Fixed Dummy Blocks

Dummy block failure is usually related to the limited elasticity of the steels used and the extreme
stresses involved, which tend to expand the block past the steel’s creep limits. When the block’s
outside diameter experiences a permanent increase of 0.020” (0.5mm), permanent loss of
elasticity is likely to have occurred. Common problems are the build-up of excessive aluminum on
the block, causing high drawback loads and blistering; and wear on the periphery of the block.
Fixed dummy blocks are commonly constructed of alloy H-13 steel, and hardened to Rockwell C 45
- 49.

Clearance Within the Container. The diameter of the dummy block must be selected to allow a
tight seal to the container during extrusion, and sufficient clearance to pass easily through the
container during the return stroke. There is no general agreement on the proper clearance, as it
will depend somewhat on the design of the block. Also, poor press alignment will require greater
clearance and thus poorer block performance. Recommended clearances between block and
container vary: most commonly 0.030” (0.75mm); but 0.4 to 1.0mm (0.016” to 0.040”) according to
other sources5. In fact, most press operators must arrive at the optimum clearance for their
situation by trial and error.

Method of Attachment to the Ram Stem. Once again, different proprietary designs tend to
prevail. The most basic method of attachment is a threaded stud connecting ram stem to dummy
block; drawbacks to this design include inflexibility, seizing, difficult changing, and occasional
loosening of the block. If the block becomes loose on the stud, the full force of extrusion will
come to bear on the stud and will likely break it. Keys and dowels are commonly used to prevent
loosening. A second popular design is the tie bar passing through the stem to a nut at the rear. In
this case the base of the block is always in contact with the stem, avoiding excessive loads on the
threads.A proprietary bayonet-type design is said to permit quick change of the block. It is also
said to avoid thread damage and to accommodate a small amount of misalignment by permitting
some radial movement.

Why Laser Tracker Technology is More Efficient for

Aluminum Extrusion Press Alignment
by Hubert Meagher | Sep 1, 2016 | Extruders, Precision Measurement | 0 comments
The misalignment of components within an aluminum extrusion press can cause significant
issues such as inconsistent die performance, uneven wear, premature failure or excessive
wear of dummy blocks, and in extreme cases, damaged and/or broken stems, containers and
tie rods. Misalignment in the press not only causes equipment damage and increased
downtime, product issues such as out-of-spec wall thickness and other product defects can
occur leading to increased scrap levels, higher costs and ultimately, unhappy end customers.
 Extrusion press alignment inspection with laser tracker

For many years, aluminum extrusion press alignment was performed using traditional
alignment methods such as machinist levels, trammel rods, plumb bobs, piano wires and
optical tooling. Though these traditional methods and tools have stood the test of time and
are still often used today, they can be limited and extremely time consuming (which means
longer downtime!). Fortunately, with the capabilities of the newer, innovative 3D metrology
tools, such as laser trackers, the inspection and alignment of aluminum extrusion presses is
much more efficient, quicker, and cost effective.
Laser trackers work exceptionally well for aluminum extrusion press alignment. Using a laser
tracker, a metrology engineer can quickly capture high tolerance dimensional measurements
– including conventional level and square measurements. Additionally, because laser trackers
work seamlessly with metrology analysis software, data is presented in real-time, allowing
for necessary adjustments to be made swiftly.
One of the problems associated with the maintenance or alignment of extrusion presses, is
their operating temperature. Traditionally, a long cool-down period had to occur before an
alignment could be performed. Although extrusion presses still cannot be serviced while in
operation, with laser trackers adapted with next-gen components, specifically the T-Probe
technology used with the Leica AT960 laser trackers, metrology engineers can now attain
measurements in hot areas that could not be measured before. This capability allows the
manufacturers of aluminum extruded products to significantly reduce press downtime – one
of the greatest benefits of using modern 3D metrology tools for press alignment.
Laser tracker technology can do more than replace traditional tooling and methods, using
these innovative instruments metrology engineers can inspect for:
 Platen-to-platen vertical and horizontal offset
 Platen-to-platen “twist”
 Centerline coincidence of ram, container, and die
 Travel profile of ram, crosshead, and stem
 Ways wear and alignment
 Container and die platen movement
 Tie rod length
 Tie rod extension under load
 Dynamic movement of components
 Foundation stability studies
 Image shows platen parallelism inspection of tie rods. Data gathered using laser tracker and displayed using metrology
software. Measurements were gathered with main ram unloaded.

If you would like to learn more about how YOU can benefit from 3D metrology services for
aluminum extrusion press alignment, please contact us. Be sure to subscribe to our Industry
Blog for regular updates on metrology tools and methodologies, case studies, industry news
and more.

Table of Contents for the Extrusion Press Maintenance Manual:

Introduction

 Acknowledgments
 References
 Useful Tables:
 Conversion of Units
 Temperature Conversion
 Calculating Stretcher Capacity - English Units
 Calculating Stretcher Capacity - Metric Units
 Weight of Extrusion Billets
 Press Specific Pressure - English Units
 Press Specific Pressure - Metric Units
 Millimeter Conversion
  Time Limits for Tooling in Oven at Temperature
 Thermocouple Types
 Glossary of Terms for Press Components
 Diagrams of Press Components

Routine Inspection and Maintenance

 Scheduled Maintenance
 Mechanical Maintenance
 Lubrication
 "Preventive Maintenance Program Recommendations" (The Voice of Experience), by David
Turnipseed
 Daily Check Sheet Procedure
 Daily Check Sheet (Sample)
 Press Troubleshooting Chart
 "Extrusion Press Maintenance - A Predictive Approach" (The Voice of Experience) by P.
Gopalan Kutty, Gulf trusions, Dubai
 Farrel Maintenance Training Course information:
 Press Installation
 Mechanical Functions of an Extrusion Press
 Mechanical Maintenance

Press Alignment

 Alignment Procedures
 Recommended Tools
 Alignment and Leveling of the Fixed Press Components
 Alignment of the Moving Press Components
 Use of the Alignment Tool Stack
 Quick Checks of Press Alignment
 Modifying the Press for Easier Adjustment of Alignment
 "Extrusion Press Alignment with Modern Technology," by J.E.V. Mulder and G.J. Smith,
University of Otago, New Zealand

Tooling

 Fixed Dummy Blocks

 Loose Dummy Blocks
  Clean-out Blocks
 Stem
 Container
 Container Liner
 "Extrusion Container Care and Maintenance," by James M. Pope, Special Projects Consultant
to Lake Park Tool
 Improvements to Container Design
 "Preventive Maintenance of Extrusion Tooling," by Gary Dion, Extrusion Consultant Minimizing
the Occurrence of Flared Billets
 "Lubrication of Extrusion Press Tooling" by James Dyla, Amcol Corp.

Inspecting and Repairing Major Components

 Procedure for Repairing Cracked Main Cylinder

 How Major Components are Designed and Tested
 "Adapting Extrusion Presses for a High Cycle Fatigue Load Environment," by J.O. Nøkleby,
Det Norske Veritas
 In-Service Inspection, Repair, and Trouble-Shooting
 Failed Components - Repair or Replace?
 Requirements for Replacement Components
 "Catastrophic Failure: A 48 Hour Remedy," by Rick Colden and Adam Cramlet, Alexandria
Extrusion

Hydraulic Equipment

 Hydraulic Oil
 Filtration
 Temperature
 Sampling & Analysis
 Air Breather
 Pumps
 Valves
 Piping
 Pressure Gauges
 System Documentation
 Troubleshooting
  "Proper System Maintenance to Avoid Contamination and Cavitation," by Jack Hayes, Oilgear
 Farrel Maintenance Training Course information:
 Hydraulic Maintenance
 Right and Wrong Ways to Install Hydraulic Tubing and Fittings
 Troubleshooting Hydraulic Problems
 Glossary of Hydraulic Terms
 ISO/CETOP Hydraulic Symbols
 Oilgear Training Bulletins:
 Hydraulic System Survival Techniques #90012
 Filtration Recommendations #90007-D
 Piping Information #90011-F
 Resistance of Valves and Fittings to Flow of Fluids
 Storage Recommendations #90006B

Electrical & Controls

 Maintenance of Control Equipment

 Container Heating
 Electric Motors
 "Extrusion Press Electrical Systems," by David Turnipseed
 "Tips for Successful Electrical Trouble Shooting of Extrusion Equipment," by David Turnipseed

Billet & Log Infeed Systems

 Billet/Log Infeed Conveyors

 Billet/Log Heaters - Gas Fired
 Refractory and Insulation
 Thermocouple Probes
 Combustion Systems
 Billet Heaters - Induction
 Log Shear
 Log Saw
 Billet Transfer Conveyor
 Billet Lubrication
Profile Handling Systems

 High Temperature Textile Materials

 Lead-out Tables
 Run-Out Conveyors
 Water Quench Systems
 Air Quench Systems
 Saws and Shears for Hot Profile Cut-Off
 Pullers
 Profile Transfer Systems and Lift-Overs
 Cooling Tables:
 Walking Beams
 Belt Conveyors
 Stretchers
 Saw Feed Conveyors
 Finish or Cold Saws
 Saw Blade Lubrication
 Saw Length Gauges
 Off-Load Conveyors
 Profile Stackers

Age Ovens

 Temperature Surveys
 Basic Age Oven Configurations
 Combustion Systems
 Routine Combustion System Maintenance
 Improving Age Oven Energy Efficiency

Die Ovens

Maintenance Schedules

 When to Perform Extrusion Plant Maintenance

 Master Maintenance Schedule
 Daily Maintenance
  Weekly Maintenance
 Monthly Maintenance
 Quarterly Maintenance
 Six Months Maintenance
 Annual Maintenance

Spare Parts

 Recommended Spare Parts

 Storage of Spare Parts

Modernizing Older Presses

 Specifying a New Press

 Modernizing the Press Feed Line
 Modernizing the Handling System
 Downstream Material Handling
 Auxiliary Equipment
 Vendor Request form for Press Upgrades
 "The Extrusion Press Line for 2024: A Forecast," by Al Kennedy
 Double-Length Run-out Systems

Safety & Environment

 Extrusion Tooling Safety

 Safe Lifting Techniques
 Mechanical Press Equipment
 Keeping Overhead Cranes Safe
 Check List of Safety Hazards
 Personal Protective Equipment
 Lock-Out Tag-out Procedures
 Environment

Managing Extrusion Plant Maintenance

 The Maintenance Level Audit

 Staffing and Required Skills
 Maintenance Engineering
 Equipment Information Files and History
  Spare Parts Inventory
 "Ten High-Tech Tools for Extrusion Plant Maintenance," by Al Kennedy

How to make aluminum press extrusion container

and extrusin liner?
 Published on April 27, 2017
Abel T.

Sales Engineer for Aluminium extrusion die(Matriz de extrusión de aluminio)

67 articles Follow

The aluminium extrusion container and liner is the main part of the extrusion press. many billets work in the
container and the liner during usage. The performance of container and liner rest with persistent maintenance
and liner processes at correct tolerances.

life-time Factors for the liner and the container:

1)Steel materials

1).Heating and cooling cycle.

2).High temperatures influence the features of steel and excessive temperatures can result in serious damages.

3).The wear of the liner during the extruding working

4)The extrusion pressure effect progresses from the liner towards the container. The liner and the container will
be harmed earlier or later case of excessive pressures.
Solution for improving life time of extrusion container and liner:

1).Use the quality steel.

2).Apply latest assembly strucuture for liner and container

3).Apply lastest heating system

4).Produce and install liners compliant with the highest standards.

5).Use precision and advanced heat treatment equipment

Extrusion container and liner maching processing:

1).Rough turning 2).Rough boring 3).Fitter 4).heat treatment 5).Fine turning 6).Fine boring

Heat Treatment:

Qualiy container and liner need quality heat treament.For liner,use oil quenching equipment for stress relieved
then do tempering three times,hardness should reach HRC48-52. For out container,the quenching and tempering
tempreature should be under better control,not low or excessive,otherwise steel performance will be
influenced.Its hardness should reach HRC38-42

Extrusion liner change/liner replacement remarks:

1)Use brand high quality steel for the new liner

2)Test the container against cracks and damages.

3)Measure the hardness of every area of the container.

4)Doing heat treatment

5).Remove the damaged liner and the liner holder when necessary.

6).Amend the container or liner holder surfaces as a result of the assessments.

7).Complete the production of the new liner in the determined dimensions.

8).Doing heat treatment

9).Assembly liner into container

Attensions:

Temperature and press pressure should be considered in the processing.

The container status needs to be well recorded even in a trouble-free production.

When designing,status of container and its variables should be calculated well.

If you have any question in working,welcome to share your experiences,we can find
effective solution together.
Abel Tsao Skype:abel8868 Email: [email protected] Whatsapp:0086-
15906155538
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Abel T.

Sales Engineer for Aluminium extrusion die (Matriz de extrusión de aluminio)

Published • 2y

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2y
 Ramzi A.A Abu surourPlants director ( Operations & technical ) at Arab aluminum manufacturing company

But to keep your container running , you have to run the press in good operation for give more life of liner and add
more : Good Mechanical alignment , there is not flashes in press but The role of thumb , How many billets in
operation then you might change the liner ? did any body have experience on that
LikeLike Ramzi A.A Abu surour’s commentReply

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2y
 Abel T.Sales Engineer for Aluminium extrusion die (Matriz de extrusión de aluminio)

yes,thanks for your contributions.for operation experience,you give the best advices.for changing liner,not easy for
all extruders and will take long time.for this problem one of my clients try to change liner,heating,hang up down and
cooling,but finally not remove the liner sucessfully.
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2y
 Денис Яровенкоadjustment of pressing tools and tooling

Thank you so much.

LikeLike Денис Яровенко’s commentReply

1 Like1 Like on Денис Яровенко’s comment · 1 Reply1 Comment on Денис Яровенко’s comment

2y
 Abel T.Sales Engineer for Aluminium extrusion die (Matriz de extrusión de aluminio)

thanks
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DUMMY BLOCK

The dummy block is a critical element of the aluminum extrusion production process. Its
successful operation depends on a number of factors. For example, press alignment (both
thermal and physical), lubrication, maintenance and so on. The most important factor in the
 effective operation of any dummy block is its efficient interaction with a round, straight,
thermally and therefore dimensionally stable container.

With these Dummy Blocks, CASTOOL again sets a new standard of excellence in the extrusion
industry.

It allows to :
 Reduce scrap, due to back end blisters and surface defects
 Reduce cost of operation
 Reduce downtimes
 Increase productivity
 Increase operating life
LEARN MORE
DATA SHEET