CROSS-REFERENCE TO RELATED APPLICATION

[0001] This PCT International Patent Application claims the benefit of U.S. Provisional Patent Application Serial No. 63/254,746, filed on October 12, 2021 and titled “Extrusion System,” the entire disclosure of which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0002] The present invention relates to an extrusion system. More particularly, the present invention relates to an extrusion system including an improved material exchanging process for providing improved throughput and for minimizing waste.

2. Related Art

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] Automobiles are the subject of a continuing effort to reduce weight and increase fuel efficiency without detracting from performance. This desire to increase fuel efficiency is both economically and environmentally motivated and has led to a reduction in the weight of a variety of automotive components. These automotive components may be made from a variety of materials, including steel, aluminum, composites, alloys, etc., each of which have various benefits depending on end-use requirements. There are numerous methodologies that are utilized in the formation of automotive components. One of the more popular methods of forming automotive parts is via an extrusion process. In typical extrusion processes, a billet of metal (or another material) is forced to flow and through an opening in a die assembly that has a cross-section for a desired component shape. Extrusion processes are particularly popular in the automotive industry because components can be formed that meet tight tolerance requirements without much material waste and high production volumes. The costs of current extrusion processes can be negatively impacted by a reduction in productivity associated with a billet exchange process when a new billet is required, and costs associated with recycling excess engineered scrap.

[0005] More particularly, a reduction in productivity can occur when the extrusion process is temporarily halted to accommodate an exchange of a billet when additional materials are required. The duration of this non-productive period can directly impact the productivity and throughput of the entire system.

[0006] Furthermore, current extrusion systems often produce two types of “engineered scrap” due to inefficiencies. Engineered scrap generally refers to the billet materials which are not converted into saleable extruded product. A first type of engineered scrap is “start-up scrap,” which is extruded material that is created prior to the system operating at steady state conditions. More particularly, during a production delay associated with exchanging a billet, a temperature of the extrusion die decreases. During the startup period associated with replacement of the billet, the die temperature and temperature of the feedstock increase until steady state conditions are achieved. The dimensions and material properties of the extruded material manufactured during the start-up event is not representative of the extruded material manufactured during steady state conditions, thus this material is recycled. Furthermore, “feedstock scrap” refers to material associated with an outer periphery of a billet and the end of the billet that is retained in the container, which is recycled.

[0007] Accordingly, there is a continuing desire to further develop and refine extrusion systems and processes such that they are more efficient and produce less scrap. SUMMARY OF THE INVENTION

[0008] It is an object of the present disclosure to provide an extrusion system that provides increased productivity of a shear extrusion process by reducing a time increment associated with a billet exchange process and reducing production of start-up scrap and feedstock scrap.

[0009] According to these and other aspects of the disclosure, an extrusion system includes a die located about and along an axis and defining at least one extrusion opening. A primary container defines a channel for holding a first billet to be extruded. The primary container is movable into a position in which the channel of the primary container is aligned with the die along the axis. At least one supplementary container defines a channel for holding a supplementary billet to be extruded. The supplementary container is movable into a position in which the channel of the supplementary container is aligned with the die along the axis. A ram is movable along the axis for axially pushing the first and supplementary billets toward the die for passing material of the billets through the at least one extrusion opening of the die.

[0010] According to the above and other aspects of the disclosure, a method for extruding a component is provided. The method includes providing a die located about and along an axis and defining at least one extrusion opening. The method also includes positioning a primary container adjacent to the die, with a channel of the primary container axially aligned with the die. The channel of the primary container contains a first billet. The method also includes axially pushing the first billet into the die with a ram such that material of the first billet is extruded through the at least one extrusion opening of the die. The method also includes positioning a supplementary container such that a channel of the supplementary container is axially aligned with the die. The channel of the supplementary container contains a supplementary billet. The method also includes axially pushing the supplementary billet into the die with a ram such that material of the supplementary billet is extruded through the at least one extrusion opening of the die.

[0011] The above-described arrangement and method provide a capability of quickly exchanging billets via the supplementary containers while minimizing an interruption to the extrusion process and minimizing a temperature loss associated with container exchanges. This arrangement and method also utilize low federate start-up to increase die temperatures to minimize an amount of startup scrap produced after the billet is exchanged.

[0012] According to the above, and other aspects of the disclosure, another extrusion system includes a die located about and along an axis and defining at least one extrusion opening. A primary container defines a channel along the axis which holds a first billet. At least one supplementary billet is axially aligned with and positioned in end to end relationship with the first billet. At least a pair of pushers are movable along the axis, where each of the pushers are in engagement with at least one of the billets and configured to axially push the at least one of the billets toward the die for passing material of the billets through the at least one extrusion opening of the die to extrude the material of the at least one billet. Each of the pushers are disconnectable from the billets respectively from one another such that the pushers can continuously push the billets toward the die after one or more of the pushers has been disconnected from the billets.

[0013] According to the above and other aspects of the disclosure, another method for extruding a component includes providing a die located about and along an axis and defining at least one extrusion opening. The method also includes positioning a primary container defining a channel holding a first billet adjacent to the die, with the channel of the primary container positioned along the axis. The method also includes axially pushing the first billet with a first pusher against the die such that material of the first billet is extruded through the die. The method also includes positioning at least one supplementary billet in axial alignment, and in end-to-end relationship with the first billet. The method also includes disconnecting the first pusher from the first billet and axially pushing the supplementary billet with a supplementary pusher such that the first and supplementary billets are axially pushed toward the die with the supplementary pusher such that material of the first and supplementary billets may be extruded through the die with the first pusher disconnected from the first billet.

[0014] The above-described arrangement and method eliminate a time increment associated with billet exchange and maintain the extrusion process during the billet exchange process by continuously pushing on the billet that is being processed while moving the other pushers. Furthermore, this arrangement and method advantageously employ the use of a stationary primary container located adjacent to the die assembly, e g., specifically adjacent to a scroll face of the die assembly, throughout the process, which allows the die to always be exposed to an elevated temperature. Due to the continuous operation of the extrusion press, startup scrap associated with feedstock change is avoided.

[0015] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter that form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other embodiments for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent embodiments do not depart from the spirit and scope of the invention as set forth in the appended claims. This section provides a general summary of the disclosure and is not to be interpreted as a complete and comprehensive listing of all of the objects, aspects, features and advantages associated with the present disclosure.

[0016] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The drawings described herein are for illustrative purposes only of selected embodiments and are not intended to limit the scope of the present disclosure. The inventive concepts associated with the present disclosure will be more readily understood by reference to the following description in combination with the accompanying drawings wherein:

[0018] FIGS. 1 A-1E are schematic views of a first embodiment of an extrusion system that is configured to quickly substitute containers containing billets;

[0019] FIGS. 2A-2E are schematic views of a second embodiment of the extrusion system that is configured to substitute containers containing billets;

[0020] FIGS. 3A-3C are schematic views of a third embodiment of the extrusion system that is configured to apply continuous pressure on a billet as additional billets are added;

[0021] FIGS. 4A-4D are schematic views of a fourth embodiment of the extrusion system that is configured to apply continuous pressure on a billet as additional billets are added;

[0022] FIGS. 5A-5I are schematic views of a fourth embodiment of the extrusion system that is configured to apply continuous pressure on a billet as additional billets are added;

[0023] FIG. 6 is a flow diagram illustrating a method of substituting containers during an extrusion process; and [0024] FIG. 7 is a flow diagram illustrating a method of maintaining pressure on billets as additional billets are added during an extrusion process.

DESCRIPTION OF THE ENABLING EMBODIMENT

[0025] Example embodiments will now be described more fully with reference to the accompanying drawings. In general, the subject disclosure is directed to an extrusion system for extruding components. However, the example embodiments are only provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well- known device structures, and well-known technologies are not described in detail.

[0026] Referring to the figures, wherein like numerals indicate corresponding parts throughout the views, embodiments of an extrusion system 10 are generally shown. The system is generally configured to reduce a time increment associated a with a billet (i .e., feedstock materials) exchange process and to reduce an amount of scrap produced during the extrusion process. It should be appreciated that the billets discussed herein may be comprised of metals or other materials.

[0027] More particularly, with initial reference to FIG. 1A, the extrusion system 10 includes a die assembly 12 and feedstock assembly 14. The feedstock assembly 14 includes a primary container 16 and one or more supplementary containers 18, 20. Each of the containers 16,

28, 20 defines a channel 22 for holding, and in some cases, for rotating a billet 24 to be extruded. The containers 16, 18, 20 may each include teeth (not shown) or other structures for holding the billets 24 for co-rotation with the container 16, 18, 20. As shown in FIG. 1A, the container 24 may be divided into an inner component 25a and an outer component 25b, with the inner component 25a being rotatable within the outer component 25b, with the outer component 25b positioned rotationally stationary. Moreover, the billets 24 may include ends with surface topographies 27 (schematically shown in FIG. IE) that permit rotationally joining with other billets 24 to be extruded to facilitate co-rotation and continuous feeding. The channels 22 are generally cylindrical shaped and are configured to be bounded on one end by a ram 26 and another end by the die assembly 12. During operation, the ram 26 moves along a center axis A and pushes the billet 24 into the die assembly 12 to extrude the billet 24 into desired shapes established by the openings 29. According to the example embodiment, the ram 26 is hydraulically actuated, but various types of actuation systems may be employed. The die assembly 12 may include a shearing surface that shears and heats the material to be extruded as well as at least one aperture for permitting the material to flow therethrough and into the extrusion openings 29. It should be appreciated that the shearing surface may be rotatable relative to the portion of the die assembly 12 with the extrusion openings 29. A control system 28 may dictate operation of the extrusion system 10 in all embodiments. The control system 28 may include one or more motors, controllers, and processors that are configured to move the components, and perform the methods described herein.

[0028] As discussed above, the billets 24 may be rotatable relative to the die assembly 12, but alternatively parts of the die assembly 12 may be rotatable relative to the billets 24 to provide the same effect.

[0029] The first embodiment of the extrusion system 10 shown in FIGS. 1A-1E illustrates a capability of quickly exchanging supplementary containers 18, 20 containing supplementary billets 24 while minimizing an interruption to the extrusion process and minimizing a temperature loss associated with container 16, 18, 20 exchanges. This embodiment also utilizes low federate start-up to increase die temperatures to minimize an amount of startup scrap produced after the billet 24 is exchanged.

[0030] More particularly, the extrusion system 10 includes two or more supplementary containers 18, 20 that are configured to be moved with a shuttle (schematically shown as 30 in FIG. 1A) into and out of axial alignment with the primary container 16. During this process, the primary container 16 is exposed to elevated temperatures, whereas the supplementary containers 18, 20 start at room temperature.

[0031] In more detail, in a first step shown in FIG. 1A, a first supplementary container 18 is axially aligned and in engagement with the primary container 16. At the point of the process shown in FIG. 1A, a first billet 24 that was originally located in the primary container 16 has already been extruded through the die assembly 12, thus leaving a supplemental billet 24 in a channel 22 of the primary container 16. As shown, the ram 26 is configured to axially move the billet 24 into contact with the die assembly 12 for extruding the billet 24 (as shown in FIG. 1A). At a point in which the billet 24 has reached a point of extrusion in which the system needs to be replenished with additional materials, as illustrated in a second step shown in FIG. IB, the ram 26 is moved axially outside of the channels 22 of the primary and first supplementary containers 16, 18 in order to provide space for a second supplementary container 20. Accordingly, at this time, the extrusion process temporarily stops. In a third step shown in FIG. 1C, the first supplementary container 18 is shuttled out of alignment with the primary container 16 (e.g., with shuttle 30), and in a fourth step shown in FIG. ID, a second supplementary container 20, which contains a supplementary billet 24, is shuttled toward axial alignment with the primary container 16 (e.g., with a shuttle 30) to a point where the billet 24 in axial alignment and axial engagement with the primary container 16. At this point, the ram 26 is configured to apply an axial force on the newly introduced billet 24 such that both billets 24 are driven toward the die assembly 12. This cycle may be repeated any number of times as materials are needed.

[0032] FIGS. 2A-2E present a second embodiment of the system 10 which is similar to the first embodiment, but at any given time includes only a single primary container 16 which is swapped with other primary containers 16 (e.g., with shuttle 30) when an additional billet 24 is required. In other words, this embodiment is distinguishable from the first embodiment in that only employs a single container 16, 18, 20 at any given time.

[0033] In accordance with the above, as set forth in FIG. 6, a method for extruding a component is shown. The method starts with 100 providing a die assembly 12 located about and along an axis A and defining at least one extrusion opening 29. The method also includes 102 positioning a primary container 16 adj acent to the die 12 with a channel 22 of the primary container 16 axially aligned with the die 12, and where the channel 22 contains a first billet 24. The method also includes 104 axially pushing the first billet 24 into the die 12 with a ram 26 such that material of the first billet 24 is extruded through the at least one extrusion opening 29 of the die 12. The method also includes 106 positioning a supplementary container 18 such that a channel 22 of the supplementary container 18 is axially aligned with the die 12, and where the channel 22 contains a supplementary billet 24. The method also includes 108 axially pushing the supplementary billet 24 into the die 12 with a ram 26 such that material of the supplementary billet 24 is extruded through the at least one extrusion opening 29 of the die 12. The method may also include 110 rotating the die 12 about the axis A during the axial pushing of the first and supplementary billets

12 with the ram 26. According to this approach, the containers 16, 18, 20 and billets 24 may remain stationary. The method may also include rotating the first and supplementary billets 24 during the axial pushing of the first and supplementary billets 24 with the ram 26. According to this approach, the die 12 may remain stationary. The method may also include moving the supplementary container 18 into axial alignment and engagement with the primary container 16 after axially pushing the first billet 24 into the die 24 with the ram 26 and before axially pushing the supplementary billet 24 into the die 12 with the ram 26. The method may also include moving the primary container 16 out of axial alignment with the die 12 and moving the channel 22 of the supplementary container 18 into axial alignment with the die 12 after pushing the first billet 24 into the die 12 with the ram 26 and before axially pushing the supplementary billet 24 into the die 12 with the ram 26.

[0034] In accordance with the above, because of the ability to quickly substitute containers 18, 20 to provide additional billets 24, a reduced time increment associated with the billet exchange process is provided relative to current exchange processes. Accordingly, temperature losses are minimized, which minimizes an amount of scrap produced. More particularly, the temperature lost during the exchanging process is restored by the conduction of heat generated by rotation of the die assembly 12 relative to the billets 24 (or vice versa). Furthermore, the control system 28 is configured to vary a rate of modulating the ram 26 based on extrusion force and die temperature inputs received from temperature and pressure sensors located near the scroll face and extrusion die of the die assembly 12.

[0035] A third embodiment of the extrusion system 10 is shown in FIGS. 3A-3D. This embodiment employs a circumferential continuous pusher concept for maintaining pressure on billets 24 throughout a material replenishing process. As shown, this embodiment includes two or more circumferential holders 32 (pushers) that are configured to be moved independently from one another through a billet 24 replenishing process while always maintaining a constant axial force on the billets 24 being extruded in the primary container 16 / extrusion system 16, thereby providing a continuous operation. More particularly, as with previous embodiments, the system 10 includes a die assembly 12 and a primary container 14 that defines a primary channel 22 for holding and rotating billets 24 to be extruded. The die assembly 12 and primary container 14 may be arranged in the same manner as those discussed above. One or more supplemental billets 24 may be arranged in axial alignment with a primary billet 24 located in the primary container 16. The plurality of holders 32 are configured to circumferentially / radially engage the billets 24 and axially drive I push the billets 24 into the primary container 16. More particularly, each of the holders 32 include a top component 34 and a bottom component 36 that engage the billet 24 on circumferentially opposite sides from one another. Each of the top and bottom components 34, 36 also includes at least one handle 38 for providing movement of the holder 32 against the billet 24. The handles 38 may be connected to various actuating mechanisms, or may be manually operated, for providing the axial and radial forces on the billets 24. As shown, the handles 38 terminate at different radial extents relative to one another to allow the holders 32 to be nested with one another. During operation, as illustrated in FIG. 3B, once the billet 24 associated with the leftmost holder 32 has reached the primary container 16, the leftmost holder 32 is removed from the billet 24 by being moved radially outwardly and moved to another billet 24. The holder 32 and associated billet 24 may then be moved to the rightmost side such that they’re “in line” for processing. During this process, the other holders 32 continue to apply axial pressure on the billet 24 in the primary container 16 via radial and axial pressure on the other billets 24, thus ensuring that no temperature losses are experienced, thereby providing scrap reduction and an efficient overall process. This cycle is repeated as additional materials are needed. [0036] A fourth embodiment of the system 10 is illustrated in FIGS. 4A-4D. This embodiment is similar to the third embodiment in that it includes an arrangement of holders / pushers 32B comprised of top and bottom components 34B, 36B, but the handles 38B of the holders 32B are circumferentially offset relative to one another in order to allow the handles 38B to extend to approximately the same radial distance as one another.

[0037] A fifth embodiment of the system 10 is illustrated in FIGS. 5A-5I. This embodiment is also similar to the second and third embodiments, but the billets 24 each present a protrusion 40 and corresponding shoulder 42 at an axial end. At least one outer pusher 44 is configured to engage the shoulder 42 while a ram 26 constitutes an additional pusher that engages axial ends of the billets 24. More particularly, the outer pusher 44 includes a top component 46 and a bottom component 48 that are positioned on circumferentially opposite sides of the billet 24 from one another. As shown, each of the top and bottom components 46, 48 includes a radially inwardly extending rim 50 that is configured to axially engage the shoulder 42 of the billet 24 to effectuate movement of the billet 24. More particularly, FIG. 5A shows a scenario in which the ram 26 applies an axial force against a billet 24. At this point, the pusher 44 is disconnected from the billet 24. At a point in which the billet 24 is running low on material, the pusher 44 is placed into the position shown in FIG. 5B such that it applies an axial force on the billet 24. At this point, the, ram 26 may be moved axially out of the way to provide another billet 24. As shown in FIG. 5E, a new billet 24 is then positioned into axial contact with the billet 24 in the primary container 16. As shown in FIG. 5F, the ram 26 may then drive both billets 24 axially toward the die assembly 12, and the pusher 44 may be moved radially out of the way until the process needs to be repeatedly.

Accordingly, the pusher 44 permits a force to be applied to the actively processed billet 24 at all times during substitution of billets 24. FIGS. 5G-5I show additional views of embodiments of components of this arrangement.

[0038] With reference to FIG. 7, according to these “continuous pushing” concepts, a method of extruding a component may include 200 providing a die 12 located about and along an axis A and defining at least one extrusion opening 19. The method may also include 202 positioning a primary container 16 defining a channel 22 holding a first billet 24 adjacent to the die 12 with the channel 22 of the primary container 16 positioned along the axis A. The method may also include 204 axially pushing the first billet 16 with a first pusher 26, 44 against the die 12 such that the material of the first billet 24 is extruded through the die 12. The method may also include 206 positioning at least one supplementary billet 24 in axial alignment, and in end-to-end relationship with the first billet 24. The method may also include 208 disconnecting the first pusher 26, 44 from the first billet 24 and axially pushing the supplementary billet 24 with a supplementary pusher 26, 44 such that the first and supplementary billet 24 are axially pushed toward the die 12 with the supplementary pusher 26, 44 such that material of the first and supplementary billets 24 may be extruded through the die 12 with the first pusher 26 disconnected from the first billet 24. During pushing of the billets, the method may also include radially engaging the first and at least one supplementary billets 24 with the first and supplementary pushers 26, 44.

[0039] According to these third through fifth “continuous pushing” embodiments, the system 10 eliminates a time increment associated with billet 24 exchange and maintains the extrusion process during the billet 24 exchange process by continuously pushing on the billet 24 that is being processed while moving the pusher 26, 44 to a new billet 24. Furthermore, these embodiments advantageously employ the use of a stationary primary container 16 located at an interface of a rotary scroll face of the die assembly 12 which may always be exposed to an elevated temperature. For the dual pusher concept of the fifth embodiment, central and outer pushers 26, 44 may be worked independently in order to maintain a constant force on the processed billet 24 in the primary container 16, enabling continuous operation. Due to the continuous operation of the extrusion press, startup scrap associated with feedstock change is avoided.

[0040] Furthermore, as previously noted, in relation to any of the above-described embodiments, a scroll face of the die assembly 12 is provided with a diameter which is equivalent or larger than a diameter of all of the billets 24, which enables 100% use of the billet 24, avoiding generation of engineered scrap which must be periodically removed from the die cavity. Likewise, the diameter of the scroll face of the die assembly 12 is also larger than a diameter of the channels 22 of the containers 18, 20 which contain the billets 24. It has been demonstrated that rotary motion of the scroll face of the die assembly 12 results in shear forces which enable a higher fraction of secondary phases such as oxides and intermetallic compounds to be used without impact of surface defects and a reduction in material properties. The rotary shear forces and ability to generate heat at the scroll face / feedstock interface enables the ability to extrude 100% of billet 24 material and continuously process billets 24 to avoid productivity and engineered scrap issues associates with both conventional extrusion and shear extrusion processing. These embodiments also maintain the extrusion process during the process of exchanging feedstock, avoiding startup scrap.

[0041] According to another aspect of the disclosure, and in conjunction with any of the previously described embodiment, the die assembly 12 (or components thereof) may rotate about the axis A while the billets 24 remain rotationally stationary, or the billets 24 may be rotatable about the axis A while the die assembly 12 remains rotationally stationary. The billets 24 may be rotated in response to all, or part of the containers 18, 20 rotating with the billets 24. [0042] It should be appreciated that the foregoing description of the embodiments has been provided for purposes of illustration. In other words, the subject disclosure it is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in any selected embodiment, even if not specifically shown or described. The same may also be varies in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of disclosure.