1. A Few ideas for the Press Maintenance Professional
A Webinar with
Al Kennedy

2. A Few ideas for the Press Maintenance Professional
A Webinar with
Al Kennedy

3. The Extrusion Press Maintenance Manual is now FREE Online at www
The Extrusion Press Maintenance Manual is now FREE Online at

4. May be downloaded to tablets & smart phones for access in the plant
This means that:
Procedures
Diagrams
Schedules
Etc.
May be downloaded to tablets & smart phones for access in the plant

5. Please thank the sponsors listed on the website for providing this free access!

6. Manual Sponsors Belco CMD Butech Amcol RL Best Carlesa NDE Castool
Compes
Granco Clark
ADS

7. Webinar outline: Maintenance Impact on Productivity
Maintenance Principles
Press Alignment
Metallurgical Issues
Energy Cost Control
Technical Tools

8. Maintenance Impact on Productivity

9. Reliability: Equipment available when scheduled for production
Maintenance Impact on Productivity
Reliability: Equipment available when scheduled for production

10. Scrap minimized: butt & billet scrap, run-out and saw scrap
Maintenance Impact on Productivity
Scrap minimized: butt & billet scrap, run-out and saw scrap
(primarily a function of equipment design)

11. Maintenance Impact on Productivity
Maximum “contact time”: time the dummy block is in contact with the billet
(dead cycle & other delays such as lubing billets, flashes, etc.)

12. Equipment working as designed
Maintenance Impact on Productivity
Equipment working as designed
Temperature calibration (die ovens, billet/log oven, container)
Log shear or saw accuracy
Puller, hot saw, run-out

15. Maintenance Principles

16. Breakdown vs. Planned? Breakdown (also called Reactive):
Only one problem is fixed
Skilled people are not available
Spare parts and test equipment are not available
Production workers are idle

17. Breakdown vs. Planned? Planned:
Many problems are worked on at the same time
Skilled people will be available
Spare parts and test equipment will be planned to be available
Production workers are scheduled off

18. Preventive Maintenance
Interval-based:
Regular, scheduled downtime
Weekly, monthly, etc.
Make detailed inspections
Perform pre-planned repairs
Keeping records of downtime will allow better planning to improve reliability

19. Maintenance Basics

21. Predictive Maintenance
Condition-Based:
Determine condition of a machine
Predict best time to make repairs
Examples:
Hydraulic oil analysis
Magnetic particle & ultrasound test of tie rods
Infrared scans of electrical equipment
Vibration monitoring

22. Magnetic Particle Inspection

23. Infrared Scan of Electrical Parts

24. Oil Analysis

25. A sound maintenance program combines both interval-based and condition-based practices

26. Maintenance Basics
Spare Parts: See Chapter B for important points on recommended spare parts & their storage
Obtain and save equipment information – drawings, part numbers, diagrams

27. Google for answers!

28. Press Alignment

29. Importance of Alignment
Process reasons
Uniform loading is critical to die performance
Equipment reasons
Avoid uneven wear and impacts

30. Methods for Press Alignment: On the Press Manual website
Conventional “millwright” methods
Date from the 1970’s
Recommended tolerances
Use traditional mechanic’s tools:
Piano wire & straightedges
Levels
Feeler gages & dial indicators
Special jigs and fixtures

33. Methods for Press Alignment: New Technologies
Using modern surveying equipment and 3D laser tracker
Some info from ET16 and Press Manual website
Two specialists:
ADS Measurement Services
CMD Cunningham Mechanical Services

35. Metallurgical Basics

36. Metallurgical Issues Failure modes tension shear torsion compression
fatigue

37. Metallurgical Issues
Fatigue (n) fa-tēg′: weakening or failure of materials under the action of repeated stresses.

38. Fatigue Failure Images

39. Metallurgical Issues Fatigue:
Press components quickly experience millions of stress cycles.
Cracks progress to catastrophic failure.
Replacements are costly and long-delivery.

40. Metallurgical Issues Fatigue:
Component testing for cracks is mandatory, increasing in frequency as cracks progress.
Types of inspection:
Visual
Dye penetrant
Ultrasonic
Magnetic Particle

41. Visual

42. Dye Penetrant

43. Ultrasonic

44. Magnetic Particle

45. Metallurgical Issues Fatigue – repairing cracks/failures Weldability:
Forged steel - very good
Cast steel - good
Cast iron – poor & very technical
Mechanical patches: very temporary

46. Metallurgical Issues
Stems

47. Metallurgical Issues
Stress relieving stems

48. Metallurgical Issues Fixed dummy blocks
May be repaired by welding with proper procedures
Avoid excessive preheating – as with dies, limit preheat time and temperature

49. Help? Metallurgical Issues Consulting metallurgist – university?
Tooling suppliers
Press component suppliers
Component testing specialists
Manual sponsors

50. Webinar Feedback from 2014 webinar
press alignment
new equipment coming out
production optimizing
post this PowerPoint online
more presentations & topics

51. Energy Cost Control
Make partners of your utility suppliers (gas, water, electric)
They usually have a different business outlook

52. Energy Cost Control
Regulated utilities usually have a fixed profit limit
Increasing profit may not be their concern
They may not care whether their profit comes from you or from another customer
Even “regulated” utilities often have secret rates

54. Energy Cost Control
Regulated utilities are more concerned with leveling their load around the clock, to maximize use of their facilities
Uninterrupted service to residential customers is a high priority
Power generating companies must provide “spinning reserve” equal to a certain factor above actual demand

55. Energy Cost Control
Understand the thought process of your energy supplier
Build cooperation with your supplier by regular contacts
Develop solutions that help both parties meet their goals

56. Energy Cost Control
Fit all gas-fired equipment including billet heaters and age ovens with gas meters (of course cast house furnaces and boilers as well).

57. Energy Cost Control
Simple meters are OK for this purpose … no need for pressure and temperature compensation.
Turbine-type meters are OK
Remote reading is convenient
A quick payback is guaranteed!

58. Energy Cost Control
Read every meter every Monday morning and track total Btus and Btu/lb
Graphing these values will identify cost saving opportunities and will highlight when problems arise.

59. Energy Cost Control
Metering electric power is more complicated and less rewarding
Consider voluntary load reduction when requested by the power company
Consider load reduction by frequency variation, soft-start, etc.

60. Energy Cost Control
Electric power is generated in plants that are 38 to 40% efficient, and there are further i2R losses during transmission
Keep this in mind when evaluation gas vs. electric heating applications
Induction heaters are always more expensive than gas, but offer better process temperature control

61. Technical Tools

62. Technical Tools
Vibration Analysis and Balancing

63. Technical Tools
Vibration Analysis and Balancing
Ludeca.com

64. Technical Tools
Alignment

65. Technical Tools
Alignment

66. Technical Tools
Infrared Thermal Imaging

67. Technical Tools
Infrared Thermal Imaging

68. Technical Tools
Infrared Thermal Imaging

69. Technical Tools
Infrared Thermal Imaging

70. Technical Tools
Smartphone Microscope

71. Technical Tools
USB Microscope

72. Technical Tools
USB Borescope

73. Technical Tools
USB Borescope

74. Technical Tools
maintenancetechnology.com

75. Machines’ sensors will talk to us through Bluetooth
Future developments?
Machines’ sensors will talk to us through Bluetooth

76. Bluetooth was named after a 10th-century king, Harald Bluetooth, King of Denmark and Norway. He was known for his unification of previously warring tribes from Denmark, by getting them to talk to each other.

77. Summary www.Pressmaintmanual.com Maintenance impact on productivity
Maintenance principles: interval-based & condition based
Press alignment
Metallurgical basics
Energy cost control
Technical tools

78. Watch for info on the Press Maintenance Workshop, in Atlanta, April 2018

79. This presentation will be available for download at the following site: www.alkennedy.net/id84.html

80. Thanks for attending. Follow-up questions are welcome
Thanks for attending! Follow-up questions are welcome. Call or

81. This presentation will be available for download at the following site: www.alkennedy.net/id84.html