HK1212947B

HK1212947B - Extrusion press systems and methods

Info

Publication number: HK1212947B
Application number: HK16100849.5A
Authority: HK
Inventors: C．L．斯特沃特
Original assignee: 曼彻斯特铜产品有限责任公司
Priority date: 2012-10-12
Filing date: 2013-10-11
Publication date: 2019-08-02

Description

Extrusion system and method

Background

The characteristics of the material are affected by the processes used to form and shape the material. The process includes heat treatment, deformation and casting. Heat treatment is a process of subjecting a metal or alloy to a particular heating and cooling protocol that produces the desired physical and chemical changes. Deformation is a process that forces a piece of material to change its thickness or shape, and some deformation techniques include forging, rolling, extrusion, and drawing. Casting is the pouring of molten metal into a mold so that the metal conforms to the shape of the mold as it solidifies. Heat treatment, deformation, and casting may be used in combination, and in some cases, specific alloying elements may be added to affect such processes in a desired manner.

Seamless metal tubes, such as copper tubes, are typically manufactured using various methods, such as cast-rolling, up-casting, or extrusion processes. To reduce the cost of metal tubes produced via conventional extrusion and casting techniques, manufacturers increase the size of the billet used to form the metal tube. These billets are typically 100 to 1000 pounds or more. Therefore, manufacturers require large facilities to accommodate the specialized large-sized machinery required to process the billet to form the metal tube. The large size of the apparatus and the billets processed through the apparatus results in an extrusion process with large start-up and maintenance costs. Furthermore, process limitations, such as extruding only one billet at a time, result in manufacturing inefficiencies, including limitations on the amount of pipe produced per run and system component wear due to the frequent starting and stopping of the manufacturing process for each run of each billet.

Disclosure of Invention

Systems, devices, and methods for extruding materials are disclosed herein. In certain embodiments, the systems, devices, and methods allow for the continuous extrusion of multiple billets. Such continuous extrusion allows for the production of a desired amount of extruded material using a relatively small billet, and thus the size of such continuous extrusion systems may be smaller than conventional extrusion processes. The system, apparatus and method allow for seamless extrusion of multiple billets in series.

In one aspect, the systems, devices, and methods of the present invention include a method for continuously loading and extruding a plurality of billets, the method comprising: loading a first billet on a receiving end of an elongated mandrel bar; transporting the first billet along the mandrel bar and passing the first billet through a clamping element that holds the mandrel bar in place and prevents rotation of the mandrel bar, wherein at any given moment, at least one clamping element clamps the mandrel bar; and extruding the first billet by pushing the first billet through a rotating die to form an extruded material, wherein the first billet is followed by an adjacent second billet forming a portion of the extruded material. The rotating die heats the billet as it advances through the rotating die. In certain embodiments, a substantially constant thrust force is provided to the first blank in a direction toward the rotating die. In certain embodiments, the rotational speed of the rotary die may be adjusted.

In certain embodiments, the method further comprises transporting the first billet along the mandrel bar and passing the first billet through cooling elements clamped to the mandrel bar and conveying a cooling fluid to the mandrel bar, wherein at any given time, at least one cooling element is clamped to the mandrel bar. The blanks may be transported along the mandrel bar via a track that intermittently moves according to the position of the first blank relative to the clamping element and the cooling element. In some embodiments, the cooling fluid is transported to a mandrel bar tip disposed on a second end of the mandrel bar opposite the receiving end, and the cooling fluid returns to the cooling element after passing through the mandrel bar tip. The mandrel bar tip may be positioned within the rotary die prior to receiving the first billet. In certain embodiments, the cooling fluid is water.

In certain embodiments, loading a plurality of billets in succession further comprises the clamping element alternately clamping the mandrel bar to allow one or more billets to pass through the clamping element. In certain embodiments, the downstream clamping element clamps the mandrel bar and the upstream clamping element is open, and the method comprises: loading one or more billets onto a mandrel bar and passing them through an open upstream clamping element; closing the upstream clamping element; and advancing the one or more blanks to a downstream gripping element. In certain embodiments, the method thereafter comprises: opening the downstream clamping element; advancing one or more blanks through the open downstream gripping element; and closing the downstream clamping element.

In certain embodiments, loading the plurality of billets in succession further comprises the cooling element alternately clamping the mandrel bar to allow one or more billets to pass through the cooling element. In certain embodiments, the downstream cooling element clamps the mandrel bar and delivers cooling fluid to the mandrel bar, and the upstream cooling element is open, and the method comprises: loading one or more billets onto a mandrel bar and passing it through an open upstream cooling element; closing the opened cooling clamp element; and advancing the one or more billets to a downstream cooling element. In certain embodiments, the method thereafter comprises: opening a downstream cooling element; advancing one or more billets through an open downstream cooling element; and shutting down the downstream cooling element.

In certain embodiments, the method further comprises: during extrusion, the portion of the first billet that has not entered the rotating die is prevented from rotating. The centering insert may grip the portion of the first billet to prevent rotation of the portion, and the centering insert may have an adjustable position relative to the rotating die. The centering insert may be cooled with a cooling fluid.

In certain embodiments, the method further comprises quenching the extruded material as it exits the rotating die. The extruded material may be quenched with water. In some embodiments, the water contacts the extruded material within about 1 inch of the rotating die. In certain embodiments, the rotary die comprises a plurality of stacked die plates. In certain embodiments, the material is copper, or the material is selected from the group consisting of copper, aluminum, nickel, titanium, brass, steel, and plastic. The plurality of blanks may extend along substantially the entire length of the mandrel bar. In certain embodiments, the method comprises flooding the interior of the extruded material with nitrogen. Each of the plurality of billets may be loaded onto the mandrel bar by a person or by an automated loading device.

In one aspect, there is provided a method for continuously loading and extruding a plurality of billets, the method comprising: loading a first billet on a receiving end of an elongated mandrel bar; transporting a first billet along the mandrel bar and through cooling elements clamped to the mandrel bar and conveying a cooling fluid to the mandrel bar, wherein at any given moment at least one cooling element is clamped to the mandrel bar; and extruding the first billet by pushing the first billet through a rotating die to form an extruded material, wherein the first billet is followed by an adjacent second billet forming a portion of the extruded material.

In certain embodiments, the first billet is transported along the mandrel bar via a track that intermittently moves according to the position of the first billet relative to the clamping element and the cooling element. In certain embodiments, the cooling fluid is transported to a mandrel bar tip disposed on a second end of the mandrel bar opposite the receiving end, and the cooling fluid returns to the cooling element after passing through the mandrel bar tip. The mandrel bar tip may be positioned within the rotary die prior to receiving the first billet. In certain embodiments, the cooling fluid is water.

In one aspect, an extrusion system includes: a mandrel bar having a first end and a second end, the first end for receiving a blank having a hole therein and the second end coupled to a mandrel bar tip; a cooling element coupled to the mandrel bar, the cooling element having a port through which a cooling fluid is delivered into the mandrel bar so as to cool the mandrel bar tip; a clamping element coupled to the spindle shaft, the clamping element including a clamp movable to secure the spindle shaft in place and prevent rotation of the spindle shaft; and a rotating extrusion die configured to receive the billet from a centering insert having a plurality of slots frictionally engaged with the billet to prevent rotation of the billet prior to entering the rotating extrusion die, wherein the mandrel bar tip is located within the rotating die.

In some embodiments, the extrusion system further comprises: a ram element having a movable first arm and a second arm that together grip the blank and provide a substantially constant thrust in the direction of the rotating die. The substantially constant pushing force causes the billet to enter the rotating die at a predetermined rate. In certain embodiments, the extrusion system further comprises a motor coupled to the shaft that controls the rotational speed of the rotating extrusion die.

In certain embodiments, the mandrel bar includes an opening proximate to the cooling element port, the opening receiving the cooling fluid. The mandrel bar may further comprise a notch around the mandrel bar on either side of the opening, wherein the notch is configured to receive an O-ring to substantially prevent leakage of the cooling fluid. The mandrel bar may further comprise a mandrel bar sleeve surrounding the opening to substantially prevent leakage of the cooling fluid. In some embodiments, the mandrel bar includes a clamping portion that is correspondingly shaped to mate with a clamp of the clamping element. In certain embodiments, the mandrel bar includes an inner tube therein that receives the cooling fluid from the cooling element and through which the cooling fluid is delivered to the mandrel bar tip. The cooling fluid may be returned from the mandrel bar tip to the cooling element along a space within the mandrel bar between the outer surface of the inner tube and the inner surface of the mandrel bar. In certain embodiments, the cooling fluid is water.

In certain embodiments, the extrusion system further comprises a track along which the billet is transported, wherein the track intermittently moves according to the position of the billet relative to the clamping element and the cooling element. The track may include an upper roller positioned above the track and configured to contact an upper surface of the blank. In certain embodiments, the extrusion system further comprises a quench tube disposed at the exit of the rotating extrusion die. The quench tube quenches the extruded material as it exits the rotating extrusion die. In certain embodiments, the extruded material is quenched with water. The water may contact the extruded material within about 1 inch of the rotating extrusion die.

In one aspect, a system for at least partially controlling extrusion of a plurality of billets is provided, the system comprising: a processor configured to provide instructions to the extrusion system to: loading a first billet on a receiving end of an elongated mandrel bar; transporting the first billet along the mandrel bar and passing the first billet through a clamping element that holds the mandrel bar in place and prevents rotation of the mandrel bar, wherein at any given moment, at least one clamping element clamps the mandrel bar; and extruding the first billet by pushing the first billet through a rotating die to form an extruded material, wherein the first billet is followed by an adjacent second billet forming a portion of the extruded material.

In certain embodiments, the processor is further configured to provide instructions to the extrusion system to intermittently move the rail on which the first billet is placed based on the position of the first billet relative to the clamping element. In certain embodiments, the processor is further configured to provide instructions to the extrusion system to adjust the rotational speed of the rotary die. In certain embodiments, the processor is further configured to provide instructions to the extrusion system to monitor the cooling fluid delivery system. In certain embodiments, the processor is further configured to provide instructions to the extrusion system to adjust the forward and reverse speeds of the ram that delivers the plurality of billets to the rotary die.

In one aspect, a non-transitory computer-readable medium for controlling, at least in part, extrusion of a plurality of billets is provided, the non-transitory computer-readable medium comprising logic recorded thereon for: loading a first billet on a receiving end of an elongated mandrel bar; transporting the first billet along the mandrel bar and passing the first billet through a clamping element that holds the mandrel bar in place and prevents rotation of the mandrel bar, wherein at any given moment, at least one clamping element clamps the mandrel bar; and extruding the first billet by pushing the first billet through a rotating die to form an extruded material, wherein the first billet is followed by an adjacent second billet forming a portion of the extruded material.

In certain embodiments, the non-transitory computer readable medium further includes logic recorded thereon for intermittently moving the track on which the first blank is placed based on a position of the first blank relative to the clamping element. In certain embodiments, the non-transitory computer readable medium further includes logic recorded thereon for adjusting the rotational speed of the rotating die. In certain embodiments, the non-transitory computer readable medium further includes logic recorded thereon for monitoring the cooling fluid delivery system. In certain embodiments, the non-transitory computer readable medium further includes logic recorded thereon for adjusting the forward and reverse speeds of the ram that delivers the plurality of blanks to the rotary die.

In one aspect, an extrusion system includes: a mandrel bar having a first end and a second end, the first end for receiving a blank having a hole therein and the second end coupled to a mandrel bar tip; cooling means for delivering a cooling fluid into the mandrel bar so as to cool the mandrel bar tip; a clamping device for fixing the spindle rod in place and preventing the spindle rod from rotating; and a rotating extrusion device for extruding billets, wherein the rotating extrusion device receives billets from a centering device having a plurality of notches that frictionally engage the billets to prevent the billets from rotating prior to entering the rotating extrusion device; wherein the mandrel bar tip is located within the rotary die.

In some embodiments, the extrusion system further comprises: an urging means for gripping the blank and providing a substantially constant urging force in the direction of the rotating die. The substantially constant pushing force causes the billet to enter the rotating die at a predetermined rate. In certain embodiments, the extrusion system further comprises means for controlling the rotational speed of the rotating extrusion device.

In some embodiments, the mandrel bar includes an opening proximate the cooling device, the opening receiving the cooling fluid. The mandrel bar may further comprise a notch around the mandrel bar on either side of the opening, wherein the notch is configured to receive an O-ring to substantially prevent leakage of the cooling fluid. The mandrel bar may further comprise a mandrel bar sleeve surrounding the opening to substantially prevent leakage of the cooling fluid. In some embodiments, the mandrel bar may include a clamping portion that is correspondingly shaped to mate with a clamping device. In certain embodiments, the mandrel bar includes an inner tube therein that receives the cooling fluid from the cooling device and through which the cooling fluid is delivered to the mandrel bar tip. The cooling fluid may be returned from the mandrel bar tip to the cooling device along a space within the mandrel bar between the outer surface of the inner tube and the inner surface of the mandrel bar. In certain embodiments, the cooling fluid is water.

In certain embodiments, the extrusion system further comprises a track along which the billet is transported, wherein the track intermittently moves according to the position of the billet relative to the clamping device and the cooling device. The rail may include an upper roller positioned above the track and configured to contact an upper surface of the blank. In certain embodiments, the extrusion system further comprises a quenching device disposed at the exit of the rotating extrusion device. The quenching device quenches the extruded material as it exits the rotating extrusion device. In certain embodiments, the extruded material is quenched with water. The water may contact the extruded material within about 1 inch of the rotating extrusion apparatus.

In one aspect, a method for continuously extruding a plurality of billets includes: transporting a plurality of billets along a non-rotating mandrel bar from a first end of the mandrel bar to a second end of the mandrel bar; and extruding the plurality of billets by pushing each of the plurality of billets through a rotating die, wherein friction created by the rotating die rotating relative to the plurality of billets that do not rotate generates heat that deforms the plurality of hollow billets, wherein the mandrel bar tip is located within the rotating die at the second end of the mandrel bar. In certain embodiments, the method comprises: during extrusion, the portion of each of the plurality of billets that has not entered the rotary die is prevented from rotating. In certain embodiments, the centering insert grips the portion of each blank to prevent the portion from rotating, and the centering insert has an adjustable position relative to the rotating die. In certain embodiments, the method further comprises cooling the mandrel bar tip during extrusion.

In one aspect, a die for extruding a material includes a die body having: a passageway defining an inlet and an outlet, wherein the diameter of the outlet is less than the diameter of the inlet; and an inner surface extending around the passage from the inlet to the outlet. The base is coupled to the mold body, and rotation of the base causes the mold body to rotate.

In certain embodiments, the die body is configured to receive a billet of material for extrusion, and the billet is not preheated prior to entering the die body. Rotation of the die body generates friction between the inner surface and a billet advanced through the inlet and into the internal passage of the die body. The friction heats the billet to a temperature sufficient to cause deformation of the billet material. In certain embodiments, the die body is configured to receive the mandrel tip through the inlet such that the mandrel tip is positionable within the internal passage of the die body. The inner surface of the die may include an angled portion configured to be positioned adjacent a corresponding tapered outer surface of the mandrel tip. The die body is configured to receive a billet urged through the internal passage of the die body to form an extruded product having an outer diameter corresponding to the diameter of the exit of the die body and an inner diameter corresponding to the diameter of the mandrel tip.

In certain embodiments, the mold body comprises a plurality of mold plates coupled together to form a stacked structure. Each die plate has a circular aperture through the center of the die plate, the perimeter of the aperture forming the inner surface in the die body. The perimeter of the bore is at different angles relative to an axis extending through the die body from the inlet to the outlet. The angle of the perimeter is greater in the mold body near the front surface of each plate than the angle of the perimeter near the back surface of an adjacent plate. The stack may include non-uniform mold plates having an aperture perimeter at a first angle near a front surface of the plates and a different second angle near a back surface of the plates. At least one of the die plates is formed of two different materials, wherein a first material forms a perimeter of the aperture in the die plate and a second material forms an exterior portion of the die plate. The first material may be a ceramic material, steel or a consumable material. In certain embodiments, a front surface of the die body near the entrance is configured to mate with a centering insert having a diameter substantially equal to a diameter of the entrance. The centering insert and the perimeter of the inlet may be formed of the same material. The centering insert does not rotate when the substrate and the mold body rotate. In certain embodiments, the base comprises a circular aperture having a diameter greater than a diameter of the outlet of the die body. A motor may supply a rotational force to the substrate.

In one aspect, a mold comprises: apparatus for extruding material, and the apparatus for extruding comprises: channel means defining an inlet and an outlet, wherein the diameter of the outlet is less than the diameter of the inlet; and inner surface means extending around the passage means from the inlet to the outlet. The die also has means for coupling the means for extruding to a rotating means, and the means for coupling causes the means for extruding to rotate.

In certain embodiments, the means for extruding is configured to receive a billet of material for extrusion, and the billet is not preheated prior to entering the die body. The rotation of the means for extruding creates friction between the inner surface means and the billet advancing through the entrance and into the passage means of the means for extruding. The friction heats the billet to a temperature sufficient to cause deformation of the billet material. The means for extruding is configured to receive a rod tip device through an entrance such that the rod tip device is positionable within a channel means of the means for extruding. The inner surface means of the means for extruding comprises an angled portion configured to be located adjacent a corresponding tapered outer surface of the rod tip means. The means for extruding is configured to receive a billet pushed through the passage means of the means for extruding to form an extruded product having an outer diameter corresponding to the diameter of the exit of the means for extruding and an inner diameter corresponding to the diameter of the rod tip means.

In certain embodiments, the means for extruding comprises a plurality of plate means coupled together to form a stacked structure. Each plate means has a circular aperture through the centre of the plate means, the perimeter of the aperture forming the inner surface means in said means for extruding. The perimeter of the bore is at different angles relative to an axis extending through the means for extruding from the inlet to the outlet. The angle of the perimeter is greater near the front surface of each plate means in the means for extruding than near the back surface of an adjacent plate means. The stacking structure includes a non-uniform plate arrangement having an aperture perimeter at a first angle near a front surface of the plate arrangement and at a second, different angle near a back surface of the plate arrangement. At least one of the plate means is formed of two different materials, wherein a first material forms a perimeter of the aperture in the plate means and a second material forms an outer portion of the plate means. The first material may be a ceramic material, steel or a consumable material. A front surface of the means for extruding near the entrance is configured to mate with a centering means having a diameter substantially equal to a diameter of the entrance. The centering device and the perimeter of the inlet may be formed of the same material. Wherein the centering device does not rotate when the means for coupling and the means for extruding rotate. The centering device comprises a gripping device preventing the rotation of the blank passing through the centering device. In some embodiments, the means for coupling comprises a circular bore having a diameter greater than a diameter of the outlet of the means for extruding, and a power device may supply a rotational force to the means for coupling.

Variations and modifications will occur to those skilled in the art upon a review of this disclosure. The foregoing features and aspects may be implemented in any combination and subcombination (including multiple dependent combinations and subcombinations) with one or more other features described herein. The various features depicted or described herein, including any components thereof, may be combined or integrated in other systems. In addition, certain features may be omitted or not implemented.

Drawings

The foregoing and other objects and advantages will be apparent from the following detailed description taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:

FIG. 1 shows a side elevation view of an illustrative extrusion system;

FIG. 2 shows a side elevation view of an illustrative billet supply rail assembly for use with the extrusion system of FIG. 1;

FIG. 3 shows a perspective view of an illustrative fluid clip;

FIGS. 4 and 5 show front and side elevational views, respectively, of the fluid clamp of FIG. 3;

FIG. 6 shows a schematic view of an illustrative mandrel bar having an opening or port for receiving cooling fluid;

FIG. 7 shows a perspective view and various cross-sectional and side views of an illustrative mandrel stem sleeve;

FIG. 8 shows a perspective cross-sectional view of an illustrative mandrel bar having an inner tube for delivering cooling fluid to the mandrel bar tip;

FIG. 9 shows a schematic view of an illustrative fluid delivery system;

FIG. 10 shows a perspective view of an illustrative spindle rod clamp;

figures 11 and 12 show front elevation views of the mandrel bar clamp of figure 10 in a clamped position (11) and a non-clamped position (12);

FIG. 13 shows a schematic view of an illustrative spindle rod having portions that mate with a spindle rod clamp;

FIG. 14 shows a perspective view of the spindle shaft portion of FIG. 13;

FIG. 15 shows a perspective view of an illustrative ram assembly with guide members;

fig. 16 shows a perspective view of an illustrative headboard;

figures 17-19 show front, side and back elevational views, respectively, of the press head plate of figure 16;

fig. 20 shows a perspective view of an illustrative headboard;

figures 21-23 show front, side and back elevational views, respectively, of the press head plate of figure 20;

FIG. 24 shows an illustrative rotating die and centering ring in an extrusion orientation;

FIG. 25 shows an illustrative cross-sectional view of the rotary die and centering ring of FIG. 24;

FIG. 26 shows an illustrative cross-sectional view of the rotary die and centering ring of FIG. 24;

FIG. 27 shows a cross-sectional view of the rotary die of FIG. 24 with a mandrel bar placed therein;

FIG. 28 shows a cross-sectional view of a billet being extruded through the rotary die of FIG. 27;

FIGS. 29 and 30 show perspective and top plan views, respectively, of an illustrative mandrel bar tip;

FIG. 31 shows an illustrative flow diagram for pre-processing billets for the extrusion system of FIG. 1;

FIG. 32 shows an illustrative flow diagram for pre-treating the mandrel bar tip for the extrusion system of FIG. 1;

FIGS. 33-36 show illustrative flow charts for operating the extrusion system of FIG. 1;

FIG. 37 shows a block diagram of an illustrative computer system for operating the extrusion system of FIG. 1;

FIG. 38 shows a cross-sectional view of a magnetic data storage medium encoded with a set of machine-executable instructions for performing the method of the present invention;

FIG. 39 shows a cross-sectional view of an optically readable data storage medium encoded with a set of machine-executable instructions for performing the method of the invention;

FIG. 40 shows a simplified block diagram of an illustrative system employing the programmable logic controller of the present invention; and

FIG. 41 shows a block diagram of an illustrative system employing the programmable logic controller of the present invention.

Detailed Description

Some illustrative embodiments will be described in order to provide an overall understanding of the systems, devices, and methods disclosed herein. Although the embodiments and features described herein are described as being used in conjunction with a continuous extrusion system, it should be understood that all of the components, connections, manufacturing methods, and other features described below may be combined with each other in any suitable manner and may be modified and applied to systems for other manufacturing processes, including but not limited to cast-rolling, up-casting, heat treatment, other extrusion processes, and other manufacturing processes. Further, while the embodiments described herein relate to extruding metal tubes using hollow billets, it should be understood that the systems, apparatus, and methods described herein may be modified and applied to systems that extrude any suitable type of extruded product using billets.

The extrusion system operates using frictional heat generated by the non-rotating hollow billet in contact with the rotating die to facilitate deforming the billet and extruding the billet. There is no need to preheat the billet or the rotating die prior to extrusion. The amount of heat generated is generally dependent on the rate at which the billet is fed to the rotating die (e.g., which is controlled by the ram speed of the ram (press-ram) elements 130, 140 of fig. 1), the rotational speed of the die (e.g., which is controlled by the rotational speed of the shaft 172 of fig. 1), and the internal profile of the rotating die. Higher head speeds and shaft rotational speeds generate relatively more heat.

The rotating die forms the outer diameter of the extruded tube produced by the extrusion system, and the mandrel bar tip located within the rotating die forms the inner diameter of the extruded tube. In certain embodiments, chilled process water or any other suitable cooling fluid is used to cool process elements, including rotating dies, centering inserts, billets and gearbox oil, and extruded tubular products. Unlike conventional extrusion techniques, the extrusion system of the present invention does not require any container for holding a billet for extrusion therein. Thus, the billet to be extruded preferably has sufficient column strength to withstand the pressure exerted by the ram element during the extrusion process. When the system is set in automatic mode, the programmable logic controller or PLC controls all or a portion of the motion of the extrusion system.

The extrusion systems, apparatus and methods described herein may be used for continuous extrusion of multiple billets to produce seamless extruded tube products according to various seamless tube standards, including, for example, the ASTM-B88 standard specification for seamless copper water tubes. The seamless extruded tube of the present invention may also conform to the NSF/ANSI-61 standard for drinking water system components.

Fig. 1 illustrates a compression system 10 according to some embodiments. The extrusion system 10 includes structural sections referred to herein as mandrel holder sections 80 and platen structural sections 90. The mandrel holder section 80 includes a mandrel bar 100, fluid clamps or cooling elements 102 and 104, mandrel clamps or clamping elements 106 and 108, and a blank transport system 110 shown in detail in fig. 2. The mandrel holder section 80 is supported by a physical support structure, which is not shown in fig. 1 to avoid overcomplicating the drawing, but which serves as a base for the components of the mandrel holder 80. The platen structure section 90 includes an inlet platen 120 and a rear mold platen 122, ram platens 130 and 140, a center platen 150, and a rotary die 160 that pushes against the rear mold platen 122. The platen structure section 90 is supported by a frame 190, the frame 190 also serving as a base for the motor 170 and associated gearbox components (not shown). The direction of loading, transporting and extruding the billet by means of the extrusion system 10 is indicated by the directional process arrow d₁And (4) indicating. The extrusion system 10 may be operated at least in part by a PLC system that controls the billet conveying subsystem 20, the extrusion subsystem 40, and the quenching or quenching of the extrusion system 10Cooling various aspects of the subsystem 60.

Mandrel clamps 106, 108 include a mandrel bar clamping system 105 designed to hold a mandrel bar in place while allowing multiple billets to be fed continuously along and around mandrel bar 100 to provide continuous extrusion. The billet may be formed from any suitable material for use in an extrusion system, including, but not limited to, various metals (including copper and copper alloys) or any other suitable non-ferrous metals (such as aluminum, nickel, titanium, and alloys thereof), ferrous metals (including steel and other ferrous alloys), polymers (such as plastics), or any other suitable material or combination thereof. The PLC system may control the mandrel clamps 106, 108 to hold the mandrel bar 100 securely so that at least one of the mandrel clamps 106, 108 clamps the mandrel bar 100 at any given time during the extrusion process. The mandrel clamps 106, 108 set the position of the mandrel bar 100 and prevent the mandrel bar 100 from rotating. When the mandrel clamps 106, 108 are in the clamped or engaged position and thereby clamp the mandrel bar 100, the mandrel clamps 106, 108 prevent the billet from being transported through the clamps along the mandrel bar 100.

The mandrel clamps 106, 108 operate by alternately clamping or engaging the mandrel bar 100 to allow one or more billets to pass through each mandrel clamp at a given time. For example, the upstream mandrel clamps 106 may be released or disengaged from the mandrel bar 100 while the downstream mandrel clamps 108 clamp the mandrel bar 100. At any given moment, at least one of the mandrel clamps 106, 108 preferably clamps or otherwise engages the mandrel bar 100. One or more billets queued or directed thereto near the upstream mandrel clamps 106 or transported along the mandrel bar 100 may pass through the open upstream mandrel clamps 106. After a certain number of billets have passed through the open upstream mandrel clamps 106, the clamps 106 may close and thereby re-clamp the mandrel bar 100, and the billets proceed to the downstream clamping elements 108. The downstream clamp element 108 may remain closed, thereby clamping the mandrel bar 100, or the downstream mandrel clamp 108 may be opened after the upstream mandrel clamp 106 clamps the mandrel bar 100 again. Although two mandrel clamps 106, 108 are shown in the extrusion system 10, it should be understood that any suitable number of mandrel clamps may be provided.

The fluid clamps 102, 104 include a mandrel bar fluid delivery system 101 designed to supply cooling fluid to the mandrel bar tip along the interior of the mandrel bar 100 during the extrusion process. The fluid clamps 102, 104 also receive cooling fluid from the mandrel bar 100 back from the mandrel bar tip. Any suitable cooling fluid may be used, including water, various mineral oils, brine, synthetic oils, any other suitable cooling fluid including gaseous fluids, or any combination thereof. The fluid clamps 102, 104 may be controlled by a PLC system to continuously supply process cooling fluid to the mandrel bar during the extrusion process while allowing multiple billets to be fed along and around the mandrel bar 100. The fluid clamps 102, 104 operate such that process cooling fluid is supplied to the mandrel bar tip without interruption or substantially without interruption during the extrusion process. Similar to the above-described operation of the mandrel clamps 106, 108, when the fluid clamps 102, 104 clamp or engage the mandrel bar 100, the fluid clamps 102, 104 prevent the billet from being transported through the fluid clamps along the mandrel bar 100.

The fluid clamps 102, 104 operate such that at any given moment during extrusion at least one fluid clamp clamps or engages the mandrel bar 100 and thereby delivers cooling fluid into the mandrel bar 100 for delivery to the mandrel bar tip. As the billet passes through one of the fluid clamps 102, 104, the fluid clamp stops delivering (and receiving) cooling fluid and releases or disengages the mandrel bar 100 to allow the billet to pass therethrough before re-clamping the mandrel bar 100 and continuing to deliver (and receive) cooling fluid. When one of the fluid clamps 102, 104 is no longer clamping or disengaging the spindle shaft 100, the other fluid clamp continues to deliver cooling fluid to the spindle shaft.

For example, the upstream fluid clamp 102 may release the spindle shaft 100 when the downstream fluid clamp 104 clamps the spindle shaft 100. At any given moment, at least one of the fluid clamps 102, 104 preferably clamps the mandrel bar 100 to continuously deliver cooling fluid. One or more billets queued or directed thereto near the upstream fluid clamp 102 or transported along the mandrel bar 100 may pass through the open upstream fluid clamp 102. After a certain number of blanks have passed through the open upstream fluid clamp 102, the fluid clamp 102 may be closed and thereby re-clamp the mandrel bar 100 and deliver cooling fluid, and the blanks advanced to the downstream fluid clamp 104. The downstream fluid clamp 104 may remain closed, thereby clamping the mandrel bar 100, or the downstream fluid clamp 104 may be opened after the upstream fluid clamp 102 again clamps the mandrel bar 100. Although two fluid clamps 102, 104 are shown in the extrusion system 10, it should be understood that any suitable number of fluid clamps may be provided.

The blank transfer system 20 includes the blank supply track assembly 110 of fig. 2. The billet feed track assembly 110 ensures that a continuous supply of billets (such as billet 30) is provided for the extrusion process. When additional billets are needed, the PLC system will cycle through the appropriate mandrel bar clamps 106, 108, fluid clamps 102, 104, and billet transfer rollers (e.g., billet feed rail assembly 110) to ensure a continuous supply of billets are provided for the extrusion process. The section of the mandrel holder 80 between the mandrel clamps 106 and the entry platen 120 may be continuously indexed to minimize the gap between the blanks fed into the ram platen section 141 of the platen structure 90. For example, at this position of the mandrel support 80, the track assembly 110 may continue to circulate the track 202 to feed blanks into the platen structure 90.

The blank feed track assembly 110 includes a chain or track 202 disposed about sprockets 204, 205. One or more of the sprockets 204, 205 can be coupled to a motor (not shown) that operates to move in the loading direction d₂The track 202 is moved or circulated. The track 202 and sprockets 204, 205 are supported by a bottom rail 206 and a lower rail 208 that are coupled together to a frame 210. The upper portion 210a of the frame 210 includes an upper roller 212 that provides upper restraint for the pierced blank 30. For example, as shown in fig. 2, the mandrel bar 100 includes a blank 30 thereon, wherein the blank 30 moves via contact with the track 202 and is held steady by the upper rollers 212. The blank supply rail assembly 110 may have any suitable length. For example, the track assembly 110 may extend along substantially the entire length of the spindle shaft 100 within the spindle bracket section 80. In certain embodiments, a plurality of track assemblies may be provided that cooperate to feed blanks along the mandrel bar 100 and willThe blank is fed into the platen structure section 90. For example, a track assembly may be provided along the mandrel bar 100 between each of the fluid clamps 102, 104 and the mandrel clamps 106, 108 so that one or more billets may be independently circulated through each of the fluid clamps 102, 104 and the mandrel clamps 106, 108 without the need to transport other billets as would be the case with only one track assembly.

Returning to fig. 1, the mandrel bar 100 extends along substantially the entire length of the extrusion system 10 and is positioned such that the mandrel bar tip is located within the rotary die 160. Adjustments are made to properly place the mandrel bar tip within the rotary die 160 by moving the mandrel holder sections 80, and thus the mandrel bar 100. The mandrel bar 100 and mandrel holder sections 80 may be adjusted toward or away from the die 160. Preferably, the mandrel bar 100 and mandrel holder section 80 cannot be adjusted while the extrusion system 10 is operating, but it should be understood that in certain embodiments, the mandrel bar 100 and/or mandrel holder section 80 may be adjusted during operation.

As described above, the press system 10 includes the platen structure section 90, the platen structure section 90 having the inlet platen 120 and the rear mold platen 122, the ram platens 130 and 140, the center platen 150, and the rotary die 160 that pushes against the rear mold platen 122. A ram assembly 141 including a first ram platen 130 and a second ram platen 140 is positioned adjacent the inlet platen 120. The first and second ram platens 130, 140 feed the blank into a central platen 150, the central platen 150 holds the blank and prevents the blank from rotating before entering a rotating die 160 that pushes against the post-die platen 122. The inlet platen 120 and the rear mold platen 122 are coupled together via a series of tie rods 124 that act as guides for the ram platens 130, 140 and the center platen 150, each tie rod 124 including a bearing 126a, 126b, 126c that moves along the tie rod 124. The rear mold platen 122 and the entrance platen 120 have mounting locations 127 through which tie rods 124 are secured. The inlet platen 120, the rear mold platen 122, and the tie rod structure 124 are supported by a frame 190. The frame 190 also carries the shaft 172 and the motor 170. A quench tube 180 is located at the exit of the rotary die 160 for rapid cooling of the extruded tube.

The ram platens 130, 140 operate by gripping the billet and providing a substantially constant pushing force in the direction of the extrusion die 160. At any given moment, at least one of the ram platens 130, 140 grips the billet and advances the billet along the mandrel bar 100 to provide a constant thrust. Ram platens 130, 140 form the final portion of billet transport subsystem 20 before the billet enters the central platen 150 and rotating die 160 of extrusion subsystem 40. Similar to the billet feed track section before the entry platen 120, the section before the ram platens 130, 140 preferably continuously index the billet to minimize any gap between the billet gripped by the ram platens 130, 140 and the next billet.

As described above, the rams 130, 140 continue to push the blank into the rotary die 160. The rams 130, 140 alternately grip and advance the blank toward and into the rotary die 160 and then release the advanced blank and retract for the next gripping/advancement cycle. Preferably, there is an overlap between the moment when one ram stops pushing and the moment when the other ram is about to start pushing, so that there is always pressure on the rotating die 160. The rams 130, 140 advance and retract via ram cylinders coupled to the respective rams. As shown, each ram has two ram cylinders 132, 142. The first set of ram cylinders 132 are located to the left and right of the inlet platen 120 (although the left ram cylinder blocks the right ram cylinder in the figure). A first set of ram cylinders 132 are coupled to the first ram platen 130 and are configured to move the first ram 130 along the tie rod 124 as the first ram 130 advances a billet and then retracts for a subsequent billet. A second set of ram cylinders 142 are located at the top and bottom of the inlet platen 120. A second set of ram cylinders 142 is coupled to the second ram platen 140 and is configured to move the second ram 140 along the tie rod 124 as the second ram 140 advances a billet and then retracts for a subsequent billet. Although two ram cylinders are shown for each of the first and second ram platens 130, 140, it should be understood that any suitable number of ram cylinders may be provided. In certain embodiments, a ram cylinder may be coupled to both rams 130, 140.

The central platen 150 receives the billets advancing through the rams 130, 140 and holds the billets against rotation during the extrusion process before the billets enter the rotary die 160. When the central platen 150 is in a position suitable for performing the extrusion process, the central platen 150 becomes part of the extrusion die 160. That is, the center insert 152 of the center platen 150 is substantially contiguous with the rotary die 160. However, the central platen 150 itself and the components therein (including the central insert 152) do not rotate with the rotary die 160. As the die 160 rotates, the central platen 150 prevents the billet, which is no longer held by the second ram 150, from rotating by holding the billet and thereby preventing the billet from rotating prior to entering the rotating die 160.

The rotary die 160 may have an integrally formed design or may include a plurality of die plates stacked together. In certain embodiments, the die comprises a bottom plate, a final plate, a second intermediate plate, a first intermediate plate, an inlet plate, and a steel end bracket, and the die plates are bolted together to form the die 160. The rotary die 160 is bolted or otherwise coupled to a shaft 172, the shaft 172 being operated via a motor 170. The gearbox is bolted to the rear mold platen 122 and houses the shaft 172 as well as the drive train, motor drive gears, gear oil reservoir and gear oil heat exchanger that are not shown in fig. 1 to avoid complicating the drawing. In certain embodiments, the gear ratio of the spindle motor 170 and the spindle/die is 2.5: 1, it should be appreciated that any suitable gear ratio may be used to rotate the rotary die 160.

At the extrusion end of the extrusion system 10, a quench box 185 is bolted or otherwise coupled to the outlet side of the gear box on the post-mold platen 122. In certain embodiments, quench tubes 180 are located within quench box 185 for rapidly quenching or cooling the extruded material as it exits rotary die 160. Water may be used as a quenching or cooling fluid, and the water may contact the extruded material at some point after the extruded material exits the rotating die 160. For example, in certain embodiments, the extruded material is quenched with cooling fluid within about 1 inch of exiting the rotating die 160. Any suitable cooling fluid may be used to quench the extruded material, including water, various mineral oils, brine, synthetic oil, any other suitable cooling fluid including gaseous fluids, or any combination thereof. Quench tube 180 may be formed from one or more tubes with passages therebetween for delivering cooling fluid to the extruded material. In certain embodiments, the quench tube 180 also includes end caps or other structures through which cooling fluid may be delivered to the extruded material. The extrusion system of the present invention may use any suitable quench tube, including, for example, the quench tube described in U.S. patent application 13/650,972 filed on 12.10.2012, the entire contents of which are incorporated herein by reference.

In certain embodiments, nitrogen or another suitable inert gas is delivered to the interior of the extruded material as the material exits the rotating die. For example, nitrogen gas may be delivered to the interior of the extrusion tube as it exits the rotating die using a cap located on the forward end of the extrusion tube. Injecting gaseous or liquid nitrogen into the interior of the rotating die assembly or the extruded material itself can minimize oxide formation by displacing the oxygen-bearing air.

Although not shown in fig. 1, the billet transfer subsystem 20 of the extrusion system 10 may include a billet transfer station having a plurality of billets to be loaded onto the extrusion system 10. The loading may be automatic, such as via an automated process, or manual.

The various components of the extrusion system 10 of fig. 1 will now be described with reference to fig. 3-30. FIG. 3 illustrates a perspective view of the fluid clip 102 of FIG. 1, according to some embodiments. The fluid clamp 102 includes a housing 302 having a base 304 and end plates 306a and 306b coupled via four tie rods 308, but it should be understood that any suitable number of tie rods may be used and that in certain embodiments, other securing techniques may be used to secure elements of the fluid clamp in addition to or in place of the tie rods 308. The tie rods 308 support inlet/outlet fluid clamps 312 through which cooling fluid, such as water, enters and exits the fluid clamp 102, and support blank fluid clamps 314, each actuated by a respective cylinder 309, 310 located between a respective fluid clamp 312, 314 and its end plate 306a, 306 b. A bracket rail 305 is located below the housing 302 to secure the fluid clamp 102 to a bracket structure that supports the mandrel bracket segment 80 of fig. 1. The inlet/outlet fluid clamp 312 includes an outflow hole 316 formed in the upper surface 312a that extends to an insert 318 inserted into the interior of the inlet/outlet fluid clamp 312. As shown in fig. 3, the blank fluid clip 314 has a clamping surface 314a and the insert 318 within the inlet/outlet fluid clip 312 has a clamping surface 318 a. The clamping surfaces 314a and 318a frictionally engage respective surfaces of a mandrel bar, such as mandrel bar 100 of extrusion system 10. In certain embodiments, the clamping surfaces 314a and 318a may engage a spindle rod sleeve (e.g., spindle rod sleeve 360 of fig. 7) disposed about a portion of the spindle rod.

Fig. 4 and 5 show front and side elevation views, respectively, of the fluid clamp 102 of fig. 3. As shown in fig. 4 and 5, for example, the outflow hole 316 in the inlet/outlet fluid clip 312 extends from the upper surface 312a of the clip 312 into a port 320 formed in the insert 318. The fluid clamp 102 delivers cooling fluid to the spindle shaft through the outflow bore 316 and the port 320 via the inlet/outlet fluid clamp 312. FIG. 4 also shows the clamping surfaces 314a and 318a of the inlet/outlet fluid clamp 312 and the blank fluid clamp 314. Although the fluid clamp 312 includes two outflow holes 316 in fluid communication with the two ports 320 of the insert 318, it should be understood that any suitable number of outflow holes and ports may be provided for delivering cooling fluid to the spindle shaft. Alternatively or additionally, in certain embodiments, the outflow holes 316 may be disposed through other surfaces of the fluid clamp, such as the front (or back) surface 312b or the side surface 312c of the inlet/outlet fluid clamp 312.

In certain embodiments, the clamping surfaces 314a and 318a of the inserts 318 of the blank fluid clamp 314 and the inlet/outlet fluid clamp 312 are configured to mate with corresponding portions of a mandrel bar. Fig. 6 illustrates a schematic view of a mandrel bar 340 having an opening or port 344 for receiving and/or returning cooling fluid from a fluid clamp, according to some embodiments. As shown in fig. 6, for example, the mandrel bar 340 includes portions 342 and 348 having respective two port sections 342a, 342b and 348a, 348b for receiving and/or returning cooling fluid from a fluid clamp, such as the fluid clamp 102. In certain embodiments, the port sections 342a and 348a are configured to send cooling fluid back to the fluid clamp, and the port sections 342b and 348b are configured to receive cooling fluid from the fluid clamp. Alternatively, the port sections 342a and 348a may receive cooling fluid and the port sections 342b and 348b may return cooling fluid. In further embodiments, the port segments 342a/348b can receive cooling fluid and the port segments 342b/348a can return cooling fluid, or vice versa. Any suitable port segment receiving/returning arrangement may be used such that at least one of the various ports receives cooling fluid and the other returns cooling fluid to the fluid clamp.

The inset illustration of the spindle rod portion 342 shows a port section 342a having an opening or port 344 for receiving and/or returning cooling fluid from the fluid clamp 102. The mandrel ports 344 are sized to correspond with the respective ports 320 of the fluid clamp 102. A series of notches 346 are provided around the spindle port 344 for receiving O-rings and thereby preventing cooling fluid from escaping or otherwise leaking out of the spindle shaft 340 via the port 344. The two mandrel rod portions 342, 348 correspond to mandrel rod portions engaged with the two fluid clamps 102, 104 of the extrusion system 10 of fig. 1, for example. As described above, in certain embodiments, the mandrel sleeve 360 may be configured to engage a clamping surface of a fluid clamp. The mandrel sleeve 360 may also function with O-rings to prevent fluid leakage from the mandrel stem 340 and fluid clamp. As shown in fig. 7, for example, the mandrel sleeve 360 includes a port 360, and cooling fluid is transferred and/or returned between the mandrel bar 340 and the fluid clamp through the port 360. The mandrel sleeve 360 also includes a slot 364 that allows the sleeve 360 to be resilient when placed over the mandrel bar 340 around the portions 342, 348 that receive and/or return cooling fluid. The O-ring in the notch 346 may create a substantially fluid tight seal between the mandrel bar 340 and the inner surface 360a of the mandrel bar sleeve 360.

Fig. 6 also shows an inner tube 350 that extends along the length of the mandrel bar 340 and delivers cooling fluid to the mandrel bar tip located within the rotary die. The cooling fluid received through the opening or port 344 in the mandrel bar 340 travels through the opening 354 in the inner tube 350, conveying the cooling fluid along the inside of the tube 350 to the mandrel bar tip where it then travels back out of the tube 350 (but within the mandrel bar) to the opening or port 344 that received the cooling fluid. Fig. 8 shows the direction of travel of the cooling fluid, and fig. 8 depicts a perspective cross-sectional view of the mandrel bar 340 and inner tube 350 of fig. 6 for delivering cooling fluid to the mandrel bar tip. The cooling fluid travels along the inside of the inner tube 350 in the direction of arrow W1 toward the mandrel bar tip and then returns in the direction of arrow W2 in the outer space 352 between the outer surface 350a of the inner tube 350 and the inner surface 340a of the mandrel bar 340. In certain embodiments, a portion of the inner surface of the mandrel bar, such as inner surface 340a of mandrel bar 340, may be formed with threads for receiving the tip of the mandrel bar, although any suitable technique may be utilized to couple the tip of the mandrel bar to the mandrel bar. In certain embodiments, a spacer may be disposed around the inner tube 350 such that the inner tube 350 is located at the center of the mandrel bar 340 along any suitable length of the mandrel bar 340. Where the spindle shaft is threaded, the washer may be threadedly engaged with the spindle shaft, but the washer may also press against the unthreaded portion of the spindle shaft.

The extrusion system 10 includes a cooling system 400 for cooling the various components of the extrusion system 10 during operation. Although the cooling system 400 of fig. 9 will be described as utilizing water as the cooling fluid, it should be understood that any suitable cooling fluid may be used. The extrusion system cooling system 400 is designed to deliver a sufficient amount and pressure of cooling water to cool the process components and the extruded product. In some embodiments, there may be two main water systems on the extrusion system, the mandrel water and the extrusion water. With respect to spindle water, a spindle water system supplies water from a storage tank. The heat exchanger cools the process water by heat exchanging heat generated during the extrusion process with cold water from a cold water system. The process water flows through the heat exchanger in a series loop and the cold water flows through the heat exchanger in a parallel loop, and the two water systems do not come into physical contact with each other. All water can be used for the spindle water system. The pressure relief valve limits the system pressure. Water not used by the spindle system is transferred to a storage tank that cools the process water therein. Water is pumped through the inner tube (e.g., inner tube 350 of fig. 6 and 8) through the inside of the mandrel bar, to the mandrel bar tip, and back along the length of the exterior space within the mandrel bar, as discussed with reference to fig. 6 and 8. When the water has circulated through the spindle cooling system, it is returned to the storage tank, which is another source of process water cooled to the storage tank. Preferably, the mandrel process water supply is not interrupted at any time while the extrusion system is running. The extrusion system water system supplies water from a storage tank. The excess water is returned to the storage tank by adjusting the flow and pressure through a pressure relief valve. The extrusion system water is pumped to the manifold where it is stroked to cool various components of the system, including the rotating dies, via high velocity water mist emitted from the cooling ring (this water stroked to cool the gearbox hydraulic oil before cooling the dies). Centering insert 152 is via a constant flow through the centering insert carrier, the blank is passed through a filling system (flow system) as it enters the Inconel, the extruded tube utilizes a quench tube that spray quenches the tube. The quench tube is received within the shaft. The process water from the above operation is returned to the storage tank.

Fig. 10 illustrates a perspective view of the mandrel clamp 106 of fig. 1, in accordance with certain embodiments. Mandrel clamp 106 includes a front plate 502 and a back plate 504 separated by a spacer 506. The front plate 502 has a cutout clamping portion 508 and an upper clamp 510 and a lower clamp 512 therein, but it should be understood that alternatively or additionally, in some embodiments, the clamps 510, 512 may be located side-by-side rather than top-to-bottom within the mandrel clamps 106. Mandrel clamp 106 also includes a cylinder 514 and a piston rod 515 coupled to a cylinder base 516. The air cylinder 514 operates to control the clamping and unclamping of the upper clamp 510 and the lower clamp 512 relative to the spindle shaft 100.

Fig. 11 and 12 show front elevation views of the mandrel holder 106 of fig. 10 in a closed or engaged gripping position (fig. 11) and a non-gripping or open position (fig. 12). As shown in fig. 11, for example, the upper clamp 510 and the lower clamp 512 are in a clamping position and engaged about a portion 518 of the mandrel bar, which portion 518 is the portion of the mandrel bar that the clamps 510, 512 clamp. When mandrel clamps 106 are in the open or undamped position, as shown in fig. 12, upper clamp 510 and lower clamp 512 are biased away from each other and from mandrel stem portion 518 relative to the clamped position, such that there is a void along mandrel portion 518 and within clamp cut 508 for the billet to pass therethrough.

In certain embodiments, the upper clamp 510 and the lower clamp 512 are configured to mate with respective portions of a mandrel bar, such as mandrel bar portion 518 of mandrel bar 540. Fig. 13 shows a schematic view of a mandrel bar 540, a portion 518 of which may be shaped or otherwise configured to mate with the upper clamp 510 and the lower clamp 512 of the mandrel clamp 106. The particular shape of the mandrel portion 518 may help the mandrel clamp 106 form and maintain a secure grip of the mandrel rod 540 to prevent the mandrel rod 540 from rotating or otherwise moving or displacing as the mandrel rod 540 is clamped by the mandrel clamp 106 during operation of the extrusion system. As shown in fig. 13, for example, the two clamping portions 518 may correspond to portions of the mandrel bar that engage the two mandrel clamps 106, 108 of the extrusion system 10 of fig. 1.

Fig. 14 shows a perspective view of a portion 518 of a mandrel bar 540. Spindle shaft portion 518 is shaped to mate with a spindle clamp, such as spindle clamp 106, and includes a circular outer peripheral portion 550 and respective flat edges 552 and 554 that mate with the upper and lower clamps of the spindle clamp. The mandrel portion 518 also includes respective recesses or cutouts 556 and 558 that are shaped to mate with complementary clips. As shown in fig. 14, the mandrel portion 518 is hollow and includes an inner surface 540a for receiving an inner tube, such as the inner tube 350 discussed above with reference to fig. 6 and 8.

In certain embodiments, the mandrel bar extends along the length of the extrusion system 10, terminating at the mandrel bar tip located within the rotary die. The mandrel bar may have a substantially continuous cross-section along its length or portions thereof, such as portions 342, 348, 518 and mandrel bar sleeve 360, may be shaped to engage components of the extrusion system, such as fluid clamps 102, 104 and mandrel clamps 106, 108. In certain embodiments, the mandrel bar may be modular and may include a plurality of attachable sections that collectively form a mandrel bar for use with the extrusion system. For example, the mandrel bar 540 of fig. 13 may be configured to be attached to other mandrel bars or mandrel bar sections, such as the mandrel bar 340 of fig. 6, fig. 6 showing a portion of the mandrel bar 340 for coupling with a fluid clip. To attach these modular portions of the mandrel bar together, mandrel bar 540 is provided with ends 542 and 544 that receive complementary ends of another mandrel bar.

Fig. 15 illustrates a perspective view of the ram assembly 141 of fig. 1 having a guide member for guiding the ram assembly 141 along the track rod 124, in accordance with certain embodiments. As shown in fig. 15, for example, the first and second ram platens 130 and 140 include guide members 600 and 610, respectively. The guide member 600 of the ram platen 130 has a suspension plate 602 coupled to a bearing 604, the bearing 604 being configured to move the ram 130 along a track rod, such as the track rod 124 of fig. 1. The guide member 610 of the ram platen 140 has a structure that also includes a suspension plate 612 and various bearings 614, the bearings 614 being configured to move the ram 140 along the track rod 124. The suspension 614 of the guide member 610 is located above the position of the tie rod 124 and the suspension 602 of the guide member 600 is located below the position of the tie rod 124. These guide members 600, 610 allow the ram platens 130, 140 to move along the tie rods 124 during the extrusion process operation so that the ram platens 130, 140 can grip and advance the billet into the rotating die and then retract to begin the next cycle.

Figure 16 illustrates a perspective view of the ram platen 130 of figure 1, in accordance with certain embodiments. Figures 17-19 show front, side and back elevation views, respectively, of the indenter platen 130 of figure 16. The ram platen 130 includes a clamp mounting plate 620 and first and second blank clamp link arms 622 and 624 coupled to a cylinder 626 about a pivot 625. The cylinder 626 operates to move the first and second link arms 622, 624 relative to each other about the pivot axis 625. Clamp mounting plate 620 is coupled to link arms 622, 624, separated by spacer 621 therebetween. As shown in fig. 19, the first and second clamps 630, 632 are mounted to the first and second link arms 622, 624 and are supported by a lower base 634 and an upper base 635. In certain embodiments, the gripping surfaces 630a, 632a of the first and second grippers 630, 632 may have serrated or other textured surfaces for improving frictional contact between the gripping surfaces 630a, 632a and the gripped blank.

Figure 20 illustrates a perspective view of the ram platen 140 of figure 1, in accordance with certain embodiments. Figures 21-23 show front, side and back elevation views, respectively, of the indenter platen 140 of figure 20. The ram platen includes a clamp mounting plate 640 and first and second billet clamp link arms 642 and 644 coupled to a cylinder 646 about a pivot 645. The cylinder 646 operates to move the first and second link arms 642, 644 relative to each other about the pivot 645. Clamp mounting plate 640 is coupled to link arms 642, 644, separated by a spacer 641 therebetween. As shown in fig. 23, the first and second clamps 650, 652 are mounted to the first and second link arms 642, 644 and are supported by a lower base 654 and an upper base 655. In certain embodiments, the gripping surfaces 650a, 652a of the first and second jaws 650, 652 may have a serrated or other textured surface for increasing frictional contact between the gripping surfaces 650a, 652a and the gripped blank.

In certain embodiments, one or both of the first and second rams 130, 140 may include a centering linkage. For example, centering linkages may be coupled to link arms 622, 624 and/or cylinder 626 of first ram 130 for synchronizing movement of the respective arms of ram 130 about pivot 625. For example, this prevents operation of cylinder 626 from extending only one arm around pivot point 625 while the other arm remains stationary. When the movement of the arms 622, 624 about the pivot 625 is synchronized using the centering linkage, the two arms move together when gripping and releasing the blank.

The billet pressed through the die 160 is extruded using heat generated by friction and force applied to the billet by the inner surface of the die 160. The die and centering insert 152 are pressed together to form a seal fit interface for extrusion before the billet is pressed into the die 160, and this is shown in fig. 24. During extrusion, the die 160 is rotated while the billet 702 is extruded through the die. The blank 702 is held by the clamp against the centering insert 152, and the centering insert 152 does not rotate, and therefore the blank 702 does not rotate as it enters the rotating die 160 at the die entrance 716. As the billet 702 is extruded through the die, the rotation of the die 160 causes friction with the outer surface of the non-rotating billet 702, and the friction heats the billet 702 to a temperature sufficient to deform the billet material. For example, friction may heat the metal blank to a temperature greater than 1000 ° F for deformation. The temperature requirements for different materials and different metals may vary, and billet temperatures of less than 1000 ° F are suitable for some applications. In contrast to other extrusion systems, the extrusion assembly in fig. 24 does not require preheating of the billet prior to extrusion, as the rotation of the die 160 and the friction created via contact with the non-rotating billet 702 provide the energy to heat the billet to a deformable temperature.

Although the billet 702 and centering insert 152 do not rotate during extrusion, the die 160 and base 700, which is connected to the die body, rotate via a motor driven shaft. As the blank 702 advances through the centering insert 152, it passes through the entrance 716 of the die 160 and contacts the inner surface of the die, which is shown in more detail in fig. 25-28. In addition to the mold 160 and interior surface details shown in fig. 24-28, other mold designs or interior surface profiles may be implemented in the rotary mold. For example, the die assembly for the extrusion system may be the die assembly described in U.S. patent application 13/650,981 filed on 12.10.2012, the entire contents of which are incorporated herein by reference. A torsional force is applied to the outer surface of the blank 702 due to the interference contact between the rotary die 160 and the blank 702. The clamps on centering insert 152 resist this twisting force and prevent billet 702 from rotating, creating friction, and creating energy to heat billet 702 prior to entering die 160.

The inner surface of the die 160 presents a tapered profile that narrows the internal passage through the die 160 from the inlet 716 to the outlet 718. Thus, as force is applied to the billet 702, extruding the billet through the die 160, the material of the billet 702 is extruded, the outer diameter of the material being forced to decrease to pass through the interior of the die 160 from the inlet 716 to the outlet 718. The dimensions of the die 160 and the interaction between the inner surface of the die 160 and the blank 702 are described in more detail below with reference to fig. 25-28.

The cross-sectional view of the die 160 in fig. 25 shows the die 160 and centering insert 152 in place for extrusion. Although fig. 25 shows the mold 160 as a single, unitary component, the mold may also be constructed from a plurality of mold plates having orifices and inner surfaces that form the channels and inner surfaces of the mold, as discussed below with reference to fig. 26. In this case, the opening 716 of the internal passage 720 in the die 160 is aligned with the centering insert 152 to receive a billet that is pressed through the opening 722 of the centering insert 152 and into the die 160 along the central axis 724 of the internal passage 720. The inner surface 726 narrows the internal passageway 720 from a maximum diameter of the passageway at the opening 716 to a minimum diameter at the outlet 718, and the narrowing of the passageway 720 causes the billet pressed into the die 160 during operation to narrow deform and extrude the billet. The extrusion process requires frictional energy generated at the interface of the inner surface 726 to heat the billet, and this energy is provided by the interaction between the rotating surface 726 and the non-rotating billet pressed into the die.

Fig. 26 shows a mold 160 having an alternative mold plate structure, the mold plate forming the body of the mold 160. The die 160 in fig. 26 includes a steel end bracket 706, an entrance plate 708, a first intermediate plate 710, a second intermediate plate 712, and an exit plate 714. Each plate includes a hole through the center of the plate and the holes are stacked adjacent to each other to form the internal channel 720 of the mold 160. The inner surface of the bore surrounding the plate is angled to form the profile of the inner surface 726 and to narrow the internal channel 720 from the inlet 716 to the outlet 718. One potential advantage of utilizing plate structures is the ability to replace individual plates when some areas of the inner surface 726 begin to wear, rather than having to replace the entire mold 160. To reduce the effects of wear on the plates, each plate may also be constructed of two different materials, one material outlining the central aperture of the plate and forming the inner surface 726 and a second material forming the periphery of the plate. Wear resistant materials, such as ceramic materials or steel, may be used to form the perimeter of the bore or consumable materials may be used and periodically replaced. Since the centering insert 152 does not rotate when the die 160 rotates, the material surrounding the bore in the steel end bracket 706 and forming the front surface 738 of the die 160 may be the same or similar to the material of the centering insert 152 to reduce the effects of wear when the two materials are in contact during extrusion.

To reduce the cost-increasing effect of frictional wear on each plate in the die 160, the plates may be designed to focus the wear on one or more plates that are replaced more often than the remaining plates. This design allows the mold to be operated by producing multiple replicas for a single plate and a single plate for the remaining plates in the stack. For example, in the stacked configuration shown in fig. 26, the second intermediate plate 712 presents a non-uniform surface profile around the center aperture through the plate. The inner surface of plate 712 includes a first portion 740 that is angled more sharply than other inner surfaces in the mold plate stack and a second portion 742 that is angled similarly to other inner surfaces in the stack. The acute angle of the first portion 740 creates a greater diameter reduction at this section of the inner surface than at other plates in the stack, and thus greater friction and potential for wear at the first portion 740. This wear may be reduced by placing a respective angled portion of the mandrel bar within the channel 720 near the portion 740 to further reduce the cost of needing to replace the plate 712. In some embodiments, the angle of the perimeter of the holes in each plate may increase from the back surface of the first plate to the front surface of the next plate toward the die outlet. For example, in fig. 26, the angle of each inner periphery near the front surface of each plate is greater than the angle of the inner surface near the back surface of the adjacent plate closer to the die entrance. For example, it is desirable for this design to concentrate work and pressure toward the exit of the die 160, and may result in the need to replace plates (e.g., plates 714 and 712) near the exit 718 more frequently than plates closer to the entrance 716.

In addition to concentrating work and pressure within the die 160, the mechanical and thermal properties of the blank material may determine the number and design of plates in the die assembly. For example, a blank material with high thermal conductivity may heat up to a deformable temperature more quickly than a material with low thermal conductivity, so a shorter die with fewer plates may be used for a high thermal conductivity material. Furthermore, for high thermal conductivity materials, the taper angle of the inner surface of the die can be larger because the billet heats up faster. In other embodiments, an equal size die with the same number of plates may be used, and the taper angle of the die may be varied to accommodate different thermal characteristics and to heat the blank to a deformable temperature, while still concentrating or spreading work and wear over the desired area of the die surface and the inner die mandrel tip surface.

Whether a one-piece die or a die plate stack die is employed, the billet extruded through the die 160 produces an extruded tube product having an outer diameter through the exit 718 of the die 160 that is approximately equal to the diameter d1 (the diameter at the narrowest portion of the internal passage 720). The inner diameter of the extruded product is selected by advancing a mandrel bar 100 having a mandrel bar tip (such as mandrel bar tip 800) into a die 160, the end dimensions of the mandrel bar tip being selected to produce the inner diameter of the tube product at the end of the mandrel bar 100.

Fig. 27 shows die 160 with mandrel bar 100 and mandrel bar tip 800 advanced through centering insert 152 and into central passage 720 of die 160. As discussed above with reference to fig. 1, the clamping elements in the extrusion system may be used to hold the mandrel bar 100 and, in the case shown in fig. 27, to resist rotation as the die 160 rotates and the billet passes over the mandrel bar 100.

Fig. 28 shows the die and mandrel bar arrangement of fig. 27 as billet 702 passes through die 160 and is extruded to form tube 728. During extrusion, die 160 rotates while mandrel bar 100 and centering insert 152 remain stationary. The blank 702 is pressed into the die 160 in the direction of arrow a and contacts the inner surface 726 of the die 160 at a first contact point 730. The interference contact between the inner surface 726 and the blank 702 begins at the point of contact 730 and generates energy that heats the blank 702 to a plastically deformable temperature. The design of the inner surface and the profile of the inner die surface may be different for different applications, in particular for extrusion of different materials. Depending on the material properties of the billet used for extrusion, such as heat transfer properties that may affect heating of the billet during extrusion, the internal profile of the die plate in the die body may be changed to concentrate work and wear on or spread over the die plate. In addition, for a particular extrusion process, the die rotation speed may be varied to increase die efficiency and avoid exceeding the material properties of the billet. For example, a mold rotation speed of between about 200rpm and about 1000rpm may be used. In some embodiments, a slower rotational speed, e.g., about 300rpm, is required to avoid applying high torsional shear to the blank while still heating the blank to a temperature sufficient to deform. Faster speeds, such as about 800rpm, can be used for materials that are not adversely affected by higher torsional shear or require more energy (and thus more friction) to heat to the deformation temperature. In other embodiments, the extrusion process may require die rotation speeds in excess of 100 rpm.

As the blank 702 advances beyond the middle portion 732 of the mandrel bar tip 800, the taper of the inner surface 726 applies pressure to the outer surface of the blank 702, urging the blank 702 inward toward the mandrel bar tip 800. Because billet 702 is in a plastically deformed state, the material in the billet is extruded in the direction of end portion 734 of mandrel bar tip 800 as die 160 reduces the outer diameter of billet 702 from initial diameter d2 to final outer diameter d 3. When billet 702 reaches intermediate portion 732, the conical narrowing of mandrel bar tip 800 toward end portion 734 causes the inner diameter of billet 702 to be squeezed and reduced from initial diameter d4 as the billet is advanced further beyond mandrel bar tip 800. In the intermediate portion 732, the tapered surface of the mandrel bar tip 800 may be placed near an acute angled portion of the inner surface 726, such as near the first acute angled portion 740, as discussed above with reference to the second intermediate plate 712. This results in the tapered middle portion 732 and the area of reduced inner diameter of the blank passing through the mandrel stem tip 800 being at the same location as the maximum pressure generated by the inner surface 726 against the die 160.

When the extruded billet 702 reaches the end portion 734, the inner diameter of the billet is reduced from the initial diameter d4 to the final diameter d5 of the final tube product 728. As the billet 702 passes the end 734, the outer diameter of the billet 702 continues to decrease to the final outer diameter d3 of the extruded tube product 728 as it exits the die at the exit 718. Upon exiting the exit, the extruded product 728 is formed. Due to friction and heating within the die 160, the product 728 is at an elevated temperature upon exiting the die 160, and cooling elements may be applied to prevent further deformation or to increase the operational safety of the extrusion system, to purge out extruded material or to maintain desired material properties. Fig. 28 shows the aperture 736 in the base plate 700 having a diameter greater than the diameter of the die outlet 718. This configuration is preferred to allow the cooling elements and cooling fluid to reach the base plate 700 and contact the extruded product 728 once the extruded product 728 exits the die 160 for easier cooling. After product 728 exits base 700 and passes through the cooling system, the extrusion process is complete and product 728 may be collected for post-processing.

Fig. 29 and 30 illustrate perspective and top plan views, respectively, of a mandrel bar tip according to some embodiments. The spindle shaft tip 800 includes a connector 802 that connects with the spindle shaft to form the spindle shaft tip of the spindle shaft. Mandrel bar tip 800 also includes respective extruded contact surfaces 804 that contact the inner surface of the hollow billet as the billet passes over the mandrel bar tip 800 within the rotating die. Mandrel stem tip 800 has a terminal contact surface 806 with a diameter D1 that sets the inner diameter of the extruded tube. During extrusion, the rotating die rotates relative to the billet and thereby generates heat, which softens the billet to allow plastic deformation of the billet. During operation of the extrusion system 10, the combination of the rotary die 160 and the mandrel bar tip 800 causes a plastic deformation zone of the billet to be formed generally in the plastic deformation zone of the mandrel bar tip 800.

The mandrel bar tip 800 may have any suitable diameter along the extrusion surface 804 and the terminal contact surface 806. For example, in certain embodiments, as shown by the mandrel bar tip 820, the terminal contact surface 826 may have a set diameter D2 that is greater than the set diameter D1 of the mandrel bar tip 800. In certain embodiments, each contact surface 804 of mandrel bar tip 800 may correspond to a respective profile of a respective mold plate within a rotary mold.

Fig. 31 illustrates a flow diagram for pre-processing a billet for the extrusion system 10 of fig. 1, in accordance with certain embodiments. At step 1010, the billet is cast using any suitable casting process. For example, casting the billet may include utilizing a casting furnace to produce a billet in a desired ratio. The cast billet may then be straightened using a roll straightening process at step 1020, followed by machining the rolled billet at step 1030. The overhead rolled billet includes, for example, cleaning any rough edges or surfaces of the billet. At step 1040, the machined blank may be strain hardened and cut. Strain hardening may include compressing the billet to induce strain hardening, which allows the billet to withstand the pressure exerted on the billet by a ram (e.g., ram platens 130, 140 of fig. 1) during the extrusion process as well as the rotational and shear stresses induced by a rotating die (e.g., die 160 of fig. 1). At step 1050, the blank may be straightened again using a suitable straightening device. At step 1060, the blank end is trimmed. Trimming allows for the removal of imperfections or other deformations at the end of the billet, such as imperfections or deformations introduced during previous machining steps or during casting. The billet is then rinsed at step 1070 with any suitable rinsing solution (such as a water-soluble degreasing solvent) or combination of rinsing solvents. At step 1080, the inner diameter of the billet is lubricated using any suitable lubricating fluid, including graphite lubricants, petroleum-based composites or non-petroleum composites, any other suitable lubricating fluid, or combinations thereof.

Fig. 32 illustrates a flow diagram for pre-processing a mandrel bar tip (such as mandrel bar tip 800 or 820 of fig. 28 and 29) for use with the extrusion system 10 of fig. 1, in accordance with certain embodiments. At step 1110, the mandrel bar tip may be heated using any suitable heating process. For example, the mandrel bar tip may be placed in a furnace or heated by a torch until the mandrel bar tip is above about 1000 degrees Fahrenheit. After this heat treatment, the mandrel bar tip is quenched in lubricant and agitated at step 1120 to ensure consistent lubricant deposition. In certain embodiments, the lubricant is a graphite lubricant, although any other suitable lubricant or combination thereof may be used. At step 1130, the mandrel bar tip is allowed to cool after quenching. At step 1140, any excess lubricant is removed from the mandrel bar tip. The mandrel bar tip is then reheated to above about 1000 degrees Fahrenheit at step 1150 and quenched and agitated in lubricant at step 1160 to ensure consistent lubricant deposition. In certain embodiments, the mandrel bar tip is quenched with a second lubricant that is different from the first lubricant used in step 1120. For example, the lubricant used in step 1120 may be a graphite lubricant, and the lubricant used in step 1160 may be a petroleum-based composite or non-petroleum composition, or any other suitable lubricant that is different from the first lubricant. In certain embodiments, the lubricant used in step 1160 may be the same as used in step 1120. At step 1170, the mandrel bar tip is allowed to cool after the quenching step 1160. In certain embodiments, after process step 1170 is complete, process steps 1150, 1160, and 1170 may be repeated. In such embodiments, the lubricant used in the repeated quenching steps may be the same as that used prior to step 1160 (which may be the same or different than the lubricant used in the first quenching step 1120).

Fig. 33-36 show various flow diagrams depicting a process of operating a compression system, such as the compression system 10 of fig. 1, in accordance with certain embodiments. Steps 1210-1240 depict certain exemplary steps of the billet transfer subsystem 20 of the extrusion system. Step 1250 depicts certain exemplary embodiments of the extrusion subsystem 40 of the extrusion system, and step 1260 depicts certain exemplary steps of the quenching subsystem 60 of the extrusion system. It should be understood that the steps of the flow chart of the present invention are merely illustrative. Any steps of the flow diagrams may be modified, omitted, or rearranged, two or more steps may be combined, or any additional steps may be added without departing from the scope of the invention.

The process 1200 begins at step 1210 where one or more billets are loaded around the mandrel bar receiving end 100a in the vicinity of the first or upstream fluid clamp 102. Each billet of the present invention is hollow along the length of the billet, which allows the billet to be placed on a stationary mandrel bar 100, allowing the billet to be moved and transported along and around the mandrel bar 100. In certain embodiments, the billet transfer subsystem 20 of the extrusion system 10 may include a billet transfer station having a plurality of billets to be loaded onto the extrusion system 10. The blank may be loaded automatically by an automated process or may be loaded manually. Once loaded, the billets may be transported along the mandrel bar by a billet feed track assembly, such as the track assembly 110 shown in fig. 2, the track assembly 110 including a track 202 that moves intermittently relative to the fluid clamps 102, 104 and the mandrel clamps 106, 108 depending on the position of the particular billet.

At step 1220, the billet is transported along the mandrel bar and through a fluid clamp that delivers a cooling fluid to the mandrel bar tip when engaged with the mandrel bar. At any given moment, at least one fluid clamp is preferably clamped or otherwise engaged to the mandrel bar to continuously or substantially continuously deliver cooling fluid to the mandrel bar. Fig. 34 illustrates the step of passing one or more billets through the various fluid clamps of the extrusion system. For example, at step 1400, one or more billets are transported to a first upstream fluid clamp, such as the fluid clamp 102 of the extrusion system 10. The PLC system determines at decision block 1402 whether the first fluid clamp is engaged with the spindle rod. If the first fluid clip is engaged with the spindle shaft, the PLC system determines at decision block 1404 whether the second fluid clip is engaged with the spindle shaft. In some embodiments, both fluid clamps may engage the mandrel bar when the billet is not passing through the fluid clamps. If the second fluid clamp is engaged, then at step 1410, the first fluid clamp is disconnected. However, if the second fluid clamp is not engaged, then at step 1404 the PLC system determines that the blank is being transported through the second fluid clamp and waits at step 1406 for the blank to be free of the second fluid clamp. Then, at step 1408, the second fluid clamp is engaged and the process proceeds to step 1410 where the first fluid clamp is disengaged. After the first fluid clamp is opened at step 1410, or when it has been determined at decision block 1402 that the first fluid clamp is opened, the process proceeds to step 1412 where one or more blanks are advanced through the first fluid clamp. When the first fluid clamp is broken to allow the billet to pass therethrough, the second fluid clamp is engaged to the mandrel bar and delivers a cooling fluid to the mandrel bar. After the desired number of blanks have been advanced through the first fluid clamp, the first fluid clamp is engaged with the mandrel bar at step 1414, and the blanks are transported to the second fluid clamp at step 1420.

The process 1220 with respect to the second fluid clamp is substantially similar to the process performed by the PLC system with respect to the first fluid clamp and is also shown in fig. 34. At step 1420, one or more billets are transported to a second downstream fluid clamp, such as the fluid clamp 104 of the extrusion system 10. The PLC system determines at decision block 1422 whether the first fluid clamp is engaged with the spindle shaft. If the second fluid clip is engaged with the spindle shaft, the PLC system determines at decision block 1424 whether the first fluid clip is engaged with the spindle shaft. In some embodiments, both fluid clamps may engage the mandrel bar when the billet is not passing through the fluid clamps. If the first fluid clamp is engaged, then at step 1430, the second fluid clamp is disconnected. However, if the second fluid clamp is not engaged, the PLC system determines that the blank is being transported through the first fluid clamp at step 1424 and waits for the blank to be freed from the second fluid clamp at step 1426. Then, at step 1428, the first fluid clamp is engaged and the process proceeds to step 1430 where the second fluid clamp is disconnected. After the second fluid clamp is disconnected at step 1430, or when it has been determined at decision block 1422 that the second fluid clamp is disconnected, the process proceeds to step 1432, where one or more blanks are advanced through the second fluid clamp. The first fluid clamp engages the mandrel bar and delivers a cooling fluid to the mandrel bar when the second fluid clamp is broken to allow the billet to pass therethrough. After the desired number of blanks have been advanced through the second fluid clamp, the second fluid clamp is engaged with the mandrel bar at step 1434.

Returning to the process 1200 of fig. 33, at step 1230, the billet is transported along the mandrel bar and through a mandrel clamp that, when engaged with the mandrel bar, holds the mandrel bar in place and prevents the mandrel bar from rotating. At any given moment, at least one mandrel clamp is preferably clamped or otherwise engaged to the mandrel bar. Fig. 35 illustrates the step of passing one or more billets through the various mandrel clamps of the extrusion system. For example, at step 1500, one or more billets are transported to a first upstream mandrel clamp, such as the mandrel clamp 106 of the extrusion system 10. The PLC system determines at decision block 1502 whether the first mandrel holder is engaged with the mandrel bar. If the first mandrel holder is engaged with the mandrel bar, the PLC system determines at decision block 1504 whether the second mandrel holder is engaged with the mandrel bar. In certain embodiments, both mandrel clamps may engage the mandrel bar when the billet is not passing through the mandrel clamps. If the second mandrel holder is engaged, then at step 1510, the first mandrel holder is disconnected. However, if the second mandrel holder is not engaged, then at step 1504 the PLC system determines that the billet is being transported through the second mandrel holder and waits for the billet to be freed from the second mandrel holder at step 1506. Then, at step 1508, the second mandrel holder is engaged and the process proceeds to step 1510 where the first mandrel holder is disconnected. After the first mandrel holder is disconnected at step 1510, or when it has been determined at decision block 1502 that the first mandrel holder is disconnected, the process proceeds to step 1512 where one or more billets are advanced through the first mandrel holder. The second mandrel holder is engaged to the mandrel bar when the first mandrel holder is broken to allow the billet to pass therethrough. After the desired number of billets have advanced through the first mandrel clamp, the first mandrel clamp engages the mandrel bar at step 1514, and the billets are transported to the second mandrel clamp at step 1520.

The process 1230 with respect to the second mandrel holder is substantially similar to the process performed by the PLC system with respect to the first mandrel holder and is also shown in fig. 35.

At step 1520, the one or more billets are transported to a second upstream mandrel clamp, such as the mandrel clamp 108 of the extrusion system 10. The PLC system determines whether the second mandrel holder is engaged with the mandrel bar at decision block 1522. If the second mandrel clamp is engaged with the mandrel bar, the PLC system determines if the second mandrel clamp is engaged with the mandrel bar at decision block 1524. In certain embodiments, both mandrel clamps may engage the mandrel bar when the billet is not passing through the mandrel clamps. If the first mandrel holder is engaged, then at 1530 the second mandrel holder is disconnected. However, if the first mandrel clamp is not engaged, the PLC system determines that the billet is being transported through the first mandrel clamp at step 1524 and waits for the billet to be freed from the second mandrel clamp at step 1526. Then, at step 1528, the first mandrel clamp is engaged and the process proceeds to step 1530 where the second mandrel clamp is disengaged. After the second mandrel holder is disconnected at step 1530, or when it has been determined at decision block 1522 that the second mandrel holder is disconnected, the process proceeds to step 1532 in which one or more billets are advanced through the second mandrel holder. The first mandrel holder is engaged to the mandrel bar when the second mandrel holder is disengaged to allow the billet to pass therethrough. After the desired number of billets have been advanced through the second mandrel clamp, the first mandrel clamp is engaged with the mandrel bar at step 1534.

Returning to the process 1200 of fig. 33, at step 1240, the blank is gripped with the ram and then advanced. The ram provides a substantially constant thrust force to the clamped blank in the direction of the rotating die. The PLC system controls the rate at which the ram operates and thus the stock enters the rotary module. Fig. 36 illustrates the step of gripping and advancing the billet with the ram of the extrusion system. For example, at step 1600, the billet is clamped via a first upstream ram, such as ram 130 of the extrusion system of fig. 1. At step 1602, the first ram is advanced toward a second downstream ram. At decision block 1604, the PLC system determines whether the second ram has been retracted to a receiving position to receive the billet. If the second ram is not in place, the first ram continues advancing the blank until the second ram is in place, step 1606. If the second ram is in place 1604, the blank is clamped via the second ram 1608. The first and second rams together advance the billet further at step 1610. This ensures that a continuous or substantially continuous thrust is applied to the blank in the direction of rotation of the die. At step 1612, the first ram releases the blank (while the second ram continues advancing the blank), and at step 1614, the first ram retracts to the receiving position, thereby gripping a subsequent blank. This arm-over-arm (arm-arm) process allows the rotating die to receive a constant flow of billet at a predetermined feed rate. The feed track assembly may continue to index the track to minimize gaps between queued adjacent blanks to be advanced through the ram before the first ram grips the blank at step 1600.

At step 1250, the billet is extruded to form an extruded material. The ram of step 1240 advances the billet through a centering insert (e.g., centering insert 152 of fig. 1) having a plurality of notches that prevent the billet from rotating prior to entering the rotary die. Once the billet enters the rotating die, the die simultaneously heats the billet and sets the outer diameter of the billet as the billet is extruded to form the extruded material. The mandrel bar is positioned so that the mandrel bar tip is within the rotary die. The mandrel bar tip sets the inner diameter of the extruded material. The position of the mandrel bar relative to the mold can be controlled by a PLC system. The PLC system may also control the rotational speed of the rotary die using a motor 170 coupled to a shaft 172.

At step 1260, the extruded material is quenched as it exits the rotating die. This step includes rapidly cooling the extruded material by spraying a cooling fluid, such as water or any other suitable cooling fluid, from the quench tube onto the extruded material at high velocity. Regardless of how high a temperature is generated during the extrusion process of step 1250, upon exiting the quench tube, the extruded material cools sufficiently to be touchable, whereby the extruded material can be processed without burning. Further, in certain embodiments, nitrogen or another suitable inert gas is delivered to the interior of the extruded material as it exits the rotating die. For example, a cap on the tube may be used to deliver nitrogen gas into the interior of the extrusion tube as it exits the rotating die. The injection of gaseous or liquid nitrogen into the rotating die assembly or within the extruded material itself minimizes oxide formation by displacing the oxygen-bearing air.

It should be understood that while one or more billets undergo the process 1200 as thus described, other billets may be advancing through the extrusion system at any other step of the process 1200. For example, while the first set of billets (including one or more billets) are being transported through the fluid clamp at step 1220, another set of billets (including one or more billets) may be simultaneously loaded onto the mandrel bar at step 1210 or transported through the mandrel clamps at step 1230 or any other step in the process 1200. In this manner, the extrusion system is able to continuously supply multiple billets to the rotating die to extrude the billets to form an extruded material.

Fig. 37 illustrates a block diagram of a programmable logic control system for operating the extrusion system of fig. 1, in accordance with certain embodiments. As mentioned above, the extrusion system 10 includes functional subsystems: a billet transfer subsystem 20, an extrusion subsystem 40, and a cooling or quenching subsystem 60. PLC system 1700 may control the operation of certain components of any one or more of these subsystems 20, 40, 60. The various operational steps of the subsystems 20, 40, 60 are described above with reference to the process 1200 of fig. 33-36.

Instructions for performing the method of the present invention for extruding material may be encoded on a machine-readable medium, run by a suitable computer or similar device, to implement the method of the present invention for programming or configuring a PLC or other programmable device having the above-described configuration. For example, a personal computer may be equipped with an interface that can be connected to the PLC, and a user can program the PLC through the personal computer using an appropriate software tool.

Fig. 38 shows a cross-section of a magnetic data storage medium 1800 that may be encoded with a machine-executable program that may be executed by a system such as the aforementioned personal computer or other computer or similar device. The medium 1800 may be a floppy disk or a hard disk or a magnetic tape having a suitable substrate 1801 (which may be conventional) and a suitable coating 1802 (which may be conventional) on one or both sides, the coating 1802 containing magnetic domains (not visible) of magnetically changeable polarity or direction. In addition to being magnetic tape, the media 1800 may also have an opening (not shown) for receiving a spindle or other data storage device of a disk drive.

The magnetic domains of the coating 1802 of the medium 1800 may be polarized or oriented so as to encode a machine-executable program in a manner (which may be conventional) that is run by a programming system, such as a personal computer or other computer or similar system, having a socket or peripheral attachment into which a PLC is to be programmed, to configure the appropriate portions of the PLC in accordance with the present invention, including its dedicated processing blocks (if any).

Fig. 39 shows a cross-section of an optically readable data storage medium 1810, which may also be encoded with a machine executable program, which may be executed by a system such as the aforementioned personal computer or other computer or similar device. The medium 1810 may be a conventional compact disc read only memory (CD-ROM) or digital versatile disc read only memory (DVD-ROM) or a rewritable medium such as a CD-R, CD-RW, DVD-R, DVD-RW, DVD + R, DVD + RW or DVD-RAM or an optically readable and magneto-optical rewritable magneto-optical disk. The medium 1810 preferably has a suitable substrate 1811 (which may be conventional) and a suitable coating 1812 (which may be conventional) typically on one or both sides of the substrate 1811.

For CD-based or DVD-based media, as is well known, the coating 1812 is reflective and is embossed with a plurality of pits (pit)1813 disposed on one or more layers to encode a machine-executable program. The placement of the pits is read by reflecting the laser light on the surface of the coating 1812. A protective coating 1814, preferably substantially transparent, is disposed over the coating 1812.

For magneto-optical disks, as is well known, the coating 1812 does not have pits 1813, but has a plurality of magnetic domains that, when heated above a certain temperature, can magnetically change the polarity or direction of the magnetic domains, such as by a laser (not shown). The direction of the magnetic domains can be read by measuring the polarization of the laser light reflected from the coating 1812. The arrangement of the magnetic domains encodes the program, as described above.

PLC1700 programmed according to the present invention can be used with a wide variety of electronic devices. One possible use is for the data processing system 1900 shown in FIG. 40. Data processing system 1900 may include one or more of the following components: a processor 1901; a memory 1902; I/O circuitry 1903; and a peripheral device 1904. These components may be coupled together via a system bus 1905 and located on a circuit board 1906 included in an end user system 1907, which end user system 1907 may include an end unit 1407 for operating the compression system.

System 1900 may be used for a variety of applications, including as an instrument for an extrusion system or any other suitable application where the advantages of using programmable or reprogrammable logic are desired. PLC1700 can be used to perform a variety of different logic functions. For example, PLC1700 can be configured as a processor or controller that cooperates with processor 1901. PLC1700 can also function as an arbiter for arbitrating access to a shared resource in system 1900. In another embodiment, PLC1700 can be configured as an interface between processor 1901 and one of the other components in system 1900. It should be noted that system 1900 is merely exemplary. For example, in some embodiments, the user terminal may be disposed proximate to the compression system. In other embodiments, a networking device may be provided that allows the user terminal to be remotely connected to the compression system.

FIG. 41 is a block diagram of a computing device 2200 for performing at least some of the extrusion system logical processes described above in accordance with certain embodiments. Computing system 2200 includes a PLC system, such as PLC1700, at least one network interface unit 2204, an input/output controller 2206, a system memory 2208, and one or more data storage devices 2214. The system memory 2208 includes at least one Random Access Memory (RAM)2210 and at least one Read Only Memory (ROM) 2212. All of these elements communicate with a Central Processing Unit (CPU)2202 to facilitate operation of the computing device 2200. The computing device 2200 may be configured in a number of different ways. For example, computing device 2200 may be a conventional standalone computer, or alternatively, the functionality of computing device 2200 may be distributed across multiple computer systems and architectures. Computing device 2200 may be configured to perform some or all of the extrusion system logic processes described above, or these functions may be distributed across multiple computer systems and architectures. In the embodiment shown in fig. 23, the computing device 2200 is connected to a third party 2224 through a communication network 2150 via a communication network 2150 or a local network 2124.

Computing device 2200 can be configured as a distributed architecture, where the databases and processors are housed in different units or locations. The computing device 2200 may also be implemented as a server located on-site at the extrusion facility or located outside of the extrusion facility. Some of these units perform the primary processing functions and include at least a general purpose controller or processor 2202 and a system memory 2208. In such embodiments, each of these units is attached via the network interface unit 2204 to a communications hub or port (not shown) that serves as the primary communications line for connecting to other servers, clients, user computers, and other related devices. Communication line concentratorThe device or port itself may have the lowest processing power and function primarily as a communications router. Various communication protocols may be part of the system, including but not limited to: ethernet, SAP, SAS^TM、ATP,BLUETOOTH^TMGSM, and TCP/IP.

The CPU 2202 includes a processor (such as one or more conventional microprocessors) and one or more supplemental co-processors (such as mathematical co-processors) to share the workload of the CPU 2202. The CPU 2202 communicates with the network interface unit 2204 and the input/output controller 2206, through which the CPU 2202 communicates with other devices, such as other servers, user terminals, or devices. The network interface unit 2204 and the input/output controller 2206 may include multiple communication channels for communicating with, for example, other processors, servers, or client terminals simultaneously. Devices that communicate with each other need not continuously transmit information. Instead, such devices only need to send information to each other when needed, and in fact may not exchange data most of the time, and may need to perform several steps to establish a communication line between the devices.

The CPU 2202 also communicates with a data storage device 2214. The data storage 2214 may include a suitable combination of magnetic, optical, and/or semiconductor memory, and may include, for example, RAM, ROM, flash memory disks, optical disks (optical and/or hard disks), or drives. Both the CPU 2202 and the data storage 2214 may reside, for example, entirely within a single computer or other computing device; or may be interconnected by communication media, such as USB ports, serial interface lines, coaxial cables, Ethernet-type cables, telephone lines, radio frequency transceivers, or other similar wireless or wired media or combinations of the foregoing. For example, the CPU 2202 can be connected to the data storage 2214 via the network interface unit 2204.

The CPU 2202 may be configured to perform one or more particular processing functions. For example, the computing device 2200 may be configured to control, at least in part, one or more aspects of the billet transport subsystem 20, the extrusion subsystem 40, and the quenching subsystem 60 via a PLC.

The data storage 2214 may store, for example, (i) an operating system 2216 for the computing device 2200; (ii) one or more applications 2218 (e.g., computer program code and/or computer program product) adapted to direct the CPU 2202 in accordance with the present invention, and more particularly in accordance with the procedures described in detail with reference to the CPU 2202; and/or (iii) a database 2220 suitable for storing information that may be used to store information needed by the program.

The operating system 2216 and/or application programs 2218 may be stored, for example, in a compressed format, an uncompiled format, and/or an encrypted format, and may include computer programming code. Instructions of the program may be read into the main memory of the processor from a computer-readable medium, such as from ROM 2212 or RAM 2210, instead of the data storage device 2214. Fixed circuitry may be used in place of, or in combination with, software instructions to implement the processes of the present invention, although execution of sequences of instructions in a program will cause the CPU 2202 to perform the process steps described herein.

As used herein, the term "computer-readable medium" refers to any non-transitory medium that provides or participates in providing instructions to a computing device (or any other processor of a device described herein) for execution. Such a medium may take many forms, including but not limited to, non-volatile media and volatile media. Non-volatile media includes optical, magnetic, or opto-magnetic disks or integrated circuit memory such as flash memory. Volatile media include Dynamic Random Access Memory (DRAM), which typically constitutes a main memory. Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, an EPROM or EEPROM (electrically erasable programmable read-only memory), a FLASH-EEPROM, any other memory chip or cartridge, or any other computer-readable non-transitory memory.

Various forms of computer readable media may be involved in carrying one or more sequences of one or more instructions to CPU 2202 (or any other processor of a device described herein) for execution. For example, the instructions may initially be carried on a magnetic disk of a remote computer (not shown). The remote computer can load the instructions into its dynamic memory and send the instructions over an Ethernet connection, a cable, or a telephone line using a modem. Communication devices within the computing device (e.g., server) may receive data on various communication lines and place the data on a system bus for use by the processor. The system bus may carry data to main memory, from which the processor obtains and executes instructions. The instructions received by main memory may optionally be stored in memory either before or after execution by processor. Further, the instructions may be received via a communication port as electrical, electromagnetic, or optical signals (which are exemplary forms of wireless communication or data streams carrying various types of information).

The foregoing merely illustrates the principles of the invention and the systems, devices and methods may be practiced otherwise than as described, which are presented for purposes of illustration and not of limitation. It should be understood that the systems, apparatus, and methods disclosed herein, while shown for use with an extrusion system, may be applied to other manufacturing processes, including but not limited to cast-rolling and heat treatment processes. Furthermore, the present invention may be implemented as a post-processing step of another manufacturing process (including other extrusion processes) or may be implemented simultaneously with another manufacturing process.

Variations and modifications will occur to those skilled in the art upon a review of this disclosure. The disclosed features can be implemented in any combination and subcombination (including multiple dependent combinations and subcombinations) with one or more other features described herein. The various features depicted or described above, including any components thereof, may be combined or integrated in other systems. In addition, certain features may be omitted or not implemented.

Those skilled in the art may determine alterations, substitutions and examples of variations without departing from the scope of the information disclosed herein. All references cited herein are incorporated in their entirety and form a part of this application.

Claims

1. A method for continuously loading and extruding a plurality of billets, the method comprising:

loading a first billet on a receiving end of an elongated mandrel bar;

transporting the first billet along the mandrel bar and passing the first billet through a clamping element that holds the mandrel bar in place and prevents rotation of the mandrel bar, wherein at any given moment, at least one clamping element clamps the mandrel bar;

transporting a first billet along the mandrel bar and through cooling elements clamped to the mandrel bar and conveying a cooling fluid to the mandrel bar, wherein at any given moment at least one cooling element is clamped to the mandrel bar; and

a first billet is extruded by pushing the first billet through a rotating die to form an extruded material, wherein the first billet is followed by an adjacent second billet that forms a portion of the extruded material.

2. The method of claim 1, wherein the first billet is transported along the mandrel bar via a track that moves intermittently according to the position of the first billet relative to the clamping element and the cooling element.

3. The method of claim 1, wherein the cooling fluid is transported to a mandrel bar tip disposed on a second end of the mandrel bar opposite the receiving end.

4. The method of claim 3, wherein the cooling fluid returns to the cooling element after passing through the mandrel bar tip.

5. The method of claim 3, wherein the mandrel bar tip is positioned within the rotary die prior to receiving the first billet.

6. The method of claim 1, wherein the cooling fluid is water.

7. The method of claim 1, wherein loading a plurality of billets in succession further comprises:

the clamping elements alternately clamp the mandrel bar to allow one or more blanks to pass through the clamping elements.

8. The method of claim 7, wherein the downstream clamping element clamps the mandrel bar and the upstream clamping element opens.

9. The method of claim 8, further comprising:

loading the one or more billets onto a mandrel bar and through an open upstream clamping element;

closing the open upstream clamping element; and

advancing the one or more blanks to a downstream gripping element.

10. The method of claim 9, further comprising:

opening the downstream clamping element;

advancing the one or more blanks through the open downstream gripping element; and

the downstream clamping element is closed.

11. The method of claim 1, wherein loading a plurality of billets in succession further comprises:

the cooling elements are alternately clamped to the mandrel bar to allow one or more billets to pass through the cooling elements.

12. The method of claim 11, wherein the downstream cooling element clamps the mandrel bar and delivers the cooling fluid to the mandrel bar, and the upstream cooling element is open.

13. The method of claim 12, further comprising:

loading the one or more billets onto a mandrel bar and passing them through an open upstream cooling element;

closing the open upstream cooling element; and

advancing the one or more billets to a downstream cooling element.

14. The method of claim 13, further comprising:

opening a downstream cooling element;

advancing the one or more billets through an open downstream cooling element; and

the downstream cooling element is turned off.

15. The method of claim 1, further comprising:

during extrusion, the portion of the first billet that has not entered the rotating die is prevented from rotating.

16. The method of claim 15, wherein the centering insert grips the portion of the first billet to prevent the portion from rotating, and wherein the centering insert has an adjustable position relative to the rotating die.

17. The method of claim 16, further comprising cooling the centering insert with a cooling fluid.

18. The method of claim 1, wherein the rotating die heats the billet as the billet advances through the rotating die.

19. The method of claim 1, further comprising providing a substantially constant thrust to the first billet in a direction toward the rotating die.

20. The method of claim 1, further comprising quenching the extruded material as it exits the rotating die.

21. The method of claim 20, wherein the extruded material is quenched with water.

22. The method of claim 21, wherein the water contacts the extruded material within about 1 inch of the rotating die.

23. The method of claim 1, wherein the rotary die comprises a plurality of stacked die plates.

24. The method of claim 1, wherein the extruded material is copper.

25. The method of claim 1, wherein the extruded material is aluminum, nickel, titanium, brass, steel, or plastic.

26. The method of claim 1, further comprising adjusting a rotational speed of the rotating die.

27. The method of claim 1, wherein the plurality of blanks extend along substantially an entire length of the mandrel bar.

28. The method of claim 1, further comprising flooding the interior of the extruded material with nitrogen.

29. The method of claim 1, each of the plurality of billets being loaded onto a mandrel bar by a person or by an automated loading device.

30. A method for continuously loading and extruding a plurality of billets, the method comprising:

receiving a first billet at a receiving end of an elongated mandrel bar;

31. The method of claim 30, wherein the first billet is transported along the mandrel bar via a track that intermittently moves according to a position of the first billet relative to the cooling element.

32. The method of claim 30, wherein the cooling fluid is transported to a mandrel bar tip disposed on a second end of the mandrel bar opposite the receiving end.

33. The method of claim 32, wherein the cooling fluid returns to the cooling element after passing through the mandrel bar tip.

34. The method of claim 32, wherein the mandrel bar tip is positioned within the rotary die prior to receiving the first billet.

35. The method of claim 30, wherein the cooling fluid is water.

36. An extrusion press system comprising:

a mandrel bar having a first end and a second end, the first end for receiving a blank having a hole therethrough and the second end coupled to a mandrel bar tip;

a cooling element coupled to the mandrel bar, the cooling element having a port through which a cooling fluid is delivered into the mandrel bar so as to cool the mandrel bar tip;

a clamping element coupled to the spindle shaft, the clamping element including a clamp movable to secure the spindle shaft in place and prevent rotation of the spindle shaft; and

a rotating extrusion die configured to receive a billet from a centering insert having a plurality of slots frictionally engaged with the billet to prevent rotation of the billet prior to entering the rotating extrusion die;

wherein the mandrel bar tip is located within the rotary die.

37. The extrusion press system of claim 36, further comprising:

a ram element having first and second movable arms that together grip the blank, the first and second arms providing a substantially constant thrust in the direction of the rotating die.

38. The extrusion press system of claim 37, wherein the substantially constant thrust causes the billet to enter the rotary die at a predetermined rate.

39. The extrusion press system of claim 36, wherein the mandrel bar includes an opening proximate to a port of the cooling element, the opening receiving the cooling fluid.

40. The extrusion press system of claim 39, wherein the mandrel bar further comprises notches around the mandrel bar on either side of the opening, wherein the notches of the mandrel bar are configured to receive O-rings to prevent leakage of the cooling fluid.

41. The extrusion press system of claim 40, further comprising a mandrel bar sleeve surrounding the opening to prevent leakage of cooling fluid.

42. The extrusion press system of claim 36, wherein the mandrel bar includes an inner tube therein that receives the cooling fluid from the cooling element and through which the cooling fluid is delivered to the mandrel bar tip.

43. The extrusion press system of claim 42, wherein the cooling fluid returns to the cooling element from the mandrel bar tip along a space within the mandrel bar between the outer surface of the inner tube and the inner surface of the mandrel bar.

44. The extrusion press system of claim 36 wherein the cooling fluid is water.

45. The extrusion press system of claim 36, wherein the mandrel bar includes a clamping portion that is correspondingly shaped to mate with a clamp of the clamping element.

46. The extrusion press system of claim 36, further comprising a track along which the billet is transported, wherein the track intermittently moves according to the position of the billet relative to the clamping element and the cooling element.

47. The extrusion press system of claim 46, further comprising an upper roller positioned above the rail and configured to contact an upper surface of the billet.

48. The extrusion press system of claim 36, further comprising a quench tube disposed at an exit of the rotating extrusion die.

49. The extrusion press system of claim 48, wherein the quench tube quenches the extruded material as the extruded material exits the rotating extrusion die.

50. The extrusion press system of claim 49, wherein the extruded material is quenched with water.

51. The extrusion press system of claim 50, wherein the water contacts the extruded material within about 1 inch of the rotating extrusion die.

52. The extrusion press system of claim 36, further comprising a motor coupled to a shaft that controls the rotational speed of the rotating extrusion die.