Abstract
An extrusion method using an extrusion press including an end platen to which a pressure ring is provided, a die, a container, a drive part for movement of the container, and a main cylinder device having an extrusion stem to form a billet into a shape includes extruding the billet loaded in the container by the extrusion stem from the die to shape it to an extruded material, releasing sealing pressure from the die, cutting the billet between the die and the container and between the die and the pressure ring by moving the die, and resuming shaping of extruded materials by the billet remaining inside the container.
Claims
1. An extrusion method using an extrusion press including an end platen to which a pressure ring is provided, a die, a container, a drive part for movement of the container, and a main cylinder device having an extrusion stem to form a billet into a shape, the method comprising: extruding said billet loaded in said container by said extrusion stem from said die to shape it to an extruded material, releasing sealing pressure from said die, shearing said billet between said die and said container and between said die and said pressure ring by moving said die, and resuming shaping of extruded materials by the billet remaining inside said container, wherein a container core holding device is attached to an upper guide of said container so that the core of said container does not change when shearing said billet.
2. The method according to claim 1, further comprising exchanging said die, wherein said shearing is performed when a predetermined length of an extruded material is extruded, then said exchanging said die is performed.
3. The method according to claim 1, further comprising performing said shearing when extruded material leaks from the space between the die and container to the outside.
4. The method according to claim 3, wherein a swingable shear knife is attached to a die cassette of said die to contact an end surface of the container when shearing said billet in said shearing.
5. The method according to claim 1, comprising performing said shearing when extruded material sticks in the die.
6. The method according to claim 1, further comprising enabling positioning of a space between said container and said die when releasing said sealing pressure from said die and shearing the billet between said die and said container.
7. An extrusion method using an extrusion press including an end platen to which a pressure ring is provided, a die having a die ring and bolster, a container, a drive part for movement of the container, and a main cylinder device having an extrusion stem to form a billet into a shape, the method comprising: extruding said billet loaded in said container by said extrusion stem from said die to shape it to an extruded material, releasing sealing pressure from said die, shearing said billet between said die ring and said container and between said die ring and said bolster, and resuming shaping of the extruded material by the billet remaining inside said container, wherein container core holding device is attached to an upper guide of said container so that the core of said container does not change when shearing said billet.
8. The method according to claim 7, further comprising exchanging said die, wherein said shearing is performed when a predetermined length of an extruded material is extruded, then said exchanging said die is performed.
9. The method according to claim 7, further comprising performing said shearing when extrusion material leaks from the space between the die and container to the outside.
10. The method according to claim 9, wherein a swingable shear knife is attached to a die cassette of said die to contact a container sealing surface when shearing said billet in said shearing.
11. The method according to claim 7, comprising performing said shearing when extrusion material sticks in the die.
12. The method according to claim 7, further comprising enabling positioning of a space between said container and said die when releasing said sealing pressure from said die and shearing the billet between said die and said container.
Description
BRIEF DESCRIPTION OF DRAWINGS
(1) FIG. 1 is an overall schematic side view of an extrusion press of the present invention.
(2) FIGS. 2(a) and 2(b) are detailed side cross-sectional views of billet cutting in the present invention. They show a first embodiment of a case of cutting by the die 4 as a whole. FIG. 2(a) is a side cross-sectional view at the time of interrupting extrusion before cutting the billet and FIG. 2(b) is a side cross-sectional view when the die rises and cuts the billet.
(3) FIGS. 3(a) and 3(b) are detailed side cross-sectional views of billet cutting in the present invention. They show a second embodiment of a case of cutting by the die ring 29 as a whole. FIG. 3(a) is a side cross-sectional view of the time when interrupting extrusion before cutting the billet. FIG. 3(b) is a side cross-sectional view of the time when the die ring rises and cuts the billet.
(4) FIGS. 4(a) to 4(d) are detailed views of the die of the present invention. FIG. 4(a) is a plan view of a die cutting block (in the present embodiment, 36) rising together with the die in the first embodiment of the case of cutting by the die as a whole. FIG. 4(b) is a plan view of a die ring cutting block (in the present embodiment, 37) rising together with the die ring in the second embodiment of the case of cutting by only the die ring 29. FIG. 4(c) is a front view showing a die slide 38 etc. used for die exchange in FIG. 4(a) or FIG. 4(b). FIG. 4(d) is a front view of a die cassette 35 in the case of cutting in the direction of movement of the die slide 38 in FIG. 4(c).
(5) FIGS. 5(a) and 5(b) are views of an end platen, die, and container in the present invention. FIG. 5(a) is a side cross-sectional view of a die cutting device, while FIG. 5(b) is a front cross-sectional view of a container core holding device.
(6) FIG. 6 is an explanatory view for explaining a space positioning device between a container and die in the present invention.
(7) FIGS. 7(a) to 7(f) are explanatory views of the flow of operation at the time of cutting by a die ring of FIG. 3(b) of the present invention.
(8) FIGS. 8(a) to 8(f) are explanatory views of the flow of operation combining the method of making the die ring move to cut the billet in the present invention and the method of removing the discard without using a main shear.
(9) FIGS. 9(a) to 9(f) are explanatory views of the flow of operation combining the method of making the die of FIG. 2(b) move to cut the billet in the present invention and the method of removing the discard without using a main shear. FIGS. 9(a) to 9(f) are plan cross-sectional views seen from above. FIG. 9(b) includes being seen from side.
(10) FIGS. 10(a) and 10(b) are view of attachment of a swingable shear knife to a die cassette of the present invention.
DESCRIPTION OF EMBODIMENTS
(11) Embodiments of the method for extruding a billet from a die to form it into a shape in an extrusion press according to the present invention will be explained below in detail while referring to the drawings using a ferrous metal or aluminum among nonferrous metals as examples.
(12) First, the extrusion press of the present invention will be explained in brief using FIG. 1. An end platen 1 side is made the front and a main cylinder 2 side is made the rear. As shown in FIG. 1, the extrusion press used in the present invention has an end plate 1 and a main cylinder 2 arranged facing each other and connects the two by a plurality of tie rods 3. At the inside surface of the end platen 1 (surface at rear side), a container 5 is arranged facing a die 4 formed with extrusion holes. Inside the container 5, a billet 6 is loaded. By pushing this toward the die 4, an extruded material 14 having a cross-section corresponding to the holes is extruded. At the end platen 1, a pressure ring 25 receiving pushing force from the die 4 is attached. The container 5 is moved by the moving means comprised of a container movement drive part (cylinder rods 15, 61, etc. in FIG. 6).
(13) The main cylinder 2 generating the extrusion force houses a main ram 9. This can be pressed and moved toward the container 5. At the front end part of this main ram 9, an extrusion stem 7 is attached to the main crosshead 8 in a state sticking out toward the container 5 so as to be arranged coaxially with a billet loading hole of the container 5. At the front end of the extrusion stem 7, a dummy block (not shown) is attached in close contact. Therefore, if driving the main cylinder 2 to make the main crosshead 8 advance, the extrusion stem 7 is inserted into the billet loading hole of the container 5. The extrusion stem 7 presses against the back end face of the loaded billet 6 to extrude the extruded material. The extrusion press apparatus of the present invention comprises the end platen 1, die 4, container 5, drive part for movement of the container, main cylinder 2 having the extrusion stem 7, etc.
(14) At the main cylinder 2, a plurality of side cylinders 10 are arranged parallel to the center of the axis of the extrusion. Their cylinder rods 11 are connected with the main crosshead 8. Due to this, as a preparatory step of the extrusion step, the extrusion stem 7 is initially made to move until the front end of the billet 6 abuts against the die 4. The operation for pressing and extrusion is performed using both the main cylinder 2 and the side cylinders 10.
(15) First Embodiment
(16) FIGS. 2(a) and 2(b) are views explaining cutting by the die 4 as a whole in the present invention. The die 4 is comprised of a die ring 29 and a bolster 30. The die 4 of FIGS. 2(a) and 2(b) is for the case of extruding multiple extruded materials 14. The die ring 29 is comprised of a backer 291 and a die 292. The die cutting cylinder 27 and support 28 sandwich and fasten the die 4. By driving the die cutting cylinder 27, the die 4 moves vertically. In the case of FIGS. 2(a) and 2(b), the die 4 moves vertically, but it may also move horizontally due to the die slide cylinder rod 39 like in FIG. 4(d). In normal extrusion, after a predetermined length is extruded, the extrusion is ended or interrupted and the sealing pressure is released from the die 4. The die cutting cylinder 27 is driven to simultaneously make the die ring 29 and bolster 30 rise. At this time, the billet material is simultaneously cut (sheared) between the container 5 and die 4 and between the pressure ring 25 and die 4. Due to this, the billet 6 is cut by the shearing force. In FIG. 2, the die 4 is designed to move vertically, but it may also move horizontally due to the die slide cylinder 39. When the billet 6 finishes being cut, the extrusion is resumed or the die 4 is exchanged. If the die cassette 35 moves horizontally and the die 4 is exchanged, there is no need to return to the original center of the extrusion press. If the die 4 is not exchanged, the die cassette 35 returns to the original center of the extrusion press.
(17) Second Embodiment
(18) FIGS. 3(a) and 3(b) are views for explaining cutting of the billet 6 by the die ring 29 of the present invention. The die 4 is comprised of a die ring 29 and a bolster 30. The die cutting cylinder 27 and support 28 sandwich and fasten the die ring 29. By driving the die cutting cylinder 27, the die ring 29 moves vertically. In normal extrusion, after a predetermined length is extruded, the extrusion is ended or interrupted and the sealing pressure is released from the die 4. As shown in FIG. 3(b), the die cutting cylinder 27 is driven to make only the die ring 29 rise. At this time, the billet material is simultaneously cut between the container 5 and die ring 29 and between the bolster 30 and die ring 29. Due to this, the billet 6 is cut by the shear force. When the billet 6 finishes being cut, the extrusion is resumed or the die 4 is replaced.
(19) FIG. 4(a) shows the die cutting block 36 of the first embodiment for the case of cutting by the die as a whole. This corresponds to FIG. 2(b). FIG. 4(b) is a view of the cutting block 37 of the second embodiment in the case of cutting by only the die ring 29. This corresponds to FIG. 3(b). When cutting the billet 6, the die cutting cylinder 27 is driven and the regions of the member shown by hatchings in FIG. 4(a) and FIG. 4(b) are respectively simultaneously lifted upward to cut the billet 6. The die cutting blocks 36, 37 move up and down by the die cutting cylinder 27 from the die cassette 35. Further, in FIG. 4(d), the die slide 38 is driven by the die slide cylinder rod 39 at the time of exchange of the die or when the die 4 moves horizontally and cuts the billet 6. At the time of exchanging a die, the die 4 is unloaded to the outside of the extrusion press.
(20) FIG. 5(b) is a view of a container core holding device 20 of the present invention. The core holding device 20 is attached at the position of each of the two tie rods 3 above the extrusion press. A taper seat 21 is attached to each tie rod 3. On the other hand, at the upper guide 24 of the container 5, a hydraulic cylinder 23 is attached. At the rod of the hydraulic cylinder 23, a taper block 22 is attached. By driving this taper block 22 by the hydraulic cylinder 23, the taper block 22 and taper seat 21 closely contact each other. By pushing against each other, even if the die cutting cylinder 27 wants to push the die 4 upward or even if it wants to move it in the horizontal direction, a holding force acts on the container 5. Due to this, the core 5c of the container 5 will not deviate. Reference numeral 26 shows the main shear of the discard cutting device.
(21) FIG. 6 is a view of a space positioning device between a container and die in the present invention. Each cylinder rod 61 of the hydraulic cylinder 60 attached to the end platen 1 has a shim 62 bolted to it. The cylinder rod 61 is designed to push against the container holder 12. At the limit of advance of the cylinder 60, the space between the container and die is adjusted by the shim 62 to become S. This space S is set so that metal sticking does not occur when cutting the billet. Note that this position of the hydraulic cylinder 60 is the position shown by the notation 32 of FIG. 5(b) and includes two locations.
(22) FIGS. 7(a) to 7(f) show the flow of operation in the case of cutting using a die ring 29 of the present invention. (a) A certain length of extruded material is extruded, then the extrusion is ended or interrupted to release the sealing pressure from the die 4. (b) The die ring 29 is moved vertically to thereby simultaneously cut the billet 6 between the container 5 and die ring 29 and between the bolster 30 and the die ring 29. (c) The extrusion is resumed. (d) One billet 6 finishes being extruded. (e) The main shear 26 descends to cut off the discard 16. (f) The die ring 29 moves for cutting the billet 6, then the die cassette 35 moves for exchange of the die 4.
(23) FIGS. 8(a) to 8(f) show the flow of operations when combining the method of the present invention of making the die ring 29 move vertically to cut the billet and the method of removing the discard 16 without using the main shear 26. FIGS. 8(d) and 8(e) are views of an extrusion press seen from above. (a) A certain length of extruded material is extruded, then the extrusion is ended or interrupted to release the sealing pressure from the die 4. (b) The die ring 29 is moved vertically to thereby simultaneously cut the billet 6 between the container 5 and die ring 29 and between the bolster 30 and the die ring 29. (c) The extrusion is resumed. (d) One billet 6 finishes being extruded. (e) After the completion of the extrusion, the die 4 is moved horizontally to thereby simultaneously cut the billet 6 between the container 5 and die ring 29 and between the bolster 30 and the pressure ring 25. Simultaneously, the extrusion stem 7 advances and the discard 16 is pushed out. (f) The die cassette 35 moves for cutting and exchange of the die 4.
In the above way, in the present invention, the billet 6 is cut between the die 4 and container 5, so only a short discard 16 remains inside the container 5. If the discard 16 is pushed out by the extrusion stem 7, the discard 16 can be easily removed, so the main shear 26 like in the prior art becomes unnecessary.
(24) FIGS. 9(a) to 9(f) show the flow of operations when combining the method of the present invention of making the die 4 move horizontally to cut the billet and the method of removing the discard 16 without using the main shear 26. FIG. 9 except FIG. 9(b) is a view of an extrusion press seen from above. FIG. 9(b) includes the case of viewing from the side. (a) A certain length of extruded material is extruded, then the extrusion is ended or interrupted to release the sealing pressure from the die 4. (b) The die 4 is moved horizontally to thereby simultaneously cut the billet 6 between the container 5 and die 4 and between the pressure ring 25 and die 4. (c) The die 4 is replaced or the same die 4 is used to resume extrusion. (d) One billet finishes being extruded. (e) After the completion of the extrusion, the die 4 is moved horizontally to thereby simultaneously cut the billet 6 between the container 5 and die 4 and between the pressure ring 25 and die 4. Simultaneously, the extrusion stem 7 advances and the discard 16 is pushed out. (f) The die cassette 35 moves for exchange of the die 4.
In the above way, in the present invention, the billet 6 is cut between the die 4 and container 5, so only a short discard 16 remains inside the container 5. Therefore, if the discard 16 is pushed out by the extrusion stem 7, the discard 16 can be easily removed, so the main shear 26 like in the prior art becomes unnecessary.
(25) FIG. 10 is a view of a shear knife 71 attached to a die cassette. When cutting between the die 4 or die ring 29 and the container 7, metal deposits on the container 7 surface. The shear knife 71 supported at one end by the top and bottom springs 72 removes the deposited metal by swinging about the shaft 76. Similarly, when the die cassette moves horizontally as well, it is possible to arrange the shear knife 71 in the perpendicular direction so as to give the same function as the above.
(26) (1) In the prior art, the billet was broken between the die and container after making the container retract, then the parts of the extruded material sticking out from the die and container were cut off by shear knives. Therefore, a long stroke was required for making the container and extrusion stem retract from the die. As opposed to this, the present invention is not configured to use shear knives for cutting, but just cuts the billet by the die or die ring, so the time is shortened and the productivity is improved.
(27) (2) In the prior art, to cut off the billet, a die side shear knife and a container side shear knife were used to cut off parts and the die cassette was moved, so the part of the billet remaining inside the die slide ended up becoming scrap. As opposed to this, in the present invention, only an amount of the length of the die ring becomes scrap, so the yield ratio is improved. Furthermore, there is no end material of the aluminum material, so separation of the die ring and bolster is easy and die handling is easy.
(28) (3) In the prior art, the billet was broken between the die and the container by making the container retract, so the fracture surfaces became distorted and even if parts were cut off by the shear knives, the billet did not become sufficiently flat. As a result, there was the possibility of blister-like shape forming at the next product. As opposed to this, in the present invention, the cut surfaces are clean, no blister-like form, and the quality is improved.
(29) (4) In the prior art, the extruded material sticking out from the container side was pressed and compressed and the next die was exchanged with. At this time, the billet inside the container is formed in a state of work hardening, so does not easily become flat, so there was the possibility of blister-like shape forming at the next product. As opposed to this, in the present invention, the cut surfaces are clean, no blister-like form, and the quality is improved.
(30) (5) In the present invention, the main shear which was attached in prior art for cutting the billet between the die and the container becomes unnecessary, so the cost of the installation members is reduced and simultaneously the facility becomes lower in height and space is saved. Further, the cycle time becomes shorter and maintenance is no longer required.
REFERENCE SIGNS LIST
(31) 1. end platen
(32) 2. main cylinder
(33) 3. tie rod
(34) 4. die
(35) 5. container
(36) 6. billet
(37) 7. extrusion stem
(38) 8. main crosshead
(39) 9. main ram
(40) 10. side cylinder
(41) 11. side cylinder rod
(42) 12. container holder
(43) 13. machine base
(44) 14. extruded material
(45) 15. container cylinder rod
(46) 16. discard
(47) 17. dummy block
(48) 20. container core holding device
(49) 21. taper seat
(50) 22. taper block
(51) 23. hydraulic cylinder
(52) 24. upper guide
(53) 25. pressure ring
(54) 26. main shear
(55) 27. die cutting cylinder
(56) 28. support
(57) 29. die ring
(58) 30. bolster
(59) 31. container key
(60) 32. container and die space positioning device
(61) 35. die cassette
(62) 36. die cutting block
(63) 37. die ring cutting block
(64) 38. die slide
(65) 39. die slide cylinder rod
(66) 60. container and die space positioning cylinder
(67) 61. container and die space positioning cylinder rod
(68) 62. shim
(69) 71. knife
(70) 72. spring
(71) 76. shaft
(72) 77. die slide gib
