CA1242672A - Continuous extrusion of metals - Google Patents
Continuous extrusion of metalsInfo
- Publication number
- CA1242672A CA1242672A CA000519819A CA519819A CA1242672A CA 1242672 A CA1242672 A CA 1242672A CA 000519819 A CA000519819 A CA 000519819A CA 519819 A CA519819 A CA 519819A CA 1242672 A CA1242672 A CA 1242672A
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- Canada
- Prior art keywords
- wheel
- rotated
- abutment member
- predetermined
- groove
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Abstract
ABSTRACT
CONTINUOUS EXTRUSION OF METALS
A rotary wheel member adapted for use in a rotary, friction type, continuous extrusion apparatus is produced by a method which comprises the steps of:
(a) producing a rotary wheel having formed in its cylindrical peripheral parts a continuous radially-extending groove, and secured in that groove for movement with said peripheral parts of said wheel an annular metal mass;
(b) rotating said wheel about its rotary axis; and (c) applying to the periphery of said annular metal mass secured in said wheel a tool of predetermined end shape, and progressively advancing said tool in a radial direction as said wheel continues to rotate whereby to machine in the peripheral parts of said annular metal mass a working groove of predetermined desired transverse cross sectional shape;
said peripheral parts of said annular metal mass which define said working groove being of a composition which is substantially the same as that of a feedstock metal that is to be extruded in a said apparatus when equipped with the wheel member so produced; and said predetermined end shape of said tool being substantially the same as that of an abutment member which is to be used in that apparatus to close the end of an arcuate passageway which is formed in said working gooove by a shoe member which co-operates with said cylindrical peripheral parts of said wheel member.
CONTINUOUS EXTRUSION OF METALS
A rotary wheel member adapted for use in a rotary, friction type, continuous extrusion apparatus is produced by a method which comprises the steps of:
(a) producing a rotary wheel having formed in its cylindrical peripheral parts a continuous radially-extending groove, and secured in that groove for movement with said peripheral parts of said wheel an annular metal mass;
(b) rotating said wheel about its rotary axis; and (c) applying to the periphery of said annular metal mass secured in said wheel a tool of predetermined end shape, and progressively advancing said tool in a radial direction as said wheel continues to rotate whereby to machine in the peripheral parts of said annular metal mass a working groove of predetermined desired transverse cross sectional shape;
said peripheral parts of said annular metal mass which define said working groove being of a composition which is substantially the same as that of a feedstock metal that is to be extruded in a said apparatus when equipped with the wheel member so produced; and said predetermined end shape of said tool being substantially the same as that of an abutment member which is to be used in that apparatus to close the end of an arcuate passageway which is formed in said working gooove by a shoe member which co-operates with said cylindrical peripheral parts of said wheel member.
Description
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CON~INUOUS ~XTRUSION 0~ M~TALS
TECHNICA~ D
This invention relates to an apparatus for effecting continuous extrusion of metal from a feedstock in particulate, comminuted or solid form, which apparatus includes:-(a) a rotatable wheel member arranged for rotation when in operation by a driving means, said wheel member having formed peripherally thereon a continuous circumferential groove;
(b) a cooperating shoe member which extends circumferentially around a substantial part of the periphery of said wheel member and which has a portion which projects in a radial direction partly into said groove with small working clearance from the side walls of said groove, said shoe member portion defining with the walls of said groove an enclosed passageway extending circum*erentially of said wheel member;
(c) feedstock inlet means disposed at an inlet end of said passageway for enabling feedstock to enter said passageway at said inlet end whereby to be engaged and carried frictionally by said wheel member, when rotating, towards the opposite, outlet end of said passageway;
(d) an abutment member carried on said shoe member and projecting radially into said passageway at said outlet end thereof so as to substantially close said passagewa~ at that end and thereby impede the passage of feedstock frictionally carried in said groove by said wheel member, thus creating an ex-trusion pressure in said passageway at said outlet end thereof; and (e) a die member carried on said shoe member and having a die orifice opening from said ~ 7 ,~
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passageway at said outlet end thereof, through which orifice feedstock carried in said groove and frictionally compressed by rotation of said wheel member, when driven, is compressed and extruded in continuous form, to exit from said shoe member via an outlet aperture.
The invention is particularly concerned with a method o~ producing a said rotatable ~heel member for use in such a rotary, friction--type, continuous extrusion apparatus.
BA~KGROU~D AR~
In operating such an extrusion apparatus, the parts defining said passageway adjacent said outlet end thereof su~fer very great working loads and very high operating temperatures. Of such highly stressed (mechanically and thermally) parts, those that suffer greatest wear or damage are the stationary, feedstock-engaging parts of, or associated with, said stationary shoe member, particularly on said abutment member, said die member and the stationary parts that support those items.
~ or the convenience of readily making good worn or damaged surfaces or parts, the abutment member, and the die member and its supporting parts are made as separate replaceable items ~hich are rigidly but removably secured in the stationary shoe member.
In order to reduce the temperatures at which those replaceable items operate, such items have been provided with internal cooling passages through which cooling water has been circulated.
~owever, such cooling measures have not been very effective, for the reasons that (a) the small sizes of those items and the high ~echanical loads to which they are subjected \
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have severely restricted both the si~es of the internal cooling passages and their proximity to the source of heat, so that the cooling water has been unable to extract heat at an adequate rate, and (b) the materials used for such small items (e.g. high-speed tool steels) have relatively poor heat transmission properties.
As a consequence of the low dissipation of heat by the cooling water, plastic flow of the tip of the abutment member, at its free end adjoining the bottom of the groove in the wheel member, has been experienced, due to the excessive tip temperature~
reached. This has severely limited the life of the abutment member, and the running time of the apparatus between successive occasions when the abutment member has to be replaced. ~his in turn has led to a reduction in the quantity of the output extrusion product produced, due to the down-time during which the apparatus cannot be operated.
Also, with prolonged use, there has been the risk that the extrusion die may overheat to a temperature at which its mechanical strength is impaired, with the consequent risk of deformation and/or increased wear of the die.
After experimentation with various different arrangemen-ts of internal cooling passages~
particularly in the abutment member, highly satisfactory results have now been achieved by means of an entirely different arrangement for cooling the abutment member. Such different arrangement, and various modifications thereof, have been described and claimed in the copending, parent patent application No. , filed , 1983, from which application this present application has been divided.
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The use o~ the invention of that parent application enables such a rotary, friction-type, continuous extrusion apparatus to operate at lower temperatures, for longer periods of time, and ~ith longer operating lives for those parts of the apparatus that are subjected to high mechanical and ; thermal stresses.
The beneficial results obtained by the use of that invention can be enhanced by the use in conjunction therewith of the invention of this divisional application.
By way of introduction to the present invention, reference should be made to the passage in the specification of that parent application, which begins - "It is believed that the highly beneficial ..." and ends - "... at which heat will be conveyed to the cooling zone by the wheel member."
That passage appears later in this specification, since the description given later with reference to the drawing figures is the same as that given in said parent application.
DISC~OSUR~ OF INVE~TION
According to the present invention, a method of producing a rotary wheel member adapted for use, in a rotary, friction type, continuous extrusion apparatus comprises the steps o~:
(a) producing a rotary wheel having formed in its cylindrical peripheral parts a continuous 9 radially-extending groove, and secured in that groove for movement with said peripheral parts of said wheelan annular metal mass;
(b) rotating said wheel about its rotary axis; and (c) applying to the periphery of said annular metal mass secured in said wheel a tool of lZ'1~6 7Z 2020~0RDIV
predetermined end shape, and progressively advancing said tool in a radial direction as said wheel continues to rotate whereby to machine in the peripheral parts of said annular metal mass a working groove of predetermined desired transverse cross sectional shape;
said peripheral parts of said annular metal mass which define said working groove being of a composition which is substantially the same as that of a predetermined feedstock metal that is to be extruded in a said apparatus when equipped with the wheel member so produced; and said predetermined end shape of said tool being substantially the same as that of a predetermined abutment member which is to be used in that apparatus to close the end of an arcuate passageway which is formed in said working groove by a shoe member which when the apparatus is in operation co-operates with said cylindrical peripheral parts of said wheel member.
Preferably, said annular metal mass secured in said wheel groove i9 in good thermal relationship with said wheel.
Said annular metal mass secured in said wheel groove may comprise an annulus of a first predetermined metal lying concentrically with said wheel in 3aid wheel groove and being enveloped within a sheath of a second predetermined metal, said second predetermined metal defining said working groove and being in good thermal relationship with said first predetermined metal.
Said annular metal mass secured in said wheel groove may alternatively comprise an annulus of a first predetermined metal lying concentric with said wheel in the bottom o~ said wheel groove and being overlaid by a second annulus of a second 3LZ~Z~72 2020~0RDIV
predetermined metal, said first predetermined metal being in good thermal relationship with ~aid second predetermined metal, and said second predetermined metal defining said working groove.
Preferably, said first and second predetermined metals each have a product of thermal conductivity and specific heat per unit volume that is greater than that of the material of the wheel.
Advantageously, said product for said first predetermined metal is greater than that for said second predetermined metal.
In carrying out the methods of the present invention, said wheel is preferably mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said wor~ing groove.
The present invention also provides wheel members prepared by methods according -to the present invention.
Other features and advantages of the present invention will appear from a reading of the description that follows hereafter, and from the claims appended at the end of that description.
BRIE~ DESCRIPTION 0~ DRAWI~GS
One continuous extrusion apparatus embodying the present invention will now be described ~0 by way of example and with reference to the accompanying diagrammatic drawings in which:
~igure 1 shows a medial, vertical cross-section taken through the essential working parts of the apparatus~ the plane of that section being ~5 indicated in ~igure 2 at I-I;
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~igure 2 shows a transverse sectional view taken on the section indicated in ~igure 1 at II-II;
~igures 3 and 4 show in sectional views similar -to that of ~igure 2 two arrangemen-ts which are alterna-tives to that of ~igure 2;
~igure 5 shows a schematic block diagram of a ~ystem embodying the apparatus of the ~igures 1 and 2;
~igure 6 shows a graph depicting the variation of a heat extraction rate with variation of a cooling water. ~low rate, as obtained from tests on one apparatus according to the present invention;
~igures 7 to 9 show, in views similar to that of ~igure 2, various modified forms of a wheel member incorporated in 3aid apparatus; and ~igure 10 shows, in a view similar to that of ~igure 1, a modified form o~ the apparatus shown in the ~igures 1 and 2.
MODES 0~ CARRYI~G OUT ~HE I~VE~TION
Referring now to Figures 1 and 2, the apparatus there shown includes a rotatable wheel member 10 which is carried in bearings (not shown) and coupled through gearing (not shown) to an electric driving motor (not shown) so as to be driven when in operation at a ~elected speed within the range O to 20 RPM (though greater speeds are possible).
The wheel member has formed around its periphery a groove 12 whose radial cross-~ection is depicted in ~igure 2. The deeper par-t o~ the groove has parallel annular sides 14 which merge with a radiused bottom surface 16 of the groove. A
convergent mouth part 18 of said groove i~ de~ined by oppositely-directed frusto-conical surfaces 20, 22.
A stationary shoe member 24 carried on a 1;~ 72 2020~0RDIV
lower pivot pin 26 extends around and coopera-tes closely with approximately one quarter of the periphery of the wheel member 10. The shoe member is retained in its operating position as shown in 5 ~igure 1 by a withdrawable stop member 28.
The shoe member includes centrally (in an axial direction) a circumferentially-extending projecting portion 30 which projects partly into the groove 12 in the wheel member 10 with small axial or 10 transverse clearance gaps 32, 34 on either side.
~hat projecting, portion 30 is constituted in part by a series of replaceable inserts, and comprises a radially-directed abutment member 36, an abutment support 38 downstream of the abutment member, a die 15 block 40 (incorporating an extrusion die 42) upstream of the abutment member, and an arcuate wear-resisting member 44 upstream of ~aid die block. Upstream of the member 44 an integral entry part 46 of the shoe member completes an arcuate passageway 48 which 20 extend~ around the wheel member from a vertically-oriented feedstock inlet passage 50 disposed below a feedstock hopper 52, downstream as far as the front face 54 of the abutment member 36. ~hat passageway ha~ a radial cross-section which in the ~igure 2 is 25 defined by the annular side wall~ 14 and bottom surface 16 of the groove 12, and the inner surface 56 of the said central portion 30 of the shoe member 24.
~he said abutment member 36, die block 40, 30 die 42 and arcuate member 44 are all made of suitably hard, wear-resistant metals, e.g. high-speed tool steels.
~ he shoe member is provided with an outlet aperture 58 which is aligned with a corresponding 35 aperture 60 formed in the die block 40 and through ~;~4~
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_g_ which ~he extruded output metal product 61 (e.g. a round wire) from the orifice of the die 42 emerges.
On rotation of the wheel member 10, comminuted feedstock admitted to the inlet end of the said arcuate passageway 48 from the hopper 52 via the inlet passage 50 is carried by the moving groove surfaces of the wheel member in an anti-clockwise direction as seen in ~igure 1 along the length of said arcuate passageway 48, and is agglomerated and compacted to form a solid slug of metal devoid of inter~tices in the lower section of the passageway adjacent said die block 40. ~hat slug of metal is continuously urged under great pressure against the abutment member by the ~rictional drag of the moving groove surfaces. ~hat pressure is sufficient to ex-trude the metal of said slug through the orifice of the extrusion die and thereby provide an extruded output product which issues through the apertures 58 and 60 in the shoe member and die block. In the particular case, the output produc-t compri~es a bright copper wire produced from small chopped pieces of wire which constitute the said feedstock.
A water pipe 62 secured around the lower end of the shoe member 24 has an exit nozzle 64 positioned and secured on the side of the shoe member that lie~ adjacent the wheel member 10. ~he nozæle is aligned so as, when the pipe is ~upplied with cooling water, to direct a jet of water directly at the downstream parts of the abutment member where it lies in and abuts the groove 12 in the wheel member 10. ~hus, the tip of the free end of the abutment member (where in operation most of the heat is genera-ted) and the adjoining surfaces of the wheel member and groove are directly cooled by the flow thereover of water from the jet directed towards ~L~ 2 2020~0RDI~
them.
The die block 40 is provided with internal water passages (not shown) and a supply o~ cooling water for enveloping the output product leaving the die and extracting some of the heat being carried away in that product. But no such internal passages are ~ormed in the abutment member. Thus, the s-trength of that member is not reduced in the interests of providing internal water cooling for cooling that member.
If desired, the cooling of the apparatus may be enhanced by providing cooling water sprinklers 65 over the hopper 52 so a~ to feed ~ome cooling water into the said arcuate passageway 48 with the comminuted feedstock.
In the ~igure 2, the slug of compacted metal in the extrusion zone adjacent the die block 40 i3 indicated at 66. ~rom that metal slug, the output product i3 extruded through the extrusion die 42 by the pressure in that zone. That pressure also acts to extrude some o~ the metal through the said axial clearance gaps 32 and 34 between the side walls of the groove and the respective opposing sur~aces o~
the die block and abutment member. That extruded metal gradually builds up in a radial direction to form 3trips 68 o~ waste metal or "~lash". In order to prevent those waste strips growing too large to handle and control, a plurality of transversely-directed teeth 70 are secured on the divergent walls 20, 22 which constitute the said mouth 18 o~
the groove l2. Those teeth are uniformly spaced around the wheel member, the teeth on one o~ the walls being disposed opposite the corresponding teeth on the opposite wall. I~ desired, the teeth on one wall may alternatively be staggered relative to 7~
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corresponding teeth on the other wall.
In operation, the inclined surfaces 72 of the die block 40 deflect the extruded waste strips 68 obliquely into the paths of the respective sets of moving teeth 70. Interception of such a waste strip 68 by a moving tooth causes a piece of that strip to be cut or otherwise torn away from the extruded metal in the clearance gap. ~hus, ~uch waste extruded strips are removed as soon as they extend radially far enough to be intercepted by a moving tooth. In this way the "flash" is prevented from reaching unmanageable proportions.
The said teeth do not need to be sharp, and can be secured in any satisfactory manner on the wheel member 10, e.g. by welding.
In the Figures 3 and 4 are shown other teeth Pitted in analogous manners to appropriate surface~ of other forms of said wheel member 10.
In those alternative arrangements, the external surfaces of the wheel member 10 cooperate with correspondingly shaped surfaces of the cooperating shoe member 24 whereby to effect control of the flash in a particular desired way. In Figure 3, the flash i9 cau~ed to grow in a purely tranverse or axial direction, until it is intercepted by a radially projecting tooth, whereupon that piece of flash is torn away ~rom the extruded metal in the associated clearance gap.
In Figure 4, the flash is cau~ed to grow in an oblique direction (as in the case of Figure 2), but is intercepted by teeth which project radially from the surface of the wheel member 10.
For various reasons that will appear later, it may be desirable, or even necessary, to treat the extrusion product (wire 61) issuing from ~ ~12L~I267;~
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the continuous extrusion apparatus described above in an extrusion product treatment apparatus before passing it to a product collection and storage means.
Moreover, it may be desirable or advantageous to treat the extrusion product whilst it still remains hot from the continuous extrusion process in which it was produced.
Such a treatment apparatus may, for example, be arranged to provide the extrusion product with a better or different surface finish (for example, a drawn finish), and/or a more uniform external diameter or gauge. Such a treatment apparatus may also be used to provide, at different times, ~rom the same continuous extrusion product, finished products of various different gauges and/or tolerances. ~or such purposes, the said treatment apparatus may comprise a simple drawing die through which said extrusion product is first threaded and then drawn under tension, to provide a said finished product of desired size, tolerance, and/or quality.
~he use of such a treatment apparatus to treat the extrusion product would enable the continuous extrusion die 42 of the continuous extrusion apparatus to be retained in service for a longer period before having to be discarded because o~ the excessive enlargement of its die aperture caused by : wear in service. Moreover, such a treatment apparatus may have its die readily and speedily interchanged, whereby to enable an output product of a different gauge, tolerance and/or quality to be produced instead.
One example of a continuous extrusion system incorporating a continuous extrusion apparatus and an extrusion product treatment apparatus will now be described with reference to the igure 5.
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Referring now to the ~igure 5, the system there shown includes at reference 100 a continuous extrusion apparatus as just described above and, if desired, modified as described below, the output copper ~ire produced by that apparatus being indicated at 102, and being drawn through a sizing die 104 (for reducing its gauge to a desired lower value) by a tensioning pulley device 106 around which the wire passes a plurality of times before passing via an accummulator 108 to a coiler 11 O.
The pulley device 106 is coupled to the output ~haft o:e an electrical torque mo-tor 112 whose energisation is provided and controlled by a control apparatus 114. The latter is responsive to (a) a 15 first electrical signal 116 derived from a wire tension sensor 118 which engages the wire 102 at a position between the extru~ion apparatus 100 and the sizing die 104, and which provides as said first signal an electrical signal dependent on the tension 20 in the wire 102 at the output of the extrusion apparatus 100; and to (b) a second electrical signal 120 derived from a temperature sensor 122 which measures the temperature OI the wire 102 as it leaves the extrusion apparatus 100.
The control apparatus 114 incorporates a function generator 124 which is responsive to said second (temperature) signal 120 and provides at its output circuit a third electrical signal representative of the yield stress tension for the particular wire 102 when at the particular temperature represented by the said second (temperature) signal. That third electrical signal 126 is supplied as a reference signal to a comparator 128 (also part of said control apparatus) in which the said first (tension) signal 116 is compared with 1~4Z~7Z
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said third signal (yield stress tension). The output signal o~ the comparator constitutes the signal for controlling the energisation of the torque motor.
In operation, the torque motor is energised to an extent su~ficient to maintain the tension in the wire leaving the extrusion apparatus 100 at a value ~hich lies a predetermined amount below the yield stress tension for the particular wire at the particular temperature at which it leaves the extru~ion apparatus.
Wherea3 in the description above re~erence has been made to the use of a water jet for cooling the abutment member tip, jets o~ other cooling liquids (or even cooling gases) could be u~ed instead. Even jets of appropriate liquified gase~
may be used~
Regarding the flash-removing teeth 70 referred to in the above description, it should be noted that:-(a) the shaping of the leading edge (i.e. the cutting or tearing edge) of each tooth is not critical, as long as the desired ~lash removal function is ful~illed;
(b) the working clearance between the tip f each tooth 70 and the adjacent opposing sur~ace of the stationary shoe member 24 i9 not critical, and is typically not greater than 1 to 2 mm, according to the speci~ic design of the apparatu~;
(c) the greater the number o~ teeth 3paced around each side of the wheel member 10, the smaller will be the lengths o~ "~lash" removed by each tooth;
(d) the teeth may be made o~ any 3uitable material, such a~ for example, tool steel; and (e) an~ convenient method o~ securing the -~LZ~ 7;2 2020~0RDIV
teeth on the wheel member ma~y be used.
~ he ability of the apparatus to deliver an acceptable output extrusion product from feedstock in loose particulate or communited form is considerably enhanced by causing the radial depth (or height) of the arcuate passageway 48, in a pressure-building zone which lies immediately ahead (i.e. upstream) of the front face 54 of the abutment member 36, to diminish relatively rapidly in a preferred manner in the direction of rotation of the wheel member 10, for example in the manner illustrated in the drawings.
The removable die block 40 is arranged to be circumferentially co-extensive with that zone, and the said progressive reduction of the radial depth of the arcuate passageway is achieved by appropriately shaping the surface 40A of the die block that faces the bottom of the groove 12 in the wheel member 10.
That surface 40A of the die block is preferably shaped in a manner such as to achieve in the said zone, when the apparatus is operating, a feedstock metal flow pattern that closely resembles that which is achieved when using instead feedstock in solid form. In the preferred embodiment illustrated in the drawings, that surface 40A
comprises a plane surface which is inclined at a suitable small angle to a tangent to the bottom of the groove 12 at its point of contact with the abutment member 36 at its front face 54.
That angle is ideally set at a value such that the ratio of (a) the area of the abutment member 36 that i3 exposed to feedstock metal at the extrusion pressure, to (b) the radial cross-sectional area of the passageway 48 at the entry end of said zone (i.e. at the radial cross-section adjacent the upstream end of the die block 40) is equal to the ~Z~2~7~
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ratio of (i) the apparent density of the feedstock entering that zone at said entry end thereof, to (ii) the density of the ~ully-compacted feedstock lying adjacent the front face 54 of the abutment member 36.
In one satisfactory arrangement, the said plane surface 40A of the die block was inclined at an angle such that the said area of the abutment member that is exposed to feedstock metal at the extrusion pressure is equal to one half of the said radial cross-sectional area of the passageway 48 at the en-try end of said zone (i.e. at the upstream end of the die block).
If desired, in an alternative embodiment the surface of the die block facing the bottom of the groove 12 may be inclined in the manner referred to above over only a greater part of it~ circumferential length which extends from the said upstream end of the die block, the part of the die block lying immediately adjacent the front face 54 of the abutment member being provided with a surface that lies parallel (or substantially parallel) with the bottom of the groove 12.
The greater penetration of the die block 40 into the groove 12, which resul-ts from the said shaping of the surface 40A referred to above, serves al~o to offer increa~ed phy~ical resistance to the unwanted extrusion o~ flash-forming metal through the clearance gaps 32 and 34, so that the amount of feedstock metal going to the formation of such flash is greatl~ reduced. Moreover, that penetration of the die block into the groove 12 results in reductions in (a) the redundant work done on the ~eedstock, (b) in the amount of flash produced, and (c) the bending moment imposed on the abutment member ~2~26~;~2 2020~0RDIV
by the metal under ~res~ure. ~urthermore, the choice of a plane working surface 40A for the die block reduces the cost of producing that die block.
Whereas in the above description, the wheel member 10 is driven by an electric driving motor, at speeds within the stated range, other like-operating continuous extrusion machines may utilise hydraulic driving means and operate at appropriate running speeds.
As an alternative to introducing additional cooling water into the passageway 48 via the ~prinklers 65, hopper 52 and passage 50, such additional cooling water may be introduced into that pa~sageway (for example, via a pas3age 67 formed in the shoe member 24) at a position at which ~aid pa3~ageway i~ filled with particulate feedstock, bu-t at which said particulate feedstock therein is not yet fully compacted.
It is believed that the highly beneficial cooling effects provided by the present invention arise very largely from the fact that the heat absorbed by a part of the wheel member lying temporarily adjacent the hot metal in the confined extrusion zone upstream of the abutment member is conveyed (both by thermal conduction and rotation of the wheel member) from that hot zone to a cooling zone situated downstream of the abutment member, in which cooling zone a copious ~upply of cooling fluid is caused to flow over relatively large areas of the wheel member pas~ing through that cooling zone ~o as to extract therefrom a high proportion o~ the heat absorbed by the wheel member in the ho-t extrusion zone.
In this cooling zone access to the wheel ~5 member is less restricted 9 and relatively large ~2~ 67~
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~urfaces of that member are freely available for cooling purposes. This is in direct contrast to the extremely small and con~ined cooling surfaces that can be provided directly adjacent the extrusion zone in the parts of the said shoe member (i.e. the die block and abutment member) that bound that extrusion zone. As has been mentioned above, the cooling surfaces that can be provided in those parts are severely limited in size by the need to conserve the mechanical strengths of those parts and so enable them to sa~ely withstand the extrusion pressure exerted on them.
The conveying o~ heat absorbed by the wheel member to the said cooling zone can be greatly enhanced by the incorporation in said wheel member of metals having good thermal conductivities and good specific heats (per unit volume). However, since the said wheel member, for reasons o~ providing adequate mechanical strength, is made of physically strong metals, (e.g. tool steels), it has relatively poor heat transmission properties. Thus, the ability of the wheel member to convey heat to said cooling zone can be greatly enhanced by incorporating intimately in said wheel member an annular band of a metal having good thermal absorption and transmission properties, for example, a band of copper.
Such a thermally conductive band may conveniently be constituted by an annular band secured in the periphery of the said wheel member and preferably constituting, at least in part, the part of said wheel member in which the said circumferential groove is formed to provide (with the shoe member) the said passageway (48).
In cases where the e~trusion product o~ the machine is o~ a metal having suitably good thermal ~2~26'7;~
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properties, the said thermally conductive band may be composed of the same metal as the extrusion product (e.g. copper).
In other cases, said thermally~conductive band may be embedded in, or be overlaid by, a second annular band, which second band is of the same metal as the extrusion product o~ the machine and is in contact with the tip portion of the said abutment member, the two bands being of different metals.
Metals which may be used for the said thermally-conductive band are selected to have a higher product of thermal conduc-tivity and specific heat per unit volume than tool stee1, and include the ~ollowing (in decreasing order of said higher product):-Copper, silver, beryllium, gold, aluminium,tung~ten, rhodium, iridium, molybdenum, ru-thenium, zinc and iron.
~ he rate at which heat can be conveyed by such a thermally-conductive band from the extrusion zone to the cooling zone i9 dependent on the radial cross-sectional area of the band, and is increased by increasing that cross-sectional area. ~hus, for a given cross-sectional dimension measured transversely of the circumference o~ the wheel member, the greater the radial depth of a said band, the greater the rate at which heat will be conveyed to the cooling zone by the wheel member.
Calculations have shown that for a said wheel member having an ef~ective diameter o~ 233 mm, and a speed of rotation of 10 RPM, and a said thermally-conductive band of copper having a radial cross-section o~ U-shape, the rate "R" of conveying heat from the extrusion zone to the said cooling zone by the wheel member, by virtue of its rotation alone,
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CON~INUOUS ~XTRUSION 0~ M~TALS
TECHNICA~ D
This invention relates to an apparatus for effecting continuous extrusion of metal from a feedstock in particulate, comminuted or solid form, which apparatus includes:-(a) a rotatable wheel member arranged for rotation when in operation by a driving means, said wheel member having formed peripherally thereon a continuous circumferential groove;
(b) a cooperating shoe member which extends circumferentially around a substantial part of the periphery of said wheel member and which has a portion which projects in a radial direction partly into said groove with small working clearance from the side walls of said groove, said shoe member portion defining with the walls of said groove an enclosed passageway extending circum*erentially of said wheel member;
(c) feedstock inlet means disposed at an inlet end of said passageway for enabling feedstock to enter said passageway at said inlet end whereby to be engaged and carried frictionally by said wheel member, when rotating, towards the opposite, outlet end of said passageway;
(d) an abutment member carried on said shoe member and projecting radially into said passageway at said outlet end thereof so as to substantially close said passagewa~ at that end and thereby impede the passage of feedstock frictionally carried in said groove by said wheel member, thus creating an ex-trusion pressure in said passageway at said outlet end thereof; and (e) a die member carried on said shoe member and having a die orifice opening from said ~ 7 ,~
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passageway at said outlet end thereof, through which orifice feedstock carried in said groove and frictionally compressed by rotation of said wheel member, when driven, is compressed and extruded in continuous form, to exit from said shoe member via an outlet aperture.
The invention is particularly concerned with a method o~ producing a said rotatable ~heel member for use in such a rotary, friction--type, continuous extrusion apparatus.
BA~KGROU~D AR~
In operating such an extrusion apparatus, the parts defining said passageway adjacent said outlet end thereof su~fer very great working loads and very high operating temperatures. Of such highly stressed (mechanically and thermally) parts, those that suffer greatest wear or damage are the stationary, feedstock-engaging parts of, or associated with, said stationary shoe member, particularly on said abutment member, said die member and the stationary parts that support those items.
~ or the convenience of readily making good worn or damaged surfaces or parts, the abutment member, and the die member and its supporting parts are made as separate replaceable items ~hich are rigidly but removably secured in the stationary shoe member.
In order to reduce the temperatures at which those replaceable items operate, such items have been provided with internal cooling passages through which cooling water has been circulated.
~owever, such cooling measures have not been very effective, for the reasons that (a) the small sizes of those items and the high ~echanical loads to which they are subjected \
~2~2G~7~
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have severely restricted both the si~es of the internal cooling passages and their proximity to the source of heat, so that the cooling water has been unable to extract heat at an adequate rate, and (b) the materials used for such small items (e.g. high-speed tool steels) have relatively poor heat transmission properties.
As a consequence of the low dissipation of heat by the cooling water, plastic flow of the tip of the abutment member, at its free end adjoining the bottom of the groove in the wheel member, has been experienced, due to the excessive tip temperature~
reached. This has severely limited the life of the abutment member, and the running time of the apparatus between successive occasions when the abutment member has to be replaced. ~his in turn has led to a reduction in the quantity of the output extrusion product produced, due to the down-time during which the apparatus cannot be operated.
Also, with prolonged use, there has been the risk that the extrusion die may overheat to a temperature at which its mechanical strength is impaired, with the consequent risk of deformation and/or increased wear of the die.
After experimentation with various different arrangemen-ts of internal cooling passages~
particularly in the abutment member, highly satisfactory results have now been achieved by means of an entirely different arrangement for cooling the abutment member. Such different arrangement, and various modifications thereof, have been described and claimed in the copending, parent patent application No. , filed , 1983, from which application this present application has been divided.
:~
~12~26'~;~
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The use o~ the invention of that parent application enables such a rotary, friction-type, continuous extrusion apparatus to operate at lower temperatures, for longer periods of time, and ~ith longer operating lives for those parts of the apparatus that are subjected to high mechanical and ; thermal stresses.
The beneficial results obtained by the use of that invention can be enhanced by the use in conjunction therewith of the invention of this divisional application.
By way of introduction to the present invention, reference should be made to the passage in the specification of that parent application, which begins - "It is believed that the highly beneficial ..." and ends - "... at which heat will be conveyed to the cooling zone by the wheel member."
That passage appears later in this specification, since the description given later with reference to the drawing figures is the same as that given in said parent application.
DISC~OSUR~ OF INVE~TION
According to the present invention, a method of producing a rotary wheel member adapted for use, in a rotary, friction type, continuous extrusion apparatus comprises the steps o~:
(a) producing a rotary wheel having formed in its cylindrical peripheral parts a continuous 9 radially-extending groove, and secured in that groove for movement with said peripheral parts of said wheelan annular metal mass;
(b) rotating said wheel about its rotary axis; and (c) applying to the periphery of said annular metal mass secured in said wheel a tool of lZ'1~6 7Z 2020~0RDIV
predetermined end shape, and progressively advancing said tool in a radial direction as said wheel continues to rotate whereby to machine in the peripheral parts of said annular metal mass a working groove of predetermined desired transverse cross sectional shape;
said peripheral parts of said annular metal mass which define said working groove being of a composition which is substantially the same as that of a predetermined feedstock metal that is to be extruded in a said apparatus when equipped with the wheel member so produced; and said predetermined end shape of said tool being substantially the same as that of a predetermined abutment member which is to be used in that apparatus to close the end of an arcuate passageway which is formed in said working groove by a shoe member which when the apparatus is in operation co-operates with said cylindrical peripheral parts of said wheel member.
Preferably, said annular metal mass secured in said wheel groove i9 in good thermal relationship with said wheel.
Said annular metal mass secured in said wheel groove may comprise an annulus of a first predetermined metal lying concentrically with said wheel in 3aid wheel groove and being enveloped within a sheath of a second predetermined metal, said second predetermined metal defining said working groove and being in good thermal relationship with said first predetermined metal.
Said annular metal mass secured in said wheel groove may alternatively comprise an annulus of a first predetermined metal lying concentric with said wheel in the bottom o~ said wheel groove and being overlaid by a second annulus of a second 3LZ~Z~72 2020~0RDIV
predetermined metal, said first predetermined metal being in good thermal relationship with ~aid second predetermined metal, and said second predetermined metal defining said working groove.
Preferably, said first and second predetermined metals each have a product of thermal conductivity and specific heat per unit volume that is greater than that of the material of the wheel.
Advantageously, said product for said first predetermined metal is greater than that for said second predetermined metal.
In carrying out the methods of the present invention, said wheel is preferably mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said wor~ing groove.
The present invention also provides wheel members prepared by methods according -to the present invention.
Other features and advantages of the present invention will appear from a reading of the description that follows hereafter, and from the claims appended at the end of that description.
BRIE~ DESCRIPTION 0~ DRAWI~GS
One continuous extrusion apparatus embodying the present invention will now be described ~0 by way of example and with reference to the accompanying diagrammatic drawings in which:
~igure 1 shows a medial, vertical cross-section taken through the essential working parts of the apparatus~ the plane of that section being ~5 indicated in ~igure 2 at I-I;
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~igure 2 shows a transverse sectional view taken on the section indicated in ~igure 1 at II-II;
~igures 3 and 4 show in sectional views similar -to that of ~igure 2 two arrangemen-ts which are alterna-tives to that of ~igure 2;
~igure 5 shows a schematic block diagram of a ~ystem embodying the apparatus of the ~igures 1 and 2;
~igure 6 shows a graph depicting the variation of a heat extraction rate with variation of a cooling water. ~low rate, as obtained from tests on one apparatus according to the present invention;
~igures 7 to 9 show, in views similar to that of ~igure 2, various modified forms of a wheel member incorporated in 3aid apparatus; and ~igure 10 shows, in a view similar to that of ~igure 1, a modified form o~ the apparatus shown in the ~igures 1 and 2.
MODES 0~ CARRYI~G OUT ~HE I~VE~TION
Referring now to Figures 1 and 2, the apparatus there shown includes a rotatable wheel member 10 which is carried in bearings (not shown) and coupled through gearing (not shown) to an electric driving motor (not shown) so as to be driven when in operation at a ~elected speed within the range O to 20 RPM (though greater speeds are possible).
The wheel member has formed around its periphery a groove 12 whose radial cross-~ection is depicted in ~igure 2. The deeper par-t o~ the groove has parallel annular sides 14 which merge with a radiused bottom surface 16 of the groove. A
convergent mouth part 18 of said groove i~ de~ined by oppositely-directed frusto-conical surfaces 20, 22.
A stationary shoe member 24 carried on a 1;~ 72 2020~0RDIV
lower pivot pin 26 extends around and coopera-tes closely with approximately one quarter of the periphery of the wheel member 10. The shoe member is retained in its operating position as shown in 5 ~igure 1 by a withdrawable stop member 28.
The shoe member includes centrally (in an axial direction) a circumferentially-extending projecting portion 30 which projects partly into the groove 12 in the wheel member 10 with small axial or 10 transverse clearance gaps 32, 34 on either side.
~hat projecting, portion 30 is constituted in part by a series of replaceable inserts, and comprises a radially-directed abutment member 36, an abutment support 38 downstream of the abutment member, a die 15 block 40 (incorporating an extrusion die 42) upstream of the abutment member, and an arcuate wear-resisting member 44 upstream of ~aid die block. Upstream of the member 44 an integral entry part 46 of the shoe member completes an arcuate passageway 48 which 20 extend~ around the wheel member from a vertically-oriented feedstock inlet passage 50 disposed below a feedstock hopper 52, downstream as far as the front face 54 of the abutment member 36. ~hat passageway ha~ a radial cross-section which in the ~igure 2 is 25 defined by the annular side wall~ 14 and bottom surface 16 of the groove 12, and the inner surface 56 of the said central portion 30 of the shoe member 24.
~he said abutment member 36, die block 40, 30 die 42 and arcuate member 44 are all made of suitably hard, wear-resistant metals, e.g. high-speed tool steels.
~ he shoe member is provided with an outlet aperture 58 which is aligned with a corresponding 35 aperture 60 formed in the die block 40 and through ~;~4~
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_g_ which ~he extruded output metal product 61 (e.g. a round wire) from the orifice of the die 42 emerges.
On rotation of the wheel member 10, comminuted feedstock admitted to the inlet end of the said arcuate passageway 48 from the hopper 52 via the inlet passage 50 is carried by the moving groove surfaces of the wheel member in an anti-clockwise direction as seen in ~igure 1 along the length of said arcuate passageway 48, and is agglomerated and compacted to form a solid slug of metal devoid of inter~tices in the lower section of the passageway adjacent said die block 40. ~hat slug of metal is continuously urged under great pressure against the abutment member by the ~rictional drag of the moving groove surfaces. ~hat pressure is sufficient to ex-trude the metal of said slug through the orifice of the extrusion die and thereby provide an extruded output product which issues through the apertures 58 and 60 in the shoe member and die block. In the particular case, the output produc-t compri~es a bright copper wire produced from small chopped pieces of wire which constitute the said feedstock.
A water pipe 62 secured around the lower end of the shoe member 24 has an exit nozzle 64 positioned and secured on the side of the shoe member that lie~ adjacent the wheel member 10. ~he nozæle is aligned so as, when the pipe is ~upplied with cooling water, to direct a jet of water directly at the downstream parts of the abutment member where it lies in and abuts the groove 12 in the wheel member 10. ~hus, the tip of the free end of the abutment member (where in operation most of the heat is genera-ted) and the adjoining surfaces of the wheel member and groove are directly cooled by the flow thereover of water from the jet directed towards ~L~ 2 2020~0RDI~
them.
The die block 40 is provided with internal water passages (not shown) and a supply o~ cooling water for enveloping the output product leaving the die and extracting some of the heat being carried away in that product. But no such internal passages are ~ormed in the abutment member. Thus, the s-trength of that member is not reduced in the interests of providing internal water cooling for cooling that member.
If desired, the cooling of the apparatus may be enhanced by providing cooling water sprinklers 65 over the hopper 52 so a~ to feed ~ome cooling water into the said arcuate passageway 48 with the comminuted feedstock.
In the ~igure 2, the slug of compacted metal in the extrusion zone adjacent the die block 40 i3 indicated at 66. ~rom that metal slug, the output product i3 extruded through the extrusion die 42 by the pressure in that zone. That pressure also acts to extrude some o~ the metal through the said axial clearance gaps 32 and 34 between the side walls of the groove and the respective opposing sur~aces o~
the die block and abutment member. That extruded metal gradually builds up in a radial direction to form 3trips 68 o~ waste metal or "~lash". In order to prevent those waste strips growing too large to handle and control, a plurality of transversely-directed teeth 70 are secured on the divergent walls 20, 22 which constitute the said mouth 18 o~
the groove l2. Those teeth are uniformly spaced around the wheel member, the teeth on one o~ the walls being disposed opposite the corresponding teeth on the opposite wall. I~ desired, the teeth on one wall may alternatively be staggered relative to 7~
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corresponding teeth on the other wall.
In operation, the inclined surfaces 72 of the die block 40 deflect the extruded waste strips 68 obliquely into the paths of the respective sets of moving teeth 70. Interception of such a waste strip 68 by a moving tooth causes a piece of that strip to be cut or otherwise torn away from the extruded metal in the clearance gap. ~hus, ~uch waste extruded strips are removed as soon as they extend radially far enough to be intercepted by a moving tooth. In this way the "flash" is prevented from reaching unmanageable proportions.
The said teeth do not need to be sharp, and can be secured in any satisfactory manner on the wheel member 10, e.g. by welding.
In the Figures 3 and 4 are shown other teeth Pitted in analogous manners to appropriate surface~ of other forms of said wheel member 10.
In those alternative arrangements, the external surfaces of the wheel member 10 cooperate with correspondingly shaped surfaces of the cooperating shoe member 24 whereby to effect control of the flash in a particular desired way. In Figure 3, the flash i9 cau~ed to grow in a purely tranverse or axial direction, until it is intercepted by a radially projecting tooth, whereupon that piece of flash is torn away ~rom the extruded metal in the associated clearance gap.
In Figure 4, the flash is cau~ed to grow in an oblique direction (as in the case of Figure 2), but is intercepted by teeth which project radially from the surface of the wheel member 10.
For various reasons that will appear later, it may be desirable, or even necessary, to treat the extrusion product (wire 61) issuing from ~ ~12L~I267;~
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the continuous extrusion apparatus described above in an extrusion product treatment apparatus before passing it to a product collection and storage means.
Moreover, it may be desirable or advantageous to treat the extrusion product whilst it still remains hot from the continuous extrusion process in which it was produced.
Such a treatment apparatus may, for example, be arranged to provide the extrusion product with a better or different surface finish (for example, a drawn finish), and/or a more uniform external diameter or gauge. Such a treatment apparatus may also be used to provide, at different times, ~rom the same continuous extrusion product, finished products of various different gauges and/or tolerances. ~or such purposes, the said treatment apparatus may comprise a simple drawing die through which said extrusion product is first threaded and then drawn under tension, to provide a said finished product of desired size, tolerance, and/or quality.
~he use of such a treatment apparatus to treat the extrusion product would enable the continuous extrusion die 42 of the continuous extrusion apparatus to be retained in service for a longer period before having to be discarded because o~ the excessive enlargement of its die aperture caused by : wear in service. Moreover, such a treatment apparatus may have its die readily and speedily interchanged, whereby to enable an output product of a different gauge, tolerance and/or quality to be produced instead.
One example of a continuous extrusion system incorporating a continuous extrusion apparatus and an extrusion product treatment apparatus will now be described with reference to the igure 5.
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Referring now to the ~igure 5, the system there shown includes at reference 100 a continuous extrusion apparatus as just described above and, if desired, modified as described below, the output copper ~ire produced by that apparatus being indicated at 102, and being drawn through a sizing die 104 (for reducing its gauge to a desired lower value) by a tensioning pulley device 106 around which the wire passes a plurality of times before passing via an accummulator 108 to a coiler 11 O.
The pulley device 106 is coupled to the output ~haft o:e an electrical torque mo-tor 112 whose energisation is provided and controlled by a control apparatus 114. The latter is responsive to (a) a 15 first electrical signal 116 derived from a wire tension sensor 118 which engages the wire 102 at a position between the extru~ion apparatus 100 and the sizing die 104, and which provides as said first signal an electrical signal dependent on the tension 20 in the wire 102 at the output of the extrusion apparatus 100; and to (b) a second electrical signal 120 derived from a temperature sensor 122 which measures the temperature OI the wire 102 as it leaves the extrusion apparatus 100.
The control apparatus 114 incorporates a function generator 124 which is responsive to said second (temperature) signal 120 and provides at its output circuit a third electrical signal representative of the yield stress tension for the particular wire 102 when at the particular temperature represented by the said second (temperature) signal. That third electrical signal 126 is supplied as a reference signal to a comparator 128 (also part of said control apparatus) in which the said first (tension) signal 116 is compared with 1~4Z~7Z
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said third signal (yield stress tension). The output signal o~ the comparator constitutes the signal for controlling the energisation of the torque motor.
In operation, the torque motor is energised to an extent su~ficient to maintain the tension in the wire leaving the extrusion apparatus 100 at a value ~hich lies a predetermined amount below the yield stress tension for the particular wire at the particular temperature at which it leaves the extru~ion apparatus.
Wherea3 in the description above re~erence has been made to the use of a water jet for cooling the abutment member tip, jets o~ other cooling liquids (or even cooling gases) could be u~ed instead. Even jets of appropriate liquified gase~
may be used~
Regarding the flash-removing teeth 70 referred to in the above description, it should be noted that:-(a) the shaping of the leading edge (i.e. the cutting or tearing edge) of each tooth is not critical, as long as the desired ~lash removal function is ful~illed;
(b) the working clearance between the tip f each tooth 70 and the adjacent opposing sur~ace of the stationary shoe member 24 i9 not critical, and is typically not greater than 1 to 2 mm, according to the speci~ic design of the apparatu~;
(c) the greater the number o~ teeth 3paced around each side of the wheel member 10, the smaller will be the lengths o~ "~lash" removed by each tooth;
(d) the teeth may be made o~ any 3uitable material, such a~ for example, tool steel; and (e) an~ convenient method o~ securing the -~LZ~ 7;2 2020~0RDIV
teeth on the wheel member ma~y be used.
~ he ability of the apparatus to deliver an acceptable output extrusion product from feedstock in loose particulate or communited form is considerably enhanced by causing the radial depth (or height) of the arcuate passageway 48, in a pressure-building zone which lies immediately ahead (i.e. upstream) of the front face 54 of the abutment member 36, to diminish relatively rapidly in a preferred manner in the direction of rotation of the wheel member 10, for example in the manner illustrated in the drawings.
The removable die block 40 is arranged to be circumferentially co-extensive with that zone, and the said progressive reduction of the radial depth of the arcuate passageway is achieved by appropriately shaping the surface 40A of the die block that faces the bottom of the groove 12 in the wheel member 10.
That surface 40A of the die block is preferably shaped in a manner such as to achieve in the said zone, when the apparatus is operating, a feedstock metal flow pattern that closely resembles that which is achieved when using instead feedstock in solid form. In the preferred embodiment illustrated in the drawings, that surface 40A
comprises a plane surface which is inclined at a suitable small angle to a tangent to the bottom of the groove 12 at its point of contact with the abutment member 36 at its front face 54.
That angle is ideally set at a value such that the ratio of (a) the area of the abutment member 36 that i3 exposed to feedstock metal at the extrusion pressure, to (b) the radial cross-sectional area of the passageway 48 at the entry end of said zone (i.e. at the radial cross-section adjacent the upstream end of the die block 40) is equal to the ~Z~2~7~
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ratio of (i) the apparent density of the feedstock entering that zone at said entry end thereof, to (ii) the density of the ~ully-compacted feedstock lying adjacent the front face 54 of the abutment member 36.
In one satisfactory arrangement, the said plane surface 40A of the die block was inclined at an angle such that the said area of the abutment member that is exposed to feedstock metal at the extrusion pressure is equal to one half of the said radial cross-sectional area of the passageway 48 at the en-try end of said zone (i.e. at the upstream end of the die block).
If desired, in an alternative embodiment the surface of the die block facing the bottom of the groove 12 may be inclined in the manner referred to above over only a greater part of it~ circumferential length which extends from the said upstream end of the die block, the part of the die block lying immediately adjacent the front face 54 of the abutment member being provided with a surface that lies parallel (or substantially parallel) with the bottom of the groove 12.
The greater penetration of the die block 40 into the groove 12, which resul-ts from the said shaping of the surface 40A referred to above, serves al~o to offer increa~ed phy~ical resistance to the unwanted extrusion o~ flash-forming metal through the clearance gaps 32 and 34, so that the amount of feedstock metal going to the formation of such flash is greatl~ reduced. Moreover, that penetration of the die block into the groove 12 results in reductions in (a) the redundant work done on the ~eedstock, (b) in the amount of flash produced, and (c) the bending moment imposed on the abutment member ~2~26~;~2 2020~0RDIV
by the metal under ~res~ure. ~urthermore, the choice of a plane working surface 40A for the die block reduces the cost of producing that die block.
Whereas in the above description, the wheel member 10 is driven by an electric driving motor, at speeds within the stated range, other like-operating continuous extrusion machines may utilise hydraulic driving means and operate at appropriate running speeds.
As an alternative to introducing additional cooling water into the passageway 48 via the ~prinklers 65, hopper 52 and passage 50, such additional cooling water may be introduced into that pa~sageway (for example, via a pas3age 67 formed in the shoe member 24) at a position at which ~aid pa3~ageway i~ filled with particulate feedstock, bu-t at which said particulate feedstock therein is not yet fully compacted.
It is believed that the highly beneficial cooling effects provided by the present invention arise very largely from the fact that the heat absorbed by a part of the wheel member lying temporarily adjacent the hot metal in the confined extrusion zone upstream of the abutment member is conveyed (both by thermal conduction and rotation of the wheel member) from that hot zone to a cooling zone situated downstream of the abutment member, in which cooling zone a copious ~upply of cooling fluid is caused to flow over relatively large areas of the wheel member pas~ing through that cooling zone ~o as to extract therefrom a high proportion o~ the heat absorbed by the wheel member in the ho-t extrusion zone.
In this cooling zone access to the wheel ~5 member is less restricted 9 and relatively large ~2~ 67~
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~urfaces of that member are freely available for cooling purposes. This is in direct contrast to the extremely small and con~ined cooling surfaces that can be provided directly adjacent the extrusion zone in the parts of the said shoe member (i.e. the die block and abutment member) that bound that extrusion zone. As has been mentioned above, the cooling surfaces that can be provided in those parts are severely limited in size by the need to conserve the mechanical strengths of those parts and so enable them to sa~ely withstand the extrusion pressure exerted on them.
The conveying o~ heat absorbed by the wheel member to the said cooling zone can be greatly enhanced by the incorporation in said wheel member of metals having good thermal conductivities and good specific heats (per unit volume). However, since the said wheel member, for reasons o~ providing adequate mechanical strength, is made of physically strong metals, (e.g. tool steels), it has relatively poor heat transmission properties. Thus, the ability of the wheel member to convey heat to said cooling zone can be greatly enhanced by incorporating intimately in said wheel member an annular band of a metal having good thermal absorption and transmission properties, for example, a band of copper.
Such a thermally conductive band may conveniently be constituted by an annular band secured in the periphery of the said wheel member and preferably constituting, at least in part, the part of said wheel member in which the said circumferential groove is formed to provide (with the shoe member) the said passageway (48).
In cases where the e~trusion product o~ the machine is o~ a metal having suitably good thermal ~2~26'7;~
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properties, the said thermally conductive band may be composed of the same metal as the extrusion product (e.g. copper).
In other cases, said thermally~conductive band may be embedded in, or be overlaid by, a second annular band, which second band is of the same metal as the extrusion product o~ the machine and is in contact with the tip portion of the said abutment member, the two bands being of different metals.
Metals which may be used for the said thermally-conductive band are selected to have a higher product of thermal conduc-tivity and specific heat per unit volume than tool stee1, and include the ~ollowing (in decreasing order of said higher product):-Copper, silver, beryllium, gold, aluminium,tung~ten, rhodium, iridium, molybdenum, ru-thenium, zinc and iron.
~ he rate at which heat can be conveyed by such a thermally-conductive band from the extrusion zone to the cooling zone i9 dependent on the radial cross-sectional area of the band, and is increased by increasing that cross-sectional area. ~hus, for a given cross-sectional dimension measured transversely of the circumference o~ the wheel member, the greater the radial depth of a said band, the greater the rate at which heat will be conveyed to the cooling zone by the wheel member.
Calculations have shown that for a said wheel member having an ef~ective diameter o~ 233 mm, and a speed of rotation of 10 RPM, and a said thermally-conductive band of copper having a radial cross-section o~ U-shape, the rate "R" of conveying heat from the extrusion zone to the said cooling zone by the wheel member, by virtue of its rotation alone,
2 ~ Z 6 ~ Z
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varies in the manner shown below with variation of the radial depth or extent to which a said abutment (36) cooperating with the wheel member penetrates into that copper band, that is to sa~, with variation of the radial thickness "~" of the copper band that remains at the bottom of the said circumferential groove (12). The~e calculations were based on a said copper band having with the adjacent parts (tool steel) o~ the wheel member an inter~ace of generally circular configuration as seen in a radial cross section. ~ence, the radial cross-sectional area "A"
o~ the copper band varies in a non-linear manner with the ~aid radial thickne~s "~" o-~ copper at the bottom o~ ~aid groove (12).
~ (mm) A (sq. mm) R (kW) 1.0 18.0 5.1 1.5 22.7 6~4 2.0 27-4 7.7 2-5 32.1 9,1
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varies in the manner shown below with variation of the radial depth or extent to which a said abutment (36) cooperating with the wheel member penetrates into that copper band, that is to sa~, with variation of the radial thickness "~" of the copper band that remains at the bottom of the said circumferential groove (12). The~e calculations were based on a said copper band having with the adjacent parts (tool steel) o~ the wheel member an inter~ace of generally circular configuration as seen in a radial cross section. ~ence, the radial cross-sectional area "A"
o~ the copper band varies in a non-linear manner with the ~aid radial thickne~s "~" o-~ copper at the bottom o~ ~aid groove (12).
~ (mm) A (sq. mm) R (kW) 1.0 18.0 5.1 1.5 22.7 6~4 2.0 27-4 7.7 2-5 32.1 9,1
3- 36.8 10.4 In one practical arrangement having such a wheel member and a 2 mm radial thickness ~ of said copper band at the bottom of said groove (12), when operating at said wheel member speed and extruding copper wire of 1.4 mm diameter at a speed of 150 metres per minute, heat wa~ extracted ~rom the wheel member and abutment member in said cooling zone at a rate of 10 kW b~ cooling water ~lowing at as low a rate o~ 4 litres per minute and providing at the sur~aces to be cooled in said cooling zone a jet velocity of approximately 800 metres per minute.
~his heat extraction rate indicates that heat was reaching the cooling zone at a rate o~ some 2.3 kW as a result of the conduction of heat through the said conductive band, the adjacent wheel member 7;~
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parts, and the abutment member, induced by the temperature gradient existing between the extrusion zone and the cooling zone.
This measured rate of extracting heat by the cooling water flowing in the cooling zone compares very favourably with a maximum rate o~ heat extraction o~ some 1.9 k~ that has been found to be achievable by flowing cooling water in the prior art manner through internal cooling passages formed in the abutment member.
Figure 6 shows the way in which the rate o~
extracting heat from the wheel member and abutment member in said cooling zone was found to vary with variation of the rate of flow of -the cooling water supplied to that zone.
The extrusion machine described above with reference to the drawings was equipped for the practical tests with a said thermally-conductive band of copper, which band is shown at reference 74 in ~igure 10, and indicated, for convenience only, in dotted-line form in Figure 2. ,(It should be noted that Figure 2 also depicts, when the copper band 74 is repre~ented in full-line ~orm, the transverse sectional view taken on the section indicated in Figure 10 at II-II.) As will be understood from reference 74 in ~igure 2, the said copper band had a radial cross section of U-shape, which band lined the rounded bottom 16 of the circum~erential groove 12 and extended part-way up the parallel side walls o~
that groove.
Figure 7 shows in a view similar to that o~
Figure 2 a modification of the wheel member 10. In that modification, a solid annular band 76 of copper having a substantially rectangular radial cross-section i~ mounted in and clamped securely between `"` 124;267Z
2020FORDI~J-22-cooperating steel cheek members 78 of said wheel member, so as to be driven by said cheek members when a driving shaft on which said cheek members are carried is driven by said driving motor. ~he band 76 has, at least intially, a small internal groove 76A
spanning the tight joint 78A between the two cheek member3 78. That groove prevents the entry between those cheek members of any of the metal of said band 76 during assembly of the wheel member 10.
Complementary frusto-conical surfaces 76~ and 78~ on said band and cheek members re~pectively permit easier assembly and disassembly of those parts of the wheel member 10.
The circumferential groove 12, iæ formed in 15 the copper band by pivotally advancing the shoe member 24 about its pivot pin 26 towards the periphery of the rotating wheel member 10, so as to bring the tip of the abutment member 36 into contact with the copper band, and thereby cause it to machine the copper band progressively deeper to form said groove 12 therein.
Figure 8 shows an alternative form of said modification of Figure 7, in which alternative the thermally-conductive band comprises instead a 25 composite annular band 80 in which an inner core 82 of a metal (such as copper) having good thermal properties is encased in and in good thermal relationship with a sheath 84 of a metal (for example, zinc) which is the same as that to be extruded by the machine.
Figure 9 shows a further alternative form of said modification of Figure 7, in which alternative the thermally-conductive band comprises instead a composite band 86 in which a radially-inner 35 annular part 88 thereof is made of a metal (such as ` ` lZ~2~7~
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copper) having good thermal properties and is encircled, in good thermal relationship, by a radially-outer annular part 90 o~ a metal which is the same as that to be extruded by the machine. Said circumferential groove is machined by said abutment member wholly within said radially-outer part 90 of said band.
Metals which can be extruded by extrusion machines as described above include:-Copper and its alloys, aluminium and its alloys, zinc, silver, and gold.
It should be noted that various aspects ofthe present disclosure which are not re~erred to in the claims below have been made the subjects of the respective sets of claims o~ other patent applications all of which likewise claim priority from the same two UK patent applications, Nos. 8309836 (filed 12th April, 1983) and 8302951 (filed 3rd ~ebruary, 1983).
~his heat extraction rate indicates that heat was reaching the cooling zone at a rate o~ some 2.3 kW as a result of the conduction of heat through the said conductive band, the adjacent wheel member 7;~
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parts, and the abutment member, induced by the temperature gradient existing between the extrusion zone and the cooling zone.
This measured rate of extracting heat by the cooling water flowing in the cooling zone compares very favourably with a maximum rate o~ heat extraction o~ some 1.9 k~ that has been found to be achievable by flowing cooling water in the prior art manner through internal cooling passages formed in the abutment member.
Figure 6 shows the way in which the rate o~
extracting heat from the wheel member and abutment member in said cooling zone was found to vary with variation of the rate of flow of -the cooling water supplied to that zone.
The extrusion machine described above with reference to the drawings was equipped for the practical tests with a said thermally-conductive band of copper, which band is shown at reference 74 in ~igure 10, and indicated, for convenience only, in dotted-line form in Figure 2. ,(It should be noted that Figure 2 also depicts, when the copper band 74 is repre~ented in full-line ~orm, the transverse sectional view taken on the section indicated in Figure 10 at II-II.) As will be understood from reference 74 in ~igure 2, the said copper band had a radial cross section of U-shape, which band lined the rounded bottom 16 of the circum~erential groove 12 and extended part-way up the parallel side walls o~
that groove.
Figure 7 shows in a view similar to that o~
Figure 2 a modification of the wheel member 10. In that modification, a solid annular band 76 of copper having a substantially rectangular radial cross-section i~ mounted in and clamped securely between `"` 124;267Z
2020FORDI~J-22-cooperating steel cheek members 78 of said wheel member, so as to be driven by said cheek members when a driving shaft on which said cheek members are carried is driven by said driving motor. ~he band 76 has, at least intially, a small internal groove 76A
spanning the tight joint 78A between the two cheek member3 78. That groove prevents the entry between those cheek members of any of the metal of said band 76 during assembly of the wheel member 10.
Complementary frusto-conical surfaces 76~ and 78~ on said band and cheek members re~pectively permit easier assembly and disassembly of those parts of the wheel member 10.
The circumferential groove 12, iæ formed in 15 the copper band by pivotally advancing the shoe member 24 about its pivot pin 26 towards the periphery of the rotating wheel member 10, so as to bring the tip of the abutment member 36 into contact with the copper band, and thereby cause it to machine the copper band progressively deeper to form said groove 12 therein.
Figure 8 shows an alternative form of said modification of Figure 7, in which alternative the thermally-conductive band comprises instead a 25 composite annular band 80 in which an inner core 82 of a metal (such as copper) having good thermal properties is encased in and in good thermal relationship with a sheath 84 of a metal (for example, zinc) which is the same as that to be extruded by the machine.
Figure 9 shows a further alternative form of said modification of Figure 7, in which alternative the thermally-conductive band comprises instead a composite band 86 in which a radially-inner 35 annular part 88 thereof is made of a metal (such as ` ` lZ~2~7~
2020~0RDIV
copper) having good thermal properties and is encircled, in good thermal relationship, by a radially-outer annular part 90 o~ a metal which is the same as that to be extruded by the machine. Said circumferential groove is machined by said abutment member wholly within said radially-outer part 90 of said band.
Metals which can be extruded by extrusion machines as described above include:-Copper and its alloys, aluminium and its alloys, zinc, silver, and gold.
It should be noted that various aspects ofthe present disclosure which are not re~erred to in the claims below have been made the subjects of the respective sets of claims o~ other patent applications all of which likewise claim priority from the same two UK patent applications, Nos. 8309836 (filed 12th April, 1983) and 8302951 (filed 3rd ~ebruary, 1983).
Claims (28)
1. A method of producing a rotary wheel member adapted for use in a rotary, friction type, continuous extrusion apparatus, which method comprises the steps of:
(a) producing a rotary wheel having formed in its cylindrical peripheral parts a continuous, radially-extending groove, and secured in that groove for movement with said peripheral parts of said wheel an annular metal mass;
(b) rotating said wheel about its rotary axis; and (c) applying to the periphery of said annular metal mass secured in said wheel a tool of predetermined end shape, and progressively advancing said tool in a radial direction as said wheel continues to rotate whereby to machine in the peripheral parts of said annular metal mass a working groove of predetermined desired transverse cross-sectional shape;
said peripheral parts of said annular metal mass which define said working groove being of a composition which is substantially the same as that of a predetermined feedstock metal that is to be extruded in a said apparatus when equipped with the wheel member so produced; and said predetermined end shape of said tool being substantially the same as that of a predetermined abutment member which is to be used in that apparatus to close the end of an arcuate passageway which is formed in said working groove by a shoe member which when the apparatus is in operation co-operates with said cylindrical peripheral parts of said wheel member.
(a) producing a rotary wheel having formed in its cylindrical peripheral parts a continuous, radially-extending groove, and secured in that groove for movement with said peripheral parts of said wheel an annular metal mass;
(b) rotating said wheel about its rotary axis; and (c) applying to the periphery of said annular metal mass secured in said wheel a tool of predetermined end shape, and progressively advancing said tool in a radial direction as said wheel continues to rotate whereby to machine in the peripheral parts of said annular metal mass a working groove of predetermined desired transverse cross-sectional shape;
said peripheral parts of said annular metal mass which define said working groove being of a composition which is substantially the same as that of a predetermined feedstock metal that is to be extruded in a said apparatus when equipped with the wheel member so produced; and said predetermined end shape of said tool being substantially the same as that of a predetermined abutment member which is to be used in that apparatus to close the end of an arcuate passageway which is formed in said working groove by a shoe member which when the apparatus is in operation co-operates with said cylindrical peripheral parts of said wheel member.
2. A method according to claim 1, wherein said annular metal mass secured in said wheel groove is in good thermal relationship with said wheel.
3. A method according to claim 1 wherein said annular metal mass secured in said wheel groove comprises an annulus of a first predetermined metal lying concentrically with said wheel in said wheel groove and being enveloped within a sheath of a second predetermined metal, said second predetermined metal defining said working groove and being in good thermal relationship with said first predetermined metal.
4. A method according to claim 2 wherein said annular metal mass secured in said wheel groove comprises an annulus of a first predetermined metal lying concentrically with said wheel in said wheel groove and being enveloped within a sheath of a second predetermined metal, said second predetermined metal defining said working groove and being in good thermal relationship with said first predetermined metal.
5. A method according to claim 1, wherein said annular metal mass secured in said wheel groove comprises an annulus of a first predetermined metal lying concentric with said wheel in the bottom of said wheel groove and being overlaid by a second annulus of a second predetermined metal, said first predetermined metal being in good thermal relationship with said second predetermined metal and said second predetermined metal defining said working groove.
6. A method according to claim 2, wherein said annular metal mass secured in said wheel groove comprises an annulus of a first predetermined metal lying concentric with said wheel in the bottom of said wheel groove and being overlaid by a second annulus of a second predetermined metal, said first predetermined metal being in good thermal relationship with said second predetermined metal and said second predetermined metal defining said working groove.
7. A method according to claim 3, wherein said first and second predetermined metals, each have a product of thermal conductivity and specific heat per unit volume that is greater than that of the material of the wheel.
8. A method according to claim 4, wherein said first and second predetermined metals, each have a product of thermal conductivity and specific heat per unit volume that is greater than that of the material of the wheel.
9. A method according to claim 5, wherein said first and second predetermined metals, each have a product of thermal conductivity and specific heat per unit volume that is greater than that of the material of the wheel.
10. A method according to claim 6, wherein said first and second predetermined metals, each have a product of thermal conductivity and specific heat per unit volume that is greater than that of the material of the wheel.
11. A method according to claim 7, wherein said product for said first predetermined metal is greater than that for said second predetermined metal.
12. A method according to claim 8, wherein said product for said first predetermined metal is greater than that for said second predetermined metal.
13. A method according to claim 9, wherein said product for said first predetermined metal is greater than that for said second predetermined metal.
14. A method according to claim 10, wherein said product for said first predetermined metal is greater than that for said second predetermined metal.
15. A method according to claim 1, wherein said wheel is mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said working groove.
16. A method according to claim 2, wherein said wheel is mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said working groove.
17. A method according to claim 3, wherein said wheel is mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said working groove.
18. A method according to claim 4, wherein said wheel is mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said working groove.
19. A method according to claim 5, wherein said wheel is mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said working groove.
20. A method according to claim 6, wherein said wheel is mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said working groove.
21. A method according to claim 7, wherein said wheel is mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said working groove.
22. A method according to claim 8, wherein said wheel is mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said working groove.
23. A method according to claim 9, wherein said wheel is mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said working groove.
24. A method according to claim 10, wherein said wheel is mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said working groove.
25. A method according to claim 11, wherein said wheel is mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said working groove.
26. A method according to claim 12, wherein said wheel is mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said working groove.
27. A method according to claim 13, wherein said wheel is mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said working groove.
28. A method according to claim 14, wherein said wheel is mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said working groove.
29. A wheel member prepared by a method according to any one of claims 1, 2 or 3.
30. A wheel member prepared by a method according to any one of claims 4, 5 or 6.
31. A wheel member prepared by a method according to any one of claims 7, 8 or 9.
32. A wheel member prepared by a method according to any one of claims 10, 11 or 12.
33. A wheel member prepared by a method according to any one of claims 13, 14 or 15.
34. A wheel member prepared by a method according to any one of claims 16, 17 or 18.
35. A wheel member prepared by a method according to any one of claims 19, 20 or 21.
36. A wheel member prepared by a method according to any one of claims 22, 23 or 24.
37. A wheel member prepared by a method according to any one of claims 25, 26 or 27.
38. A wheel member prepared by a method according to
28. A method according to claim 14, wherein said wheel is mounted for rotation in a said rotary extrusion apparatus, and is rotated therein, and said tool comprises a said abutment member of said apparatus, which abutment member is advanced radially into said annular metal mass as said wheel is rotated, whereby to form said working groove.
29. A wheel member prepared by a method according to any one of claims 1, 2 or 3.
30. A wheel member prepared by a method according to any one of claims 4, 5 or 6.
31. A wheel member prepared by a method according to any one of claims 7, 8 or 9.
32. A wheel member prepared by a method according to any one of claims 10, 11 or 12.
33. A wheel member prepared by a method according to any one of claims 13, 14 or 15.
34. A wheel member prepared by a method according to any one of claims 16, 17 or 18.
35. A wheel member prepared by a method according to any one of claims 19, 20 or 21.
36. A wheel member prepared by a method according to any one of claims 22, 23 or 24.
37. A wheel member prepared by a method according to any one of claims 25, 26 or 27.
38. A wheel member prepared by a method according to
claim 28.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000519819A CA1242672A (en) | 1983-02-03 | 1986-10-03 | Continuous extrusion of metals |
Applications Claiming Priority (6)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB838302951A GB8302951D0 (en) | 1983-02-03 | 1983-02-03 | Continuous extrusion of metals |
| GB8302951 | 1983-02-03 | ||
| GB08309836A GB2134428B (en) | 1983-02-03 | 1983-04-12 | Continuous extrusion of metals |
| GB8309836 | 1983-04-12 | ||
| CA000446420A CA1225366A (en) | 1983-02-03 | 1984-01-31 | Continuous extrusion of metals |
| CA000519819A CA1242672A (en) | 1983-02-03 | 1986-10-03 | Continuous extrusion of metals |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000446420A Division CA1225366A (en) | 1983-02-03 | 1984-01-31 | Continuous extrusion of metals |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1242672A true CA1242672A (en) | 1988-10-04 |
Family
ID=27167411
Family Applications (3)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000519819A Expired CA1242672A (en) | 1983-02-03 | 1986-10-03 | Continuous extrusion of metals |
| CA000529954A Expired CA1228835A (en) | 1983-02-03 | 1987-02-17 | Continuous extrusion of metals |
| CA000529955A Expired CA1228836A (en) | 1983-02-03 | 1987-02-17 | Continuous extrusion of metals |
Family Applications After (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000529954A Expired CA1228835A (en) | 1983-02-03 | 1987-02-17 | Continuous extrusion of metals |
| CA000529955A Expired CA1228836A (en) | 1983-02-03 | 1987-02-17 | Continuous extrusion of metals |
Country Status (1)
| Country | Link |
|---|---|
| CA (3) | CA1242672A (en) |
-
1986
- 1986-10-03 CA CA000519819A patent/CA1242672A/en not_active Expired
-
1987
- 1987-02-17 CA CA000529954A patent/CA1228835A/en not_active Expired
- 1987-02-17 CA CA000529955A patent/CA1228836A/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| CA1228836A (en) | 1987-11-03 |
| CA1228835A (en) | 1987-11-03 |
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