ET 2012
posted by: Paul Robbins
Products
A Complete Castool Tooling Package:
(All necessary spares are included)- 2-3 Containers
- 6-8 Die Ovens
- 2-3 Dummy Blocks
- 2-3 Stems
- 1-2 Clean-Out Blocks
- 2-3 Pyrometers
- 1 TC Quench
- 1 Lubricator
- 1 Visual Optimizer
Quick Response Container
Castool's QR control system positions the heating elements immediately adjacent to the liner, where heat is required. The goal is to control the temperature of the liner, so that the alloy exits a preheated die uniformly at or close to optimum temperature and maximum speed.
- Reduces energy costs, increases productivity, improves die performance
SuperOvens
*Patent pending
Castool has now introduced a line of Superovens which, by enhanced utilization of radiation-conduction technology, reduce former minimum time-to-temperature by 30-40%.
Dummy Block
The RR Replaceable Wear Ring Dummy Block has a high-strength steel expanding wear ring that is quickly and easily removed or restored.
The Marathon Dummy Block is designed and produced for the press on which it will be run. It continues to set new records for longevity and economy.
- Quick-lock bayonet coupling reduces downtime
Stem
The stem acts as a column, transmitting the force of the main cylinder to the billet. It must operate under sometimes extremely high loads without bending, cracking, or upsetting.
Castool stems are custom designed and modeled specifically for the pressure of the press on which they will be used.
Clean-out Block
After each change of alloy, and also at least once each day, a clean-out block should be used to remove the build-up of oxide skin from the container liner.
The Castool clean-out block is precisely sized for maximum efficiency in cleaning the liner wall of each individual container.
Shear Blade
- Effectively ejects the butt
The optimum design of the shear blade varies with the size of the press, and the alloy - shape combination to be sheared.
The shape of the cutting edge of Castool blades is designed and customized to meet the individual requirements of the extruder. Castool blades are tempered to a toughness that resists chipping, and ensures an extra long operating life.
Alignment Tool Stack
An alignment tool stack helps the extruder to quickly and easily check and correct press alignment - the die stack alignment to the pressure plate bore and the stem alignment to the container bore.
Total Control (TC) Quench
A new PLC controlled cooling quench is now in the final stages of development and field trials, and will shortly be on the market. Each cooling zone will use the latest technology in nozzles, allowing air, mist, and flooding, from top, bottom or each side.
The extruder will be able to control the air pressure and water flow going to each manifold, and therefore the precise rate of cooling.
Visual Optimizer
The Castool Visual Optimizer is customized to fit each extruder's needs, but it will typically include ram speed, dead cycle time, billet temperature, container liner temperature, profile exit temperature, quench rate, and the status of each die being preheated.
Properly used, the Castool Visual Optimizer can be guaranteed to improve the productivity of any extrusion system.
RDX System
The Castool RDX System is an innovative process designed to assist the operator in improving productivity by making best use of the knowledge gained during Visual Optimization.
- Operator safety. Time spent moving dies in and out of die ovens is eliminated.
- Once die production formula is entered in RDX, human error is eliminated.
- Die is held at operating temperature until use.
- Valuable floor space required for die ovens and dies is considerably reduced.
Billet Lubrication
Castool Tooling Systems has developed a unique process of application of liquid boron nitride to a preheated extrusion billet prior to loading into the press.
The process enables improved coverage compared to boron nitride powder application with much less overspray and lower consumable costs, with the additional benefit of cooling the rear of the billet prior to extrusion, thus enabling higher extrusion speeds.
Remote Optical Pyrometers
These ultra-precise remote optical pyrometers consistently measure real temperatures within 1% accuracy. They are used to measure the press exit temperature, and also the profile immediately after the quench on the run-out table.
The 3T remote optical pyrometers provided by Castool are the most accurate and user-friendly available today.