We understand Aluminium

Aluminium Extrusion Presses

 OTTO JUNKER extrusion

The high innovation potential of aluminium in new process
technologies and applications imposes growing demands
on equipment manufacturers. In particular, the growing
use of high-quality extrusions calls for narrower quality
tolerances and superior levels of process reliability and
repeatability. Additional cost savings and increasingly
extensive automation and process control capabilities
have become vital objectives in plant innovation.
Each single link of the complete process chain is
important for product quality and operating costs.
This process chain starts in the casthouse with melting,
casting and homogenizing, followed by billet preparation,
extrusion and press run-out / handling operations, down to
the final heat treatment with transfer to the packing line.

As a co-ordinating equipment expert, OTTO JUNKER

provides advanced solutions for all extrusion
plant processes, from the casthouse to the
point of transfer to the packing line,
thus ensuring the cost-effectiveness
of your capital expenditure.

 Range of aluminium extrusion presses:

Extrusion force 18MN 25MN 28MN 35MN 44MN 55MN 65MN

Billet diameter* 7“/8“ 8“ 9“ 10“ 11“ 12.5“ 14“

Billet length max. – mm ** 900 1050 1200 1300 1500 1500 1600

Installed power – kW 450 750 950 1000 1400 1600 1900

Extrusion speed – mm/sec *** 19 25 25 27 27 25 22

Pre-stressed columns Option Option Option Yes Yes Yes Yes

* Billet diameter depending on the requested specific pressure

** Other billet lengths on request
*** Extrusion speed (mm/sec) may be different with more pumps.
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The OTTO JUNKER short-stroke, front loading type press
has the following major advantages:
 Press installed on floor level which results in:
• Low installation costs
• Low civil works costs
• Easy access for maintenance
 The shortest dead cycle time on the market
 Less wear due to the short stroke
 Very rigid structure
 Manufacturing according to quality standard ISO 9001
 First-quality hydraulic unit
 Main cylinder, platen, columns and container holder
made of forged steel
 Extra large tie-rods for a longer lifetime
 Reliable loading of two-part billets
 Special OTTO JUNKER billet clamping cycle
 Perfect loading of the billet in the press centre line
• Less explosion in the container
• Longer lifetime of the dies
• Simple degassing sequence
• Fewer blisters on the extrusion
 Automatic die changing device on the press operator
side
 Automatic dummy block lubrication
 Precise butt shear blade and butt ejector
 Clamping of the die during shearing
 Fixed dummy block with large flexibility always
remaining in the container
• Less alignment problems / less risks
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  A VERY SUCCESSFUL DESIGN

All the Big Names in extrusion press manufacturing are

promoting the short-stroke press, the top of them are
promoting “short stroke, front loading”.

Advantages of the short-stroke, front loading press are

now very well known:

 Main cylinder stroke reduced by 50 %, reducing the

wear.
 Length of columns and distance between column
centres reduced by 30 %.
 Much stiffer platen, which means
• Less deflection on dies and easier adjustment
• Better tolerances on extruded sections
 Major press components lasting longer
 The definitely shortest dead cycle time
 Smooth motions without hydraulic shocks

Billet upsetting
The billet is clamped in press axis between the die and the
fixed dummy block. Symmetrical upsetting deformation,
avoids press bending or die uplift phenomena.

Better degassing on fixed dummy block side, die side

and between the faces of the two-part billets. The
upsetting stroke is calculated and controlled for each
individual billet.

The maximum upsetting pressure is adjustable. Optimum

starting of the extrusion process multi-hole dies.

Press structure
 Oversize tie-rods or pre-stressed columns
 Solid forged steel platen
 Forged main cylinder
 Press dimensions calculated for continuous operation
at the breakthrough force
 Bronze bushings
 Cylinder with adjustable chevron packings
 Finite element calculation

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 Billet loader
 Horizontal transfer of the billet from the furnace axis to
the press.
 Precision of positioning < 0.3 mm.
 No mechanical stops for positioning.
 Billet loader structure located above ground level.
 The billet is clamped by two jaws to hold one- and
two-part billets. Opening of the jaws is automatically
adjusted to the billet length.
 The billet loader is linked with the press to have safe
loading between the dummy block and the die.

 Butt shear
Structure
 A vertical slide hydraulically actuated by a shear
cylinder
 Rigid structure
 Long and square guidance with adjustable bronze
pads
Vertical die clamping  Pneumatic butt ejector
 Sharp blade for precise cutting.
 Butt fall detection

Butt shear
positionning

Automatic positioning (Option)

The shear frame can tilt slightly, then the shear is
automatically sealed against the die by a hydraulic
cylinder. Whatever the die face position, the shear
blade is aligned with the die face for precise shearing.

Butt shear
Vertical die clamping devices
Horizontal die  The die is vertically clamped in the press centre line to
clamping
maintain a precise vertical position during butt
shearing
 A hydraulic cylinder moves the clamping device

Profile shear

Automatic shear blade lubrication

 Avoids any sticking of the sheared butt on the blade.
 Special soluble oil (without graphite) is sprayed on the
blade
 Automatic lubrication done during each cycle

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 Billet and dummy block lubrication device
Boron nitride lubricating device consisting of electrostatic
powder system with two automatic powder guns.

One gun outside the press to lubricate the billet face

during transfer from furnace to press. Second gun on
a movable system on the container holder to lubricate
dummy block.

Platen
 Much stiffer platen, which means:
• Less deflection on dies and easier adjustment
• Better tolerances on extruded sections
 Major press components lasting longer
 The definitely shortest dead cycle time
 Smooth motions without hydraulic shocks

Container holder
 Single-piece rigid structure
 Finite element calculation
 Guided on bottom members. Safety top shoes resting
on the upper members
 Extended guide length prevents skewing effect
 Accurate and easy adjustment, both horizontally and
vertically
 Container cylinders on both sides of the main cylinder
– short cylinder rods – easy access
 Container cylinders and movable crosshead cylinders
interchangeable

Quick tool changing device (Die Slide)

 2 cassettes in operation, located on operator side
 Die stack is supported in two “U”-shaped die holders
 Tool changing in automatic mode
 Die changing device is electrically driven

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Hydraulic equipment
 Tank above the press
 Pumps at floor level (or underground)
 Pumps under load
 Easy access for maintenance
 Easy sound proofing around the pumps
 Cartridge valves to DIN standard mounted in forged
steel manifolds give
• Quick switching procedures
• Reliability
• Circuit tightness
 Variable-delivery pumps with automatic power rating
 Automatic compensation for internal leakages as a
function of working pressure
 Electronic pressure measuring system

Switch and control gear

 Programmable logic controller with two Central
Processing Units and high scanning speed
 Automatic fault detection system
 Colour video monitor on press control desk for display
of faults and operating parameters
 Keyboard for selection of extrusion parameters

Press running modes

 Manual mode
 Semi-automatic mode
 Automatic mode
 Automatic die change
 Automatic “just in time” (JIT)
 Dry cycle
 Die trial cycle with a billet of 350 mm length
 With burp cycle:
• No. 1: press and container decompression
• No. 2: container backstroke about 3 mm

Options
 Additional pumps
 Pump sound insulation enclosure
 Quick removal of container and stem
 PC for control of production and process
parameters
 Multi-zone container heating and cooling
 Butt discharge by conveyor or elevator
 Hot billet shear
 Pumps underground
 Boosting pumps with on-line filtration and cooling
 Automatic hydraulic fault detection
 Pre-stressed tie rod members

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 The OTTO JUNKER Group offers an extensive range of products for the manufacture of
semi-finished aluminium products. Furthermore, our product range includes the following:
Die OTTO JUNKER Group bietet ein umfangreiches Prodzktionsprogramm für die Herstellung v
Aluminium-Halbzeugen . Die folgenden Anlagen gehören ebenfalls zu unseren Produktionsprog

Fuel-fired melting and pouring Continous homogenizing lines Log magazines

furnaces

Billet and log heaters Extrusion handling systems Ageing ovens

Process competence: Technological competence:

OTTO JUNKER has the capability to supply
sophisticated lines from a single source. The
product range of the OTTO JUNKER Group covers
the entire process chain, from the casthouse to the
profile destacker serving as interface with the
packing line. Our equipment is supplied to the
aluminium extrusion industry all over the world.
The OTTO JUNKER Group has many decades of
experience and remains committed to ongoing
product development and improvement. As a
result, our equipment will embody the most up-to-
date technology at all times. Apart from proprietary
development, OTTO JUNKER cooperates closely
with the Technical University of Aachen (RWTH).

OTTO JUNKER GmbH

Postfach 11 80 • D-52147 Simmerath
Phone: +49 2473 601-0
Fax: +49 2473 601-600
E-Mail: info@otto-junker-group.com

www.otto-junker-group.com