铝挤压机培训资料31docx.docx
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铝挤压机培训资料31docx
Chapter3MachineryandEquipmentforDirect/IndirectHotExtrusion
THEMACHINERYANDEQUIPMENTrequiredforrod(杆,棒,竿)andtubeextrusionisdeterminedbythespecificextrusionprocess.
Ideally,themachineryandequipmentshouldhaveflexibilitybut,also,providespecificextrusionprocesswiththeoptimum(最适宜的)qualityandeconomicefficiency.Directhotextrusionisthemostwidelyusedprocess,andthetermextrusionusuallyreferstothisprocess.Themachineryusedisusuallybasedonso-calledstandarddesigns.
Theotherextrusionprocessesusuallyrequirespeciallydevelopedmachines.Theyaredesignedaccordinglyandbuilttomeettheneedsoftheoperator.
注释:
rod[rɔd]杆,棒,竿
optimum['ɔptiməm]最适宜的
3.1MachineryforDirectExtrusion
Thedesignofadirect-extrusionpressisdeterminedbythefollowingfactors:
●Product
a.Aluminumandaluminumalloys(lightmetal)easytoextrudeand/ordifficulttoextrude.Wire(金属丝制的;金属网制的),bar(木、金属等的条),section,hollowsection,andwideflatsections
b.Copper(铜)andcopperalloysincludingbrass(黄铜)(heavymetal)easytoextrudeand/ordifficulttoextrude.Wire,bar,andsection
c.Steelandhigh-strengthsteelalloyseasytoextrudeand/ordifficulttoextrude.
●Processtechnology
a.Extrusionwithoutlubrication(润滑)andwithoutashell(壳)
b.Extrusionwithoutlubricationandwithashell
c.Extrusionwithlubricationwithoutashell
●Tooling
a.Container(挤压筒),stem(杆),dummyblock(挤压垫),anddie
Thewiderangeofdifferentdesignsforextrusionpresseshasrecentlybeenreducedinmostextrusionplantstoafewhigh-output(高输出)types.
Therefore,onlyextrusionpressdesignsthatdominate(主导)today’smarketarediscussedinthischapter.ThesearereferredtoasstandardextrusionpressesinTable3.1.
Direct-extrusionpressesaccountformorethan95%ofthetotalvolumeofallpresses.Thedirect-extrusionpressisusedforallcurrentextrusionprocesses.
Machinesforthedirecthotextrusionoflight-metalalloysaremainlyusedfortheextrusionofsection(80%),tube(10%),androd(<10%)inaluminumandaluminumalloys.Themachinesfordirecthotextrusionofheavymetals,mainlycopperandcopperalloys,areusedfortheextrusionofrod,wire,andsection(60%)(mainlyinbrass)andtube(40%)(mainlyincopper).
Steelandsteelalloysareonlyproducedbyextrusiontoalimitedextent(范围,程度),andthenonlywhenrolling(滚压;轧制)isnotpossibleorthevolumesaretoosmall.
Thefollowingmajorpointsmustbeconsideredintheconstructionofextrusionpresses:
●Technologyrequirements:
Thiscoversthemetallurgical(冶金的,冶金学的)aspectsofthedeformationtechnologyofextrusion.
●Economicfactors:
Theeconomicneedforrationalization(合理化)intheconstructionofextrusionpressesismostclearlyseeninaluminumextrusion.Newextrusionplantsarebuiltasintegrated(整合的)productionlines.Theyincludebilletstores,billetheating,extrusionpress,handlingequipmentwithlongitudinal(纵向的)andtransverse(横向的)conveyors(输送带),sectioncoolingsystems,stretcher(拉伸机),cut-to-lengthsaws(定长剪切锯床)andstackers(栈式存储器),aswellasheattreatmentequipmentandpacking(包装)lines.Similardevelopmentscanbefoundinheavy-metalextrusionplants.Sophisticated(富有经验的;精致的;复杂的)systemsforelectronicdatacollectionanddataanalysisfortheeconomicoptimalproductionarealreadyconsideredtobestandard.
注释:
Wire['waiə]金属丝制的;金属网制的
bar[bɑ:
](木、金属等的)条
Copper['kɔpə]铜
brass[brɑ:
s]黄铜
lubrication[,lu:
bri'keiʃən]润滑
shell[ʃel]壳
Container[kən'teinə]挤压筒
stem[stem]杆
dummy['dʌmi]block[blɔk]挤压垫
high-output高输出
extent[iks'tent]范围,程度
rolling['rəuliŋ]滚压;轧制
metallurgical[,metə'lə:
dʒikəl]冶金的,冶金学的
rationalization[,ræʃənəlai'zeiʃən]合理化
integrated['intigreitid]整合的
longitudinal[,lɔndʒi'tju:
dinəl]纵向的
transverse[trænz'və:
s]横向的
conveyors[kən'veiə]输送带
stretcher['stretʃə]拉伸机
cut-to-lengthsaws定长剪切锯床
stackers['stækə]栈式存储器
packing['pækiŋ]包装
Sophisticated[sə'fistikeitid]富有经验的;精致的;复杂的
3.1.1ExtrusionPressDesignPrinciples
Initialdiscussions,over50yearsago,torationalizetheconstructionofextrusionpresses,resultedinthestandardizationofextrusiontoolingin(DIN24540).Withinthelast30years,thepressmanufacturingcompanieshaveintroducedstandardizeddesignsontothemarket.
Table3.1showsthefeaturesofextrusionpressesforlightmetals,heavymetals,andsteel.
Themainfeatureofthedirect-extrusionpressisthestationarycontainerduringextrusion.Thedie,whichisalsostationary,andthesupporttoolingarelocatedatoneoftheendfacesofthecontainer,infrontofthecontainerbore((管、圆筒的)空心部分,膛孔).Oppositethedie,thedummyblocklocatedinfrontoftheextrusionstempushesthebilletthroughthecontainerbore,andthesectionemerges(形成,出现)throughthedie(Fig.3.1).
Thegeometricproportions(比例;大小)fordifferentdesignsfordirectextrusionareshowninFig.3.2.
Themostcommondesignofextrusionpresstodayistheprestressed(预应力的)four-columnpress(四柱压力机).Itisusuallybuiltwithastandardstroke(行程,冲程),whichprovidesgoodaccessandeasymaintenance(维护,保持,维修).
Inastandard-strokepress,thebilletisloadedbetweenthecontainerandthestem.Thepressstrokeisdeterminedbytheloadingstrokeandtheextrusionstroke.Therearenospecificrequirementsplacedonthequalityofthebilletgeometry;itisnotimportantforthebilletloading.Over95%ofextrusionpressesinextrusionplantsarestandard-strokes.
Figure3.3showsa75MNaluminumextrusionpresswithextrusiontoolingfortheextrusionofroundandflatbillets.ThemovingcrossheadhasX-guidingsimilartothecontainerholder.Thecontrolandinformationsystemstomonitor(监视,监听,监督)andoptimize(使最优化,使完善)theextrusionprocesscanbeseenintheforeground(最显著的位置).
Theshort-strokepressiscompact(紧凑的,紧密的,简洁的)andrequireslessspace.Theshortstroke(approximately60%ofthestandardstroke)includestheextrusionstrokeandafreestrokeformanipulation(操作;操纵;处理).Therearethreedifferentdesigns.
Thebillet-loadingrequirementsareeither:
●Billetloadingwithabilletloaderinthefreespacebetweenthedieandthecontainer,withthebilletclamped(夹住,夹紧)onthepresscenterline(themostcommondesign)
●Freespacebyextrusionstemtransversemovementonthemovingcrosshead(billetloadingwithabilletloaderbetweenthemovingcrossheadandthecontainer)
●Threecontainersthatcanberotated(旋转)aroundacolumnofthepressframe(框,结构,骨架)(billetloadingwithoutabilletloaderinoneofthethreecontainersoutsidethepress)
Figure3.4showsthecontroldesk,movableauxiliary(辅助的)controldesk(swinging(旋转的)),hotlogshear(圆棒剪)withthebilletloader,andtheshort-strokepressforaluminumalloys.Thecontainerisintheextrusionposition.Thebilletisloadedbetweenthedieandthestemwhenthecontainerhasmovedbackoverthestem.Thebilletmustbeheldexactlybetweenthedieandthestemonthepresscenterline.Thisensuresthattheclearancebetweenthebilletandthecontainerisasuniformaspossible,guaranteeingperfectupsetting(缩锻,镦锻)ofthebilletinthecontainer.
Thetolerance-relateddiametervariationsmustbecompensated(补偿)bythebilletloadertoensurethatthebilletcanbeclampedonthepresscenterline(Fig.3.5).Thisensuresthattheupsettingofthebillettakesplaceunderoptimalconditionsbecauseoftheequalclearanceonallsidestothecontainerbore.Airinclusionsarelesscritical,andtransverseforces,evenifacceptabletoasmalldegree,areavoidedduringupsetting.
Short-strokeextrusionpresseshavebeenthestateoftheartforsometime.Therearevariousreasonsforthis.Schloemannbuilttwo125MNrod-and-tubeextrusionpressesforaluminumaroundapproximately1950.Theseweremanufacturedasshort-strokepressesforproductionreasons,withbilletloadingbetweenthedieandthecontainer.Thestemtransversemovementwasusedbeforetheendofthelastcentury.Thelengthofexpensivepresscomponents,includingcolumnsandthemaincylinder,canbekepttoaminimum.
ThecompanyLoewybuiltasteeltubeextrusionpressin1960,withthreecontainersthatcouldberotatedaroundacolumn.Theaimwashigh-throughput(高生产量)extrusionwithfastpresscycles.Inpractice,thiswasunsuccessful.Themanipulationoftheheavyheatedcontainerswasonlypossiblewithexpensivetechnology.Temperaturevariationswithinthecontainerholderaswellasinadjacent(毗连的,邻近的,接近的)presscomponentscouldnotbeavoidedduringproduction.Accuratelocationoftherotatingcontainersonthepresscenterlineandinlinewiththestemandthediecouldnotbeguaranteedtothenecessaryreproducibility.Thecontinuousmovementofthelargecontainers,threerotationsof120ºwithinanextrusioncycle,requiredextensivemaintenanceandregularrepair.Onlyafewpresseswerebuilttothisdesignandactuallyusedforproduction.Ingeneral,short-strokepressesaremoreexpensivethanstandard-strokepressesbecauseofthemanipulationneededforbilletloadingandthemechanicaldesign.
注释:
bore[bɔ:
](管、圆筒的)空心部分,膛孔.
emerges[i'mə:
dʒ]形成,出现
proportions[prəu'pɔ:
ʃən]比例;大小
prestressed[pri:
'stres]预应力的
four-columnpress四柱压力机.
stroke[strəuk]行程,冲程
maintenance['meintinəns]维护,保持,维修
monitor['mɔnitə]监视,监听,监督
optimize['ɔptimaiz]使最优化,使完善
foreground['fɔ:
ɡraud]最显著的位置.
compact['kɔmpækt]紧凑的,紧密的,简洁的
manipulation[mə,nipju'leiʃən]操作;操纵;处理
clamped[klæmp]夹住,夹紧
rotated[rəu'teit]旋转
frame[freim]框,结构,骨架
auxiliary[ɔ:
ɡ'ziljəri]辅助的
swinging['swiŋiŋ]旋转的
upsetting[ʌp'setiŋ]缩锻,镦锻
compensated['kɔmpenseit]补偿
high-throughput高生产量
adjacent[ə'dʒeisənt]毗连的,邻近的,接近的
3.1.2MainSubassembliesoftheDirectExtrusionPress
Alle
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