CTS-EXT Lube - Castool Tooling Systems
Contents
1. LUE RICA TION PURPOSE e To help instantly and cleanly separate the dummy block from the billet at the end of each extrusion cycle without pulling extruded section from the die a Liquid Billet Lubrication System e Aluminium alloys stick to steel at or y above 450 C and becomes more of a problem the larger the billet diameter because of the increased surface area retract without any adhesion to the billet Operation T X s a E TOOLING SYSTEMS ALU JECT is a soluble lubricant made up of a blend of acids and salts to form a soap The lubricant dries onto the billet forming a lubricant barrier protecting the dummy block from the aluminum billet and allowing the dummy block to easily When the trigger 24 vdc from the press is received billet in position the spray cycle is executed The spray head extends and seals against the outer diameter of the billet Atomized lube is sprayed on the billet face Spray head then returns back and provides a signal cycle completion back to the press PLC Spray Head Stand Footprint 1 5 Wx3 5Hx4 5 L 457mm W x 1066mm H x 1371mm L Lube Unit Controller Footprint 2 Wx4 Hx1 5 L 609mm W x 1219mm H x 457mm L Controller amp Hardware e Moeller Eaton PLC EASY512 DC RCX e 6 Linear Non Rotating Actuator with Pressure and Flow Control Valve e Diaphragm Pump e Gerlieva Spray Head with Atomizing Nozzles e Green Led Power On e Red Led Low Lube e Test Cycle Push Button e Purg2. automatically since the flame is lit as the billet passes the burner on its way out of the preheating furnace Carbon is a good release agent but due to its small size carbon black is a carcinogenic Workers must be protected against breathing in any powder that does not stick to the billet This also causes problems with the quality of the extruded profile It can create black marks on the profile that cannot be removed and interfere with anodizing The application of electrostatic Boron Nitride BN is a good alternative Its release and lubrication characteristics outperform carbon black It is also simple to automate the coating of the billet when using BN BN is not carcinogenic is nontoxic and chemically inert There will be no white marks even inside the die therefore there are no marks on the profile surfaces Castool Tooling Systems has developed a unique process of application of a liquid soluble lubricant to a preheated extrusion billet prior to loading into the press The obstacle to their use was the Leidenfrost affect which makes it difficult to coat a surface greater than 450 C with a water based product New binders have been developed which makes it possible to now apply water based lubricant to the billet The process enables improved coverage compared to boron nitride powder application with much less overspray and lower consumable costs August 2015 CASTOOL MANES EXTRUSION BET TER CASIOOL TOOLING SYSTEMS
3. e Cycle Push Button e 4 Axis Adjustable Spray Head Stand e User Manual Power 120 240 vac Air 90psi Tank e Stainless Steel 4 75 Gal 18 Litre Capacity Tank e Mesh Filter for pouring the Lube e Two Level Indicator Windows e Lube Agitator BENEFITS of the Castool Lubrication System aes Powder Billet Lubrication System Castool s GEMA applicator has been designed to adapt to almost any required configuration The GEMA applicator utilizes the electrostatic technology to spray Boron Nitride Power The structure of Boron Nitride is very similar to graphite but with 25 better friction coefficient than graphite Boron Nitride possesses dielectric property which can be polarized to spray and adhere onto the billet with consistent dosage and coverage Experience has shown that Boron Nitride only needs to be applied for every 5 billets Release Agents Greases and oil based graphite suspensions can only be applied by hand They are cheap but require a worker to be present at all times These materials are inflammable at high temperature This can cause problems with electrical equipment Also explosions create blisters in the billet which can lead to small holes in the extruded profile This cannot be tolerated by most markets today Handling is also messy and the material is environmentally problematic Acetylene is ignited in front of the billet generating carbon black Acetylene was the first technology to operate
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