Extrusion Asia Edition 2-2021

ny such surfaces in a quality tool, cleanliness is critical. Checking of the tools for any deformities is also important. Burrs, scratches and scrapes are usually a result of careless handling and/or storage of equipment. Double and triple-layer extrusion heads pose an even greater challenge for mainten- ance. The number of sealing and centering surfaces multiplies and can magnify the results of dirty tools. During changeovers, the head may be disassembled in order to change compounds and/or tips and dies. Foreign matter is usually introduced at this point and residual materials must be thoroughly removed. Phy- sical tool damage often occurs during this phase, due to mis- handling and poor storage techniques. These are highly precise parts, but can also be heavy and bulky to remove by hand. Use of a dedicated work cart exclusively reserved and equipped for extruder head maintenance is recommended. This cart along with a supply of spare components and hardware is easi- ly justified, especially when examining the potential cost sav- ings that result from well-maintained tools. The following should be considered: 1.) Maintain a clean, organized work area with soft and clean renewable work surfaces; 2.) Use a vise with soft jaws, such as copper; 3.) Use special equipment, such as tip removal tools, etc.; 4.) Standard tools include wrenches, soft-faced hammers, etc.; 5.) Maintain a supply of soft, clean rags; 6.) Use cleaning solutions in spray bottle; 7.) Use spare parts as suggested by your tooling supplier, pro- perly organized and stored; 8.) Keep handy your equipment’s repair/maintenance manual; 9.) Have a small surface plate to provide a true flat surface; 10.) Use a set of appropriate gauge and tip pins for initial tool location adjustment; 11.) Make sure you have all the proper lifting aids available, including overhead hoists, hydraulic lifts, etc. In most situations, the head and too- ling will still be at elevated temperatures, therefore lined gloves are needed when handling. Today, tubing manufacturers compete with companies all over the world. To be a successful and profitable company, quality and efficiency are essential. This is especially true in extrusion, where material costs are usually much higher than labor costs. Like a racing car stuck in the pit, many extruders sit idle be- cause of poor or damaged tooling, plus excess maintenance time. Overhead costs add up and losing money is the result. Some start up quickly and make scrap, whereas others start up and run a product oversized to hold minimum tolerance. They waste 10% to 20% of the material, which can run from 50% to 90% of the product cost. The tooling supplier goes to great lengths so that tips and dies are machined to a determined spe- cification, ensuring perfect concentricity and alignment. The material is then distributed in the proper location as part of the finished product. Understanding Maintenance Procedures Example 1 : In this example, with an improperly centered tool, a calculated out-of-tolerance area of 0.059 in 2 (38 mm 2 ) was derived. When the two surface areas were compared, the cal- culated material waste was 11.8% of the finished product. The formula is % wall = min. wall thickness, max. wall thickness X 100. Example 2 : Alternatively, if the % wall can be increased from 80 to 95%, a savings of about 12% of total cost can re- sult. Savings will vary depending on the designs, of course. Get help for heavy parts and awkward situations. Surfaces and edges are hard and therefore somewhat brittle, so dropping a part or striking parts together can result in damage. Store your tools properly in a dry, clean area – a dedicated spot for each tool is best. These areas should have soft surfaces and each in- strument should be covered after cleaning. Also, tools should be segregated so that they do not come into contact with each other. And tools and all instruments should be cleaned tho- roughly before storage. For disassembly of tools, it is imperative to use purpose-built tooling to facilitate disassembly. These should be available from your supplier. If they are not, consult with a reputable tooling house for replacements. The cost of these tools is easily offset by potential damages, frequently caused by improper equip- ment such as hammers and drifts. Follow the guidelines out- lined in your operator’s manual. Individual tools may have spe- cific recommendations, so contact your supplier if anything is unclear. Your supplier understands that optimum performance relies on proper care and maintenance. Here are some useful tips: 1.) Clean your equipment while it is still hot as the residue is easier to remove. It helps to remove and clean one piece of tooling at a time in order to maintain elevated temperatures. 2.) When cleaning a dual compound crosshead, (plastic and rubber) clean the plastic tooling first; the rubber second. 3.) Never use steel tools such as scrapers or screwdrivers be- cause these can scratch and mar the tooling. 4.) Do not use open flames because this generates excessive heat especially in thin sections, which can affect hardness, concentricity and tolerances of components. Recommended cleaning tools and materials include: a.) Brass pliers to grip material and aid in pul- ling; b.) Brass scrapers available in different widths for cleaning flat exposed surfaces; c.) Brass bristle tube brushes that are available in diameters from 1/16" to 1" in 1 /16" increments (ideal for cleaning holes and recesses); d.)Brass rods – different diameter rods are good for pushing material out of flow holes; e.) Copper gauze for cleaning and polishing exposed round or conical surfaces; f.) Copper knives for removing residue from recesses and other hard-to-reach areas. Also, polishing com- pound restores polished surfaces; g.) Compressed air, which is more effective for releasing plastic, but also aids in rubber re- moval. Be careful not to force debris into recesses with com- 28 挤出工具 Extrusion Asia Edition 2/2021 Guill Kelpac