ffor exttrussionn prressses hass reecenntlyy beeen redduceed iin mmostt exxtruusioon pplannts to a ffew higgh-ooutpput（高高輸出）types.Therrefoore, onnly exttrussionn prresss deesiggns thaat ddomiinatte（主主導）ttodaays mmarkket aree di

8、iscuusseed iin tthiss chhaptter. Thhesee arre rrefeerreed tto aas sstanndarrd eextrrusiion preessees iin TTablle 33.1.Direect-exttrussionn prressses acccounnt ffor morre tthann 955% oof tthe tottal vollumee off alll ppresssess. TThe dirrectt-exxtruusioon ppresss iis uusedd foor aall currrennt eextrr

9、usiion proocesssess.Table 3.1 Presses for the direct extrusion of aluminum alloys (light metal), copper alloys (heavy metal), and steelMachhinees ffor thee diirecct hhot exttrussionn off liightt-meetall allloyys aare maiinlyy ussed forr thhe eextrrusiion of secctioon (80%), tubbe (10%), andd rood(10

10、%) iin aalumminuum aand aluuminnum allloyss. TThe macchinnes forr diirecct hhot exttrussionn off heeavyy meetalls, maiinlyy cooppeer aand coppperr allloyys, aree ussed forr thhe eextrrusiion of rodd, wwiree, aand secctioon (60%) (maiinlyy inn brrasss) aand tubbe (40%) (maiinlyy inn cooppeer).Steeel

11、aand steeel allloyss arre oonlyy prroduucedd byy exxtruusioon tto aa liimitted exttentt （范范圍,程度）, annd tthenn onnly wheen rrolllingg （滾滾壓；軋軋制）iis nnot posssibble or thee voolummes aree tooo ssmalll.The folllowwingg maajorr poointts mmustt bee coonsiiderred in thee coonsttrucctioon oof eextrrusiion p

12、reessees: Teechnnoloogy reqquirremeentss: TThiss cooverrs tthe mettalllurggicaal （冶冶金的,冶金學學的）aaspeectss off thhe ddefoormaatioon ttechhnollogyy off exxtruusioon. Ecconoomicc faactoors: Thhe eeconnomiic nneedd foor rratiionaalizzatiion （合理理化）iin tthe connstrructtionn off exxtruusioon ppresssess iss m

13、oost cleearlly sseenn inn allumiinumm exxtruusioon. Neww exxtruusioon pplannts aree buuiltt ass innteggratted （整合合的）pprodducttionn liiness. TTheyy inncluude billlett sttorees, billlett heeatiing, exxtruusioon ppresss, hanndliing equuipmmentt wiith lonngittudiinall （縱縱向的）and transverse（橫向的） conveyors

14、（輸送帶）, section cooling systems, stretcher（拉伸機）, cut-to-length saws（定長剪切鋸床） and stackers （棧式存儲器）, as well as heat treatment equipment and packing（包裝）lines. Similar developments can be found in heavy-metal extrusion plants. Sophisticated（富有經(jīng)驗的；精致的；復雜的）systems for electronic data collection and data an

15、alysis for the economic optimal production are already considered to be standard.注釋：Wireewaai 金屬屬絲制的；金屬網(wǎng)網(wǎng)制的bar b: (木、金金屬等的的)條Coppper kkp 銅brasss br:s 黃銅lubrricaatioon ,luu:brrikkein 潤滑shelll el 殼Conttainner kntteinn 擠壓筒stemm sstemm 桿桿dummmy dmi bloock bllk 擠壓壓墊highh-ouutpuut高輸出exteent ikksttentt 范圍,

16、程度rolllingg ruuli 滾壓壓；軋制metaalluurgiicall ,mettll:ddikl 冶金的的,冶金學學的ratiionaalizzatiion ,rrnlaiizeein 合理化化inteegraatedd inttigrreittid 整整合的longgituudinnal ,llndittju:dinnl 縱向的trannsveersee trrnzzv:s 橫向向的convveyoors knvvei輸送帶streetchher sstreet 拉伸伸機cut-to-lenngthh saaws 定長剪切鋸床stacckerrs sttk 棧式存儲器packk

17、ingg pkki 包包裝Sophhistticaatedd ssffisttikeeitiid 富有有經(jīng)驗的；精致的的；復雜雜的3.1.1 EExtrrusiion Preess Dessignn PrrinccipllesInittiall diiscuussiionss, ooverr 500 yeearss aggo, to rattionnaliize thee coonsttrucctioon oof eextrrusiion preessees, ressultted in thee sttanddarddizaatioon oof eextrrusiion tooolinng

18、iin (DINN 2445400). Witthinn thhe llastt 300 yeearss, tthe preess mannufaactuurinng ccomppaniies havve iintrroduucedd sttanddarddizeed ddesiignss onnto thee maarkeet.Tablle 33.1 shoows thee feeatuuress off exxtruusioon ppresssess foor llighht mmetaals, heeavyy meetalls, andd stteell.The maiin ffeatt

19、uree off thhe ddireect-exttrussionn prresss iss thhe sstattionnaryy coontaaineer dduriing exttrussionn. TThe diee, wwhicch iis aalsoo sttatiionaary, annd tthe suppporrt ttoollingg arre llocaatedd att onne oof tthe endd faacess off thhe cconttainner, inn frrontt off thhe cconttainner borre（ (管、圓筒的的)空

20、心部部分，膛膛孔）. Opppossitee thhe ddie, thhe ddummmy bblocck llocaatedd inn frrontt off thhe eextrrusiion steem ppushhes thee biilleet tthrooughh thhe cconttainner borre, andd thhe ssecttionn emmergges（形形成，出出現(xiàn)）tthrooughh thhe ddie (Fiig. 3.11).Fig. 3.1 Tool arrangement for direct extrusionFig. 3.2 Geometr

21、ic relationships for different designs for direct extrusionThe geoomettricc prropoortiionss (比例例；大小小)foor ddifffereent dessignns ffor dirrectt exxtruusioon aare shoown in Figg.3.2.The mosst ccommmon dessignn off exxtruusioon ppresss ttodaay iis tthe preestrresssed(預應力力的)ffourr-coolummn ppresss(四四柱壓力

22、力機). Itt iss ussuallly buiilt witth aa sttanddardd sttrokke（行行程，沖沖程）, whhichh prroviidess goood acccesss annd eeasyy maainttenaancee（維護護,保持,維修）.In aa sttanddardd-sttrokke ppresss, thee biilleet iis lloadded bettweeen tthe conntaiinerr annd tthe steem. Thee prresss sttrokke iis ddeteermiinedd byy thh

23、e lloaddingg sttrokke aand thee exxtruusioon sstrooke. Thheree arre nno sspeccifiic rrequuireemennts plaacedd onn thhe qquallityy off thhe bbilllet geoomettry; itt iss noot iimpoortaant forr thhe bbilllet loaadinng. Oveer 995% of exttrussionn prressses in exttrussionn pllantts aare staandaard-strrok

24、ees.Figuure 3.33 shhowss a 75 MN aluuminnum exttrussionn prresss wiith exttrussionn toooliing forr thhe eextrrusiion of rouund andd fllat billletts. Thee moovinng ccrosss hheadd haas XX-guuidiing simmilaar tto tthe conntaiinerr hooldeer. Thee coontrrol andd innforrmattionn syysteems to monnitoor （監(jiān)監(jiān)

25、視,監(jiān)聽,監(jiān)督）aand opttimiize（使使最優(yōu)化化，使完完善）tthe exttrussionn prroceess cann bee seeen in thee fooreggrouund（最最顯著的的位置）.Fig. 3.3 Standard stroke extrusion press. Location: Alusuisse in Chippis, SwitzerlandThe shoort-strrokee prresss iss coompaact （緊湊湊的,緊密的的,簡潔的的）annd rrequuirees llesss sppacee. TThe shoort s

26、trrokee (aapprroxiimattelyy 600% oof tthe staandaard strrokee) iinclludees tthe exttrussionn sttrokke aand a ffreee sttrokke ffor mannipuulattionn （操操作；操操縱；處處理）. Thheree arre tthreee ddifffereent dessignns.The billlett-looadiing reqquirremeentss arre eeithher: Biilleet lloaddingg wiith a bbilllet lo

27、aaderr inn thhe ffreee sppacee beetweeen thee diie aand thee coontaaineer, witth tthe billlett cllampped（夾夾住，夾夾緊）oon tthe preess cennterrlinne (thee moost commmonn deesiggn) Frree spaace by exttrussionn sttem traansvversse mmoveemennt oon tthe movvingg crrosss heead (biilleet lloaddingg wiith a bbil

28、llet loaaderr beetweeen thee moovinng ccrosss hheadd annd tthe conntaiinerr) Thhreee coontaaineers thaat ccan be rottateed（旋旋轉(zhuǎn)）aarouund a ccoluumn of thee prresss frramee（框,結(jié)構(gòu),骨架） (biilleet lloaddingg wiithoout a bbilllet loaaderr inn onne oof tthe thrree conntaiinerrs ooutssidee thhe ppresss)Fig. 3

29、.4 Short-stroke press (compact press) for direct extrusionFiguure 3.44 shhowss thhe cconttroll deesk, moovabble auxxiliiaryy （輔輔助的）control desk (swinging（旋轉(zhuǎn)的）), hot log shear（圓棒剪）with the billet loader, and the short-stroke press for aluminum alloys. The container is in the extrusion position. The b

30、illet is loaded between the die and the stem when the container has moved back over the stem. The billet must be held exactly between the die and the stem on the press centerline. This ensures that the clearance between the billet and the container is as uniform as possible, guaranteeing perfect ups

31、etting （縮鍛，鐓鍛）of the billet in the container.The tolleraancee-reelatted diaametter varriattionns mmustt bee coompeensaatedd（補償）bby tthe billlett looadeer tto eensuure thaat tthe billlett caan bbe cclammpedd onn thhe ppresss ccentterllinee (FFig. 3.5). Thhis enssurees tthatt thhe uupseettiing of thee

32、 biilleet ttakees pplacce uundeer ooptiimall coondiitioons beccausse oof tthe equual cleearaancee onn alll ssidees tto tthe conntaiinerr boore. Aiir iincllusiionss arre llesss crritiicall, aand traansvversse fforcces, evven if acccepttablle tto aa smmalll deegreee, aree avvoidded durringg uppsetttin

33、ng.Fig. 3.5 Upsetting of a billet clamped on the press centerline (good), and upsetting of a billet resting in the container (poor)Shorrt-sstrooke exttrussionn prressses havve bbeenn thhe sstatte oof tthe artt foor ssomee tiime. Thheree arre vvariiouss reeasoons forr thhis. Scchlooemaann buiilt twoo

34、 1225MNN rood-aand-tubbe eextrrusiion preessees ffor aluuminnum arooundd appprooximmateely 19550. Theese werre mmanuufaccturred as shoort-strrokee prressses forr prroduuctiion reaasonns, witth bbilllet loaadinng bbetwweenn thhe ddie andd thhe cconttainner. Thhe sstemm trranssverrse movvemeent wass u

35、ssed befforee thhe eend of thee laast cennturry. Thee leengtth oof eexpeensiive preess commponnentts, inccluddingg coolummns andd thhe mmainn cyylinnderr, ccan be keppt tto aa miinimmum.The commpanny LLoewwy bbuillt aa stteell tuube exttrussionn prresss inn 19960, wiith thrree conntaiinerrs tthatt c

36、oouldd bee rootatted arooundd a collumnn. TThe aimm waas hhighh-thhrouughpput（高高生產(chǎn)量量） eextrrusiion witth ffastt prresss cyyclees. In praactiice, thhis wass unnsucccesssfuul. Thee maanippulaatioon oof tthe heaavy heaatedd coontaaineers wass onnly posssibble witth eexpeensiive tecchnoologgy. Temmperra

37、tuure varriattionns wwithhin thee coontaaineer hholdder as welll aas iin aadjaacennt（毗毗連的,鄰近的的,接近的的）prresss coompoonennts couuld nott bee avvoidded durringg prroduuctiion. Acccurratee loocattionn off thhe rrotaatinng cconttainnerss onn thhe ppresss ccentterllinee annd iin llinee wiith thee sttem and

38、d thhe ddie couuld nott bee guuaraanteeed to thee neecesssarry rreprroduucibbiliity. Thhe cconttinuuouss moovemmentt off thhe llargge cconttainnerss, tthreee rrotaatioons of 1200 wwithhin an exttrussionn cyyclee, rrequuireed eexteensiive maiinteenannce andd reegullar reppairr. OOnlyy a feww prressse

39、s werre bbuillt tto tthiss deesiggn aand acttuallly useed ffor prooducctioon. In genneraal, shoort-strrokee prressses aree moore exppenssivee thhan staandaard-strrokee prressses beccausse oof tthe mannipuulattionn neeedeed ffor billlett looadiing andd thhe mmechhaniicall deesiggn.注釋：boree bb: (管、圓筒的

40、)空心部部分，膛膛孔.emerrgess iim:d 形成成，出現(xiàn)現(xiàn)propporttionns prupp:n比例；大小presstreesseed prii:sttress預應力的的fourr-coolummn ppresss 四四柱壓力機.strooke sttruuk 行程，沖沖程mainntennancce meeinttinns維護,保持,維修moniitorr mnitt 監(jiān)視,監(jiān)聽,監(jiān)督optiimizze ptiimaiiz 使最優(yōu)化，使使完善foreegrooundd f:rauud 最顯著的位位置.comppactt kmpkt 緊湊的,緊密的,簡潔的maniipulla

41、tiion m,niipjuuleein 操作；操縱；處理clammpeddklmp 夾住，夾緊緊rotaateddrutteitt 旋轉(zhuǎn)frammeffreiim 框,結(jié)構(gòu),骨架auxiiliaary :ziiljri 輔助的swinnginng swwiii旋轉(zhuǎn)的upseettiing pssetii 縮鍛，鐓鍛comppenssateed kmpeenseeit補償highh-thhrouughpput高高生產(chǎn)量adjaacenntdeissntt 毗連連的,鄰近的,接近的的3.1.2 MMainn Suubasssemmbliies of thee Diirecct EExtrrusi

42、ion PreessAll exttrussionn prressses connsisst oof tthe folllowwingg maain subb-asssembbliees: Prresss frramee, cconssisttingg off thhe ffolllowiing subbasssembbliees:a. MMainn cyylinnderr: OOne or twoo piiecee; hhoussingg annd mmainn cyylinnderrb. PPlatten（臺板；焊機床床面）: Onne ppiecce wwithh orr wiithoo

43、ut a ddisccardd （丟丟棄；拋拋棄；放放棄）ssheaar aand/or witth aa diiscaard sawwc. CColuumnss: RRounnd ccoluumnss wiith inbboarrd aand extternnal nutts, rouund collumnns wwithh coomprresssionn slleevves （套筒筒；套管管）(tubbulaar) andd exxterrnall nuuts, laamelllarr （薄薄片狀的的；薄層層狀的）tension elements with compression memb

44、ersd. BBed plaate（底底板）: Sttanddardd wiith rouund collumnns Moovinng ccrosssheead（聯(lián)桿器器，十字字頭）, coonsiistiing of steem hholdder , rretuurn cyllindderss, aand, iff neecesssarry,aadvaancee cyylinnderrs Coontaaineer hholdder witth cconttainner-movvingg cyylinnderrs Diie sslidde oor sshorrt ddie carrrieer,

45、 rottatiing diee caarriier, orr sttatiionaary toool ccarrrierr acctinng aas tthe diee hooldeer Diiscaard sheear andd/orr diiscaard sawwThe funnctiion of thee prresss frramee iss too wiithsstannd tthe exttrussionn looad. A preestrresssed stiiff preess fraame prooviddes: Loow ppresss eexteensiion Loow

46、 ddeeectiion （撓度度）off thhe ddie suppporrt Shhortt deecommpreessiion timmeThe preess fraame connsissts of a ccyliindeer hhoussingg wiith thee maain cyllindder andd raam, a pplatten, annd, if thee foour collumnns aare nott deesiggnedd ass teensiion andd coomprresssionn ellemeentss, aa beed pplatte aan

47、d guiide.The elaastiic bbehaavioor oof tthe preess fraame undder prooducctioon ccondditiionss iss ann immporrtannt ccharractteriistiic oof tthe exttrussionn prresss. TThe stiiffnnesss（剛度度） oof tthe macchinne iinflluenncess thhe aaccuuraccy oof tthe guiidinng aand thee diie ssuppportt duurinng eextrr

48、usiion.In mmanyy reespeectss, tthe quaalitty oof tthe preess fraame plaays an impporttantt roole in thee exxtruusioon pproccesss. TThe opeerattionnal relliabbiliity musst ffirsst bbe gguarrantteedd. FFaillurees iin tthe collumnn thhreaads（螺螺紋） musst bbe aavoiidedd att alll ccostts. Thee nootchh（刻痕痕）

49、efffecct aat tthe rooot oof tthe thrreadd caan iincrreasse tthe norrmall sttresss bby aa siigniificcantt faactoor. In praactiice, onnly thee fiirstt thhreaads cann trranssferr thhe fforcces. Thhis dissadvvanttagee iss avvoidded witth hhammmer heaad llameellaar ccoluumnss. TThe geoomettry of thee haa

50、mmeer hheadd caan bbe ooptiimizzed by finnitee ellemeent anaalyssis. Inn thhe aareaa off thhe ccyliindeer hhoussingg annd tthe plaatenn, ppresstreessiing witth rrounnd ccoluumnss iss caarriied outt, uusinng iinbooardd annd eexteernaal nnutss. TTherre iis nno ppresstreessiing bettweeen tthe houusinng

51、 aand thee pllateen, ressulttingg inn a rellatiivelly llargge eelonngattionn off thhe ppresss dduriing exttrussionn. IIf hholllow commpreessiion memmberrs aare loccateed bbetwweenn thhe hhoussingg annd tthe plaatenn innsteead of thee innboaard nutts, theen tthiss iss reeferrredd too ass a fullly pre

52、estrresssed preess fraame.Withh prresttresssedd coolummns dessignned so thaat tthe tennsioon eelemmentts aare morre hhighhly strresssed andd thhe ccomppresssivve eelemmentts ssubjjectted to lowwer strressses, thhe eelonngattionn caan bbe rreduucedd too 500% oor llesss off thhat of nonn-prresttressse

53、dd coolummns witth nnormmal dimmenssionns（規(guī)模，大大?。?For exaamplle, forr a 35.5 MMN rrod-andd-tuube preess witth aa coolummn llenggth of 12 m aand an exttrussionn looad of 30 MN, thhe eelonngattionn foor aa prresttresssedd prresss frramee iss appprooximmateely 2.55 mmm annd aapprroxiimattelyy 5 mm forr

54、 a nonn-prresttresssedd prresss frramee. FFiguure 3.66 coompaaress thhe lloadd ellonggatiion diaagraams forr booth tennsioon aand commpreessiion eleemennts andd coolummns witth nnutss foor tthiss prresss frramee.Fig. 3.6 Load diagram of a prestressed and non-prestressed press frame at a load of 31.5

55、 MN. g, platen; h, column; i, inboard nut;j, outboard nut; k, tension element; l, compression element; m, cyclindar housingIt iis ccorrrectt thhat larrgerr coolummn ddiammeteers ressultt inn a lowwer strresss annd tthuss reeducce eelonngattionn off noon-ppresstreesseed fframmes. Hoowevver, frrom the

56、e maachiine dessignn poointt off viiew, thhis appproaach cauusess prrobllemss wiith thee geeomeetryy annd tthe guiidinng ssysttem forr thhe ddie carrrieer. Theere is limmiteed sspacce aarouund thee hoousiingss wiith larrgerr coolummns, reesulltinng iin aan iincrreasse iin tthe preess crooss secctioo

57、n aand thuus tthe sizze oof tthe exttrussionn prresss.A beed pplatte iis nneedded forr thhe gguidde wwayss off thhe ddie carrrieer. Thee tootall exxtruusioon lloadd iss prroduucedd byy thhe mmainn cyylinnderr annd, wheen tteed, by thee twwo aadvaancee cyylinnderrs. Thee foorcees nneedded forr thhe a

58、auxiiliaary opeerattionns, inccluddingg biilleet lloaddingg, rram retturnn, cconttainner seaalinng （封封閉，密密封）, annd sstriippiing （剝離離；剝脫脫）, andd thhe rresuultaant （綜合合的；合合成的，組組合的）cycle times must be taken into account in the design of the cylinders.The conntaiinerr seealiing forrcess annd tthe strrip

59、ppingg foorcees ddepeend on thee deesiggn oof tthe tooolinng aand thee exxtruusioon ttechhnollogyy ass weell as thee diiscaard thiicknnesss. TThe conntaiinerr sttripppinng fforcce ffor aluuminnum exttrussionn iss deeterrminned as folllowws:wherre FFR-SSt iis tthe conntaiinerr sttripppinng fforcce, D

60、0 is thee coontaaineer ddiammeteer, lR iss thhe ddisccardd thhickknesss, lF iss thhe ddummmy bblocck llandd leengtth, andd Sis thee shhearr sttresss oof tthe billlett maaterriall.The auxxiliiaryy looadss off thhe eextrrusiion preess aree deeterrminned by thee reelevvantt fuuncttionns. Thee abbiliity