铝挤压机培训资料31docx.docx

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Chapter3MachineryandEquipmentforDirect/IndirectHotExtrusion

THEMACHINERYANDEQUIPMENTrequiredforrod（杆，棒，竿）andtubeextrusionisdeterminedbythespecificextrusionprocess.

Ideally,themachineryandequipmentshouldhaveflexibilitybut,also,providespecificextrusionprocesswiththeoptimum（最适宜的）qualityandeconomicefficiency.Directhotextrusionisthemostwidelyusedprocess,andthetermextrusionusuallyreferstothisprocess.Themachineryusedisusuallybasedonso-calledstandarddesigns.

Theotherextrusionprocessesusuallyrequirespeciallydevelopedmachines.Theyaredesignedaccordinglyandbuilttomeettheneedsoftheoperator.

注释：

rod[rɔd]杆，棒，竿

optimum['ɔptiməm]最适宜的

3.1MachineryforDirectExtrusion

Thedesignofadirect-extrusionpressisdeterminedbythefollowingfactors：

●Product

a.Aluminumandaluminumalloys（lightmetal）easytoextrudeand/ordifficulttoextrude.Wire（金属丝制的；金属网制的）,bar（木、金属等的条）,section,hollowsection,andwideflatsections

b.Copper（铜）andcopperalloysincludingbrass（黄铜）（heavymetal）easytoextrudeand/ordifficulttoextrude.Wire,bar,andsection

c.Steelandhigh-strengthsteelalloyseasytoextrudeand/ordifficulttoextrude.

●Processtechnology

a.Extrusionwithoutlubrication（润滑）andwithoutashell（壳）

b.Extrusionwithoutlubricationandwithashell

c.Extrusionwithlubricationwithoutashell

●Tooling

a.Container（挤压筒）,stem（杆）,dummyblock（挤压垫）,anddie

Thewiderangeofdifferentdesignsforextrusionpresseshasrecentlybeenreducedinmostextrusionplantstoafewhigh-output（高输出）types.

Therefore,onlyextrusionpressdesignsthatdominate（主导）today’smarketarediscussedinthischapter.ThesearereferredtoasstandardextrusionpressesinTable3.1.

Direct-extrusionpressesaccountformorethan95%ofthetotalvolumeofallpresses.Thedirect-extrusionpressisusedforallcurrentextrusionprocesses.

Machinesforthedirecthotextrusionoflight-metalalloysaremainlyusedfortheextrusionofsection（80%）,tube（10%）,androd（<10%）inaluminumandaluminumalloys.Themachinesfordirecthotextrusionofheavymetals,mainlycopperandcopperalloys,areusedfortheextrusionofrod,wire,andsection（60%）（mainlyinbrass）andtube（40%）（mainlyincopper）.

Steelandsteelalloysareonlyproducedbyextrusiontoalimitedextent（范围,程度）,andthenonlywhenrolling（滚压；轧制）isnotpossibleorthevolumesaretoosmall.

Thefollowingmajorpointsmustbeconsideredintheconstructionofextrusionpresses:

●Technologyrequirements:

Thiscoversthemetallurgical（冶金的,冶金学的）aspectsofthedeformationtechnologyofextrusion.

●Economicfactors:

Theeconomicneedforrationalization（合理化）intheconstructionofextrusionpressesismostclearlyseeninaluminumextrusion.Newextrusionplantsarebuiltasintegrated（整合的）productionlines.Theyincludebilletstores,billetheating,extrusionpress,handlingequipmentwithlongitudinal（纵向的）andtransverse（横向的）conveyors（输送带）,sectioncoolingsystems,stretcher（拉伸机）,cut-to-lengthsaws（定长剪切锯床）andstackers（栈式存储器）,aswellasheattreatmentequipmentandpacking（包装）lines.Similardevelopmentscanbefoundinheavy-metalextrusionplants.Sophisticated（富有经验的；精致的；复杂的）systemsforelectronicdatacollectionanddataanalysisfortheeconomicoptimalproductionarealreadyconsideredtobestandard.

注释：

Wire['waiə]金属丝制的；金属网制的

bar[bɑ:

]（木、金属等的）条

Copper['kɔpə]铜

brass[brɑ:

s]黄铜

lubrication[,lu:

bri'keiʃən]润滑

shell[ʃel]壳

Container[kən'teinə]挤压筒

stem[stem]杆

dummy['dʌmi]block[blɔk]挤压垫

high-output高输出

extent[iks'tent]范围,程度

rolling['rəuliŋ]滚压；轧制

metallurgical[,metə'lə:

dʒikəl]冶金的,冶金学的

rationalization[,ræʃənəlai'zeiʃən]合理化

integrated['intigreitid]整合的

longitudinal[,lɔndʒi'tju:

dinəl]纵向的

transverse[trænz'və:

s]横向的

conveyors[kən'veiə]输送带

stretcher['stretʃə]拉伸机

cut-to-lengthsaws定长剪切锯床

stackers['stækə]栈式存储器

packing['pækiŋ]包装

Sophisticated[sə'fistikeitid]富有经验的；精致的；复杂的

3.1.1ExtrusionPressDesignPrinciples

Initialdiscussions,over50yearsago,torationalizetheconstructionofextrusionpresses,resultedinthestandardizationofextrusiontoolingin（DIN24540）.Withinthelast30years,thepressmanufacturingcompanieshaveintroducedstandardizeddesignsontothemarket.

Table3.1showsthefeaturesofextrusionpressesforlightmetals,heavymetals,andsteel.

Themainfeatureofthedirect-extrusionpressisthestationarycontainerduringextrusion.Thedie,whichisalsostationary,andthesupporttoolingarelocatedatoneoftheendfacesofthecontainer,infrontofthecontainerbore（（管、圆筒的）空心部分，膛孔）.Oppositethedie,thedummyblocklocatedinfrontoftheextrusionstempushesthebilletthroughthecontainerbore,andthesectionemerges（形成，出现）throughthedie（Fig.3.1）.

Thegeometricproportions（比例；大小）fordifferentdesignsfordirectextrusionareshowninFig.3.2.

Themostcommondesignofextrusionpresstodayistheprestressed（预应力的）four-columnpress（四柱压力机）.Itisusuallybuiltwithastandardstroke（行程，冲程）,whichprovidesgoodaccessandeasymaintenance（维护,保持,维修）.

Inastandard-strokepress,thebilletisloadedbetweenthecontainerandthestem.Thepressstrokeisdeterminedbytheloadingstrokeandtheextrusionstroke.Therearenospecificrequirementsplacedonthequalityofthebilletgeometry;itisnotimportantforthebilletloading.Over95%ofextrusionpressesinextrusionplantsarestandard-strokes.

Figure3.3showsa75MNaluminumextrusionpresswithextrusiontoolingfortheextrusionofroundandflatbillets.ThemovingcrossheadhasX-guidingsimilartothecontainerholder.Thecontrolandinformationsystemstomonitor（监视,监听,监督）andoptimize（使最优化，使完善）theextrusionprocesscanbeseenintheforeground（最显著的位置）.

Theshort-strokepressiscompact（紧凑的,紧密的,简洁的）andrequireslessspace.Theshortstroke（approximately60%ofthestandardstroke）includestheextrusionstrokeandafreestrokeformanipulation（操作；操纵；处理）.Therearethreedifferentdesigns.

Thebillet-loadingrequirementsareeither:

●Billetloadingwithabilletloaderinthefreespacebetweenthedieandthecontainer,withthebilletclamped（夹住，夹紧）onthepresscenterline（themostcommondesign）

●Freespacebyextrusionstemtransversemovementonthemovingcrosshead（billetloadingwithabilletloaderbetweenthemovingcrossheadandthecontainer）

●Threecontainersthatcanberotated（旋转）aroundacolumnofthepressframe（框,结构,骨架）（billetloadingwithoutabilletloaderinoneofthethreecontainersoutsidethepress）

Figure3.4showsthecontroldesk,movableauxiliary（辅助的）controldesk（swinging（旋转的））,hotlogshear（圆棒剪）withthebilletloader,andtheshort-strokepressforaluminumalloys.Thecontainerisintheextrusionposition.Thebilletisloadedbetweenthedieandthestemwhenthecontainerhasmovedbackoverthestem.Thebilletmustbeheldexactlybetweenthedieandthestemonthepresscenterline.Thisensuresthattheclearancebetweenthebilletandthecontainerisasuniformaspossible,guaranteeingperfectupsetting（缩锻，镦锻）ofthebilletinthecontainer.

Thetolerance-relateddiametervariationsmustbecompensated（补偿）bythebilletloadertoensurethatthebilletcanbeclampedonthepresscenterline（Fig.3.5）.Thisensuresthattheupsettingofthebillettakesplaceunderoptimalconditionsbecauseoftheequalclearanceonallsidestothecontainerbore.Airinclusionsarelesscritical,andtransverseforces,evenifacceptabletoasmalldegree,areavoidedduringupsetting.

Short-strokeextrusionpresseshavebeenthestateoftheartforsometime.Therearevariousreasonsforthis.Schloemannbuilttwo125MNrod-and-tubeextrusionpressesforaluminumaroundapproximately1950.Theseweremanufacturedasshort-strokepressesforproductionreasons,withbilletloadingbetweenthedieandthecontainer.Thestemtransversemovementwasusedbeforetheendofthelastcentury.Thelengthofexpensivepresscomponents,includingcolumnsandthemaincylinder,canbekepttoaminimum.

ThecompanyLoewybuiltasteeltubeextrusionpressin1960,withthreecontainersthatcouldberotatedaroundacolumn.Theaimwashigh-throughput（高生产量）extrusionwithfastpresscycles.Inpractice,thiswasunsuccessful.Themanipulationoftheheavyheatedcontainerswasonlypossiblewithexpensivetechnology.Temperaturevariationswithinthecontainerholderaswellasinadjacent（毗连的,邻近的,接近的）presscomponentscouldnotbeavoidedduringproduction.Accuratelocationoftherotatingcontainersonthepresscenterlineandinlinewiththestemandthediecouldnotbeguaranteedtothenecessaryreproducibility.Thecontinuousmovementofthelargecontainers,threerotationsof120ºwithinanextrusioncycle,requiredextensivemaintenanceandregularrepair.Onlyafewpresseswerebuilttothisdesignandactuallyusedforproduction.Ingeneral,short-strokepressesaremoreexpensivethanstandard-strokepressesbecauseofthemanipulationneededforbilletloadingandthemechanicaldesign.

注释：

bore[bɔ:

]（管、圆筒的）空心部分，膛孔.

emerges[i'mə:

dʒ]形成，出现

proportions[prəu'pɔ:

ʃən]比例；大小

prestressed[pri:

'stres]预应力的

four-columnpress四柱压力机.

stroke[strəuk]行程，冲程

maintenance['meintinəns]维护,保持,维修

monitor['mɔnitə]监视,监听,监督

optimize['ɔptimaiz]使最优化，使完善

foreground['fɔ:

ɡraud]最显著的位置.

compact['kɔmpækt]紧凑的,紧密的,简洁的

manipulation[mə,nipju'leiʃən]操作；操纵；处理

clamped[klæmp]夹住，夹紧

rotated[rəu'teit]旋转

frame[freim]框,结构,骨架

auxiliary[ɔ:

ɡ'ziljəri]辅助的

swinging['swiŋiŋ]旋转的

upsetting[ʌp'setiŋ]缩锻，镦锻

compensated['kɔmpenseit]补偿

high-throughput高生产量

adjacent[ə'dʒeisənt]毗连的,邻近的,接近的

3.1.2MainSubassembliesoftheDirectExtrusionPress

Alle