We understand AluminiumAluminium Extrusion Presses

We understand AluminiumAluminium Extrusion Presses

The high innovation potential of aluminium in new process technologies and applications imposes growing demands on equipment manufacturers. In particular, the growing use of high-quality extrusions calls for narrower quality tolerances and superior levels of process reliability and repeatability. Additional cost savings and increasingly extensive automation and process control capabilities have become vital objectives in plant innovation.

As a co-ordinating equipment expert, OTTO JUNKER provides advanced solutions for all extrusion

plant processes, from the casthouse to the point of transfer to the packing line,

thus ensuring the cost-effectiveness of your capital expenditure.

OTTO JUNKER extrusion

2

* Billet diameter depending on the requested specific pressure ** Other billet lengths on request *** Extrusion speed (mm/sec) may be different with more pumps.

Each single link of the complete process chain is important for product quality and operating costs.

This process chain starts in the casthouse with melting, casting and homogenizing, followed by billet preparation, extrusion and press run-out / handling operations, down to the final heat treatment with transfer to the packing line.

Range of aluminium extrusion presses:

Extrusion force 18MN 25MN 28MN 35MN 44MN 55MN 65MN

Billet diameter* 7“/8“ 8“ 9“ 10“ 11“ 12.5“ 14“

Billet length max. – mm ** 900 1050 1200 1300 1500 1500 1600

Installed power – kW 450 750 950 1000 1400 1600 1900

Extrusion speed – mm/sec *** 19 25 25 27 27 25 22

Pre-stressed columns Option Option Option Yes Yes Yes Yes

3

The OTTO JUNKER short-stroke, front loading type press has the following major advantages:

Press installed on floor level which results in:Low installation costsLow civil works costsEasy access for maintenance

The shortest dead cycle time on the marketLess wear due to the short strokeVery rigid structureManufacturing according to quality standard ISO 9001First-quality hydraulic unitMain cylinder, platen, columns and container holder made of forged steelExtra large tie-rods for a longer lifetime

•••

Reliable loading of two-part billetsSpecial OTTO JUNKER billet clamping cyclePerfect loading of the billet in the press centre line

Less explosion in the containerLonger lifetime of the diesSimple degassing sequenceFewer blisters on the extrusion

Automatic die changing device on the press operator sideAutomatic dummy block lubricationPrecise butt shear blade and butt ejectorClamping of the die during shearingFixed dummy block with large flexibility always remaining in the container

Less alignment problems / less risks

••••

•

A VERY SUCCESSFUL DESIGN

All the Big Names in extrusion press manufacturing are promoting the short-stroke press, the top of them are promoting “short stroke, front loading”.

Advantages of the short-stroke, front loading press are now very well known:

Main cylinder stroke reduced by 50 %, reducing the wear.Length of columns and distance between column centres reduced by 30 %.Much stiffer platen, which means

Less deflection on dies and easier adjustmentBetter tolerances on extruded sections

Major press components lasting longerThe definitely shortest dead cycle timeSmooth motions without hydraulic shocks

••

Billet upsettingThe billet is clamped in press axis between the die and the fixed dummy block. Symmetrical upsetting deformation, avoids press bending or die uplift phenomena.

Better degassing on fixed dummy block side, die side and between the faces of the two-part billets. The upsetting stroke is calculated and controlled for each individual billet.

The maximum upsetting pressure is adjustable. Optimum starting of the extrusion process multi-hole dies.

4

Press structureOversize tie-rods or pre-stressed columnsSolid forged steel platenForged main cylinderPress dimensions calculated for continuous operation at the breakthrough forceBronze bushingsCylinder with adjustable chevron packings Finite element calculation

5

Billet loaderHorizontal transfer of the billet from the furnace axis to the press.Precision of positioning < 0.3 mm.No mechanical stops for positioning.Billet loader structure located above ground level.The billet is clamped by two jaws to hold one- and two-part billets. Opening of the jaws is automatically adjusted to the billet length.The billet loader is linked with the press to have safe loading between the dummy block and the die.

Butt shear

StructureA vertical slide hydraulically actuated by a shear cylinderRigid structureLong and square guidance with adjustable bronze padsPneumatic butt ejectorSharp blade for precise cutting.Butt fall detection

Automatic positioning (Option)The shear frame can tilt slightly, then the shear is automatically sealed against the die by a hydraulic cylinder. Whatever the die face position, the shear blade is aligned with the die face for precise shearing.

Vertical die clamping devicesThe die is vertically clamped in the press centre line to maintain a precise vertical position during butt shearingA hydraulic cylinder moves the clamping device

Automatic shear blade lubricationAvoids any sticking of the sheared butt on the blade.Special soluble oil (without graphite) is sprayed on the bladeAutomatic lubrication done during each cycle

Vertical die clamping

Butt shear positionning

Horizontal die clamping

Profile shear

Butt shear

6

Billet and dummy block lubrication deviceBoron nitride lubricating device consisting of electrostatic powder system with two automatic powder guns.

One gun outside the press to lubricate the billet face during transfer from furnace to press. Second gun on a movable system on the container holder to lubricate dummy block.

PlatenMuch stiffer platen, which means:

Less deflection on dies and easier adjustmentBetter tolerances on extruded sections

Major press components lasting longerThe definitely shortest dead cycle timeSmooth motions without hydraulic shocks

••

Container holderSingle-piece rigid structureFinite element calculationGuided on bottom members. Safety top shoes resting on the upper membersExtended guide length prevents skewing effectAccurate and easy adjustment, both horizontally and verticallyContainer cylinders on both sides of the main cylinder – short cylinder rods – easy accessContainer cylinders and movable crosshead cylinders interchangeable

Quick tool changing device (Die Slide)2 cassettes in operation, located on operator sideDie stack is supported in two “U”-shaped die holdersTool changing in automatic modeDie changing device is electrically driven

7

Hydraulic equipmentTank above the pressPumps at floor level (or underground)Pumps under loadEasy access for maintenanceEasy sound proofing around the pumpsCartridge valves to DIN standard mounted in forged steel manifolds give

Quick switching proceduresReliabilityCircuit tightness

Variable-delivery pumps with automatic power ratingAutomatic compensation for internal leakages as a function of working pressureElectronic pressure measuring system

•••

Switch and control gearProgrammable logic controller with two Central Processing Units and high scanning speedAutomatic fault detection systemColour video monitor on press control desk for display of faults and operating parametersKeyboard for selection of extrusion parameters

Press running modesManual modeSemi-automatic modeAutomatic modeAutomatic die changeAutomatic “just in time” (JIT)Dry cycleDie trial cycle with a billet of 350 mm lengthWith burp cycle:

No. 1: press and container decompressionNo. 2: container backstroke about 3 mm

••

OptionsAdditional pumpsPump sound insulation enclosureQuick removal of container and stemPC for control of production and process parametersMulti-zone container heating and coolingButt discharge by conveyor or elevatorHot billet shearPumps undergroundBoosting pumps with on-line filtration and coolingAutomatic hydraulic fault detectionPre-stressed tie rod members

Die OTTO JUNKER Group bietet ein umfangreiches Prodzktionsprogramm für die Herstellung von Aluminium-Halbzeugen . Die folgenden Anlagen gehören ebenfalls zu unseren Produktionsprogramm

The OTTO JUNKER Group offers an extensive range of products for the manufacture of semi-finished aluminium products. Furthermore, our product range includes the following:

Process competence: OTTO JUNKER has the capability to supply sophisticated lines from a single source. The product range of the OTTO JUNKER Group covers the entire process chain, from the casthouse to the profile destacker serving as interface with the packing line. Our equipment is supplied to the aluminium extrusion industry all over the world.

Technological competence: The OTTO JUNKER Group has many decades of experience and remains committed to ongoing product development and improvement. As a result, our equipment will embody the most up-to- date technology at all times. Apart from proprietary development, OTTO JUNKER cooperates closely with the Technical University of Aachen (RWTH).

Fuel-fired melting and pouring furnaces

Billet and log heaters Extrusion handling systems Ageing ovens

Continous homogenizing lines Log magazines

OTTO JUNKER GmbHPostfach 11 80 • D-52147 Simmerath

Phone: +49 2473 601-0 Fax: +49 2473 601-600

E-Mail: info@otto-junker-group.com

www.otto-junker-group.com