Papers by Author: Dirk Becker

Abstract: Curved Profile Extrusion (CPE) is an extension of the common extrusion process and offers the possibility to manufacture three-dimensionally curved profiles. Due to the flexibility of the process different curvatures can be produced with the same setup, which makes this technique efficient especially for low volume production. The process is characterized by a controlled lateral deflection of the strand which influences the material flow in the die and causes the profile curvature. In this paper, a direct comparison of the power rating between warm bending and CPE is presented. Furthermore, the investigations concerning the choice of support strategy of the surmounting profile by a robot to increase the curvature accuracy are continued. Finally, some extensions of the equipment are explained to increase the level of process integration.

Abstract: New innovative direct extrusion process variants, curved profile extrusion (CPE), twisted profile extrusion (TPE), and hollow profile extrusion (HPE), which increase the flexibility of aluminum profile manufacturing processes, are presented in this paper. These processes are characterized by influencing the material flow inside the die so that the forming process is completed when exiting the die. On the one hand, three-dimensionally curved profiles are produced and analyzed by CPE regarding the accuracy, the influencing parameters, and the compensation strategies. On the other hand, TPE and HPE make it possible to manufacture helical profiles usable, for example, as screw rotors in fluid machinery.

Abstract: This paper presents and discusses the latest achievements in the manufacture of threedimensionally curved aluminum profiles using an integrated bar extrusion process. While the conventional process chain lacks applicability and quality especially in low volume production, the new technology is promising, but still needs research to understand the correlation between the product to be manufactured and the contour accuracy to be achieved. This paper shows first results on the manufacture using a robot-guided second guiding tool and direct air quenching. The results will have an impact on further processing steps