scalpers and band saws Aluminium industry solutions

scalpers and band saws Aluminium industry solutions

InGOT scalpers Wide product range for various demands The particularly rigid design of the ingot scalpers from SMS group allow plant owners to achieve excellent surface qualities in the µm range even with hard aluminium alloys. Whether for vertical, horizontal or combined milling: SMS offers the right machine to meet the different milling applications, dimensions and power rating including chip handling, electrical equipment, automation and measuring and control engineering. scalpers FOr InGOT main surfaces Type DV featuring: Two side-mounted milling heads for machining ingots in vertical position. Type SH featuring: One top-mounted horizontal milling head, ingot turnover table for machining ingots in horizontal position Type SHE featuring: Combined edge and surface scalping devices for simultaneous scalping of main surfaces and edges scalpers FOr InGOT edges Types EK and DK featuring: Scalping devices on either one or both sides, with 2 or 3 milling heads per side. These edge scalpers can be arranged in line with any of the three surface scalpers described above Type DH featuring: One top-mounted and one bottom-mounted milling head for machining ingots in horizontal position. 2 advantages at a Glance: Multiple use of carbide tips (up to four edges) Same carbide tip for roughing and finishing operations Tiltable second finisher for optimised surface structure Clamping via draw pin in a non-contaminated position Designed for optimised chip extraction Positive rake angle leads to chip evacuation in direction of the chip suction pipes Free chip flow without any interference of clamping elements 3

InGOT scalping machines Type DV and type DH InGOT scalping machines TYpe dv The double-head ingot scalping machines, Type DV, for ingots passing in vertical position are recommended for high capacities and ingots of large dimensions. The machines can also be supplied in smaller design. As a standard the ingots are conveyed in to the movable clamping frame by an infeed swing table and taken off by the discharge swing table when the scalping process has been completed. For smaller capacities the machine can be equipped with only one swing table serving for infeed and discharge of the ingots. InGOT scalping machines TYpe dh On the double-head ingot scalping machine, Type DH, the ingots pass through the machine in a horizontal position. The machine is equipped with one top and one bottom-mounted milling head each equipped with a chip exhausting system. From the infeed roller table the ingots are conveyed to the entry lifting table which lifts them into the clam ping frame. After scalping, the ingots are taken off by the exit lifting table and lowered to the level of the discharge roller table. The DH machine type is of simple and particularly solid construction. Many machines supplied have been in operation for several decades. TYpe dv: double Head VerTIcal TYpe dh: double Head HOrIZOnTal advantages at a Glance: Both faces of the clamped ingot can be inspected immediately after scalping Efficient chip exhaust transverse to gravity Easy accessibility of the cutter heads for changing the cutting tools Ease of maintenance due to open design Direct transmission of the cutting forces into the foundations High performance 4 5

InGOT scalping machines Type SH and type SHE InGOT scalping machines TYpe sh On the single-head ingot scalping machine Type SH with one top-mounted milling head, the ingots are turned 180 by means of a turnover device when one face has been machined. In a second operation the other face is scalped. The total operation cycle is performed automatically. Due to its simple construction, the SH machine type is the most economic scalper for smaller and medium capacities. The throughput can be doubled by adding a second machine without turnover device at a later stage. The two machines are arranged inline, the turnover device of the first scalper being installed between the two machines (Type 2SH). combined main scalping and edge scalping This is performed by adding edge scalping devices to the single-head ingot scalper of the SH type. The edge scalping devices are installed in the portal of the scalper. For complete scalping, the ingots have to pass through the scalper twice. Ingot in turn over device TYpe sh: single Head HOrIZOnTal TYpe she: single Head HOrIZOnTal with edge scalping devices 6 Single-head ingot scalper with turn over device 7

InGOT edge scalpers Type ED and type ES brazing lines Clean results for aluminium ingots TYpe ed: edge scalper double side Edge scalpers for aluminium ingots have been successfully in operation for many years. An additional scalping of the ingot edges provides considerable material savings and higher operational safety in the downstream production. Edge scalping reduces trimming scrap. The strip width to be removed after the hot rolling process is reduced. In addition, the risk of edge cracking during hot rolling is decreased. The edge scalpers are arranged inline with ingot surface scalpers. Brazing lines are assembly lines for cleaning and assembly of cladded sheet material, used for aircraft sheet and heat exchangers. Plate and/or core ingot are cleaned by brushes and automatically assembled, the liners are automatically welded to the core ingot including strapping and marking equipment. Cleaning dust and welding fume is exhausted by dust/fume extraction systems. Welding process TYpe es: edge scalper single side 3 2 1 1. Brushing 2. Turn over device 3. Welding station incl. pinch roll 8 9

Band saws Customized solutions for your needs SMS group developed generation of band sawing machines which fully utilise the efficiency of modern band saw blades. SMS automatic band saws are supplied in combination with ingot handling systems, offcut and chip removal systems and form part of the SMS group product program of ingot scalpers and handling systems. The sawing machines of either single or double band type are supplied as independent units which can form part of a complete ingot machining center or can be added to existing equipment of other suppliers. Also, the ingot handling systems can be supplied as separate equipment and installed be tween existing scalping lines and soaking pits or pusher furnaces ADVANTAGES AT A GLANCE: Reduced tool costs disposable saw blades are cheaper than the costs arising from sharpening circular saws Trouble-free sawing of extremely hard alloys Nearly complete chip removal High operating feed speeds of up to 1,200mm/min Capable of sawing ingots of different dimensions in any sequence due to automated operation Reduced cutting losses of up to 90% due to the smaller sawing notch only 1.8 mm instead of 20 mm Sound protection, safety devices Automatic handling of ingots No jamming of saw blades Energy savings due to low motor ratings TYPE SBS: SINGLE BAND SAW TYPE DBS: DOUBLE BAND SAW Infeed side Exit Side 10 11

ingot scalping system Precise process for perfect results 4 SPECIAL CHARACTERISTICS OF INGOT SCALPING SYSTEM Proven heavy construction, free from vibration Heavy forged one-piece main spindle with large flanges for holding the cutter heads High-quality precision bearing for the main spindle Long-life and maintenance-free machine bed guides Automatic lubrication of all moving parts Special tool design for chip suction efficiency Quick-change system for the clamped carbidetipped cutting tools consisting of roughing cutters and finishers Guaranteed surface quality of the scalped ingots Rt 5 microns Automatic sequence control for all machine types Quick automatic adjustment to different ingot dimensions Automatic feed control Automatic ingot measurement 5 3 2 6 1 1. Double band saw 2. Handling system 3. Ingot measurement system 4. Ingot scalper 5. Turn over device 6. Chip handling system 12 13

Chip exhaust system Safe and complete removal of chips Additional equipment Ensuring high production standards Chip handling flow chart Cyclone Wet scrubber Exhaust inside the hall The milling heads of the scalpers are enclosed by chip exhaust hoods, the design of which ensures complete removal of chips. The fan sucks the chips through a special crusher to prevent damage to the impeller. In the cyclone unit the chips are separated from the suction air. Thanks to the pneumatic conveying system the chips can be transported to containers over long distances. If different alloys are used, a number of bins will be supplied for separate collection of each alloy. The bins are charged via a movable belt conveyor. The operators select the bins at the control desk of the scalping machine and a level monitoring function displays when a bin is full. Complete suction and transport systems for aluminium chips, including bins and compacting equipment, consisting of: Chip exhaust systems, chip crushers, fans, cyclones, ducts, bin systems for alloy separation and collection of chips Automatic ingot scanning devices for reducing the amount of material to be removed Controls Feeding equipment and automatic sequence control Teleservice Handling systems, including roller tables, cross conveyors, infeed devices, chain conveyors, lifting tables, etc. SERVICE Feasibility studies/consultation Tailor-made design solutions Erection and commissioning Staff training After-sales service Handling system Chip crusher Chip long distance transportation Ingot scanning device 14 15

Electrical Equipment Transparent information during the process EFFECTIVE PLANT MANAGEMENT Control systems for aluminium scalpers and slab saws are tailored to existing customer solutions in order to ensure transparent information interchange between all process levels. The automation system is essentially matched to the technological and production-specific requirements of the plant. Distributed control components with bus interconnection ensure short erection and commissioning times as well as easy plant extensions. On customer s request plant management is supported by remote services (Tele service). User-friendly machine interfaces for product as well as processrelated information guarantee simple material tracking and simple system operation. COMPONENTS Medium-voltage switchboard Low-voltage switchboard State-of-the-art process controller Fault message system Shift protocol Production databases State-of-the-art drive system Bus system for distributed control Integrated measuring systems Data exchange with main computer Monitoring system for off-line or on-line rotating equipment Scalper automation system 16 17

Notes 18 19

SMS group GMBH Business Unit Forging Plants Scalpers and Band Saws Ohlerkirchweg 66 41069 Mönchengladbach Germany Phone: +49 (0) 2161 350-1450 Fax: +49 (0) 2161 350-1859 scalpers@sms-group.com www.sms-group.com P-328E. 04/16. Printed in Germany The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.