Extrusion Press Maintenance Manual
Optimize your extrusion press with Mechanical Maintenance and Lubrication to avoid common problems. Preventive Maintenance Program Recommendations, Daily Check Sheet Procedure & Troubleshooting from experienced professionals.
By Al Kennedy
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 Extrusions, Dubai - Farrel Maintenance Training Course information:
- Press Installation
- Mechanical Functions of an Extrusion Press
- Mechanical Maintenance
- Correct Bolting Procedures
Press Alignment
- Press Alignment and Its Impact on Extrusion Performance, from a webinar by Richard Dickson, Hydro Aluminum, and Chris Jowett, Rio Tinto Aluminum
- Alignmeent Principles
- Alignment Procedures Using Traditional Mechanic’s Tools
- Use of the Alignment Tool Stack
- Quick Checks of Press Alignment
- Modifying the Press for Easier Adjustment of Alignment
- Laser Tracker Measurement Technology for the Alignment, Correction, Condition Monitoring, and Refurbishment of Extrusion Presses, from Joseph Mulder
Tooling
- Fixed Dummy Blocks
- Loose Dummy Blocks
- Clean-out Blocks
- Stem
- Container
- Container Liner
- Recent Improvements in Container Design
- Development of a Thermally Stable Container
- “Extrusion Container Care and Maintenance,”
by James M. Pope, Special Projects Consultant to Lake Park Tool - Container Life and Relining Frequency
- “Preventive Maintenance of Extrusion Tooling,”
by Gary Dion, Extrusion Consultant - Minimizing the Occurrence of Flared Billets
- “Press Tool Lubrication Systems,” by James Dyla, Amcol Corp
Inspecting and Repairing Major Components
- Procedure for Repairing Cracked Main Cylinder
- How Major Components are Designed and Tested
- Analysis of Failure of a Container Shifting Cylinder Rod
- “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 - Additional Recommendations for Successful Component Replacement
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
- Recommendations for Hydraulic Maintenance from a presentation by Jeff Grube, Rexroth, at AEC Workshop
- Oil Sampling Procedures
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 - “E-Stop” Emergency Stop Buttons
- Grounding
- Troubleshooting & Documentation
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
- “Aluminum Extrusion Saw Blade Lubrication,”
by James Dyla, Amcol Corp. - Saw Length Gauges
- Off-Load Conveyors
- Profile Stackers
Age Ovens
- Heat Treated – “T” Tempers
- Temperature Surveys
- Alternative Age Oven Configurations
- Combustion Systems
- Routine Combustion System Maintenance
- Improving Age Oven Energy Efficiency
- “The Ageing Process for Extruded Aluminum Profiles,”
paper by Al Kennedy
Die Ovens
- Temperature Uniformity
- Maintenance
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 and Purchasing a New Press
- Modernizing the Press Feed Line
- Modernizing the Handling System
- Downstream Material Handling
- Auxiliary Equipment
- Complete Extrusion Press Rebuilds
- 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 – Continuous Improvement
- Equipment Information Files and History
- Spare Parts Inventory
- “High-Tech Tools for Extrusion Plant Maintenance,”
by Al Kennedy
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
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