Conform lines
Model range of manufactured machines: YJ 300, YJ350, YJ400, YJ400S, YJ550, YJ700 and line components
Conform is a continuous extrusion equipment for the manufacture of fabricated shape, pins, trapezoidal pins, tubes, bars, flat wire, cable sheaths of optical systems and other long length products.
- Production time of the Conform line: 35-60 calendar days.
- The warranty period for the equipment: from 1 to 5 years, after commissioning.
- Accessible service support centers are in Russia, Kazakhstan, Uzbekistan, and also we have online support and remote diagnostics.
- Flexible payment terms. Partial payment before signing the contract and full payment after readiness of equipment before shipment.
- Commissioning: Qualified specialists of Habsans will install the equipment, set it up and train the staff.
Characteristics of YJ300 Conform Extruder
| YJ300 Conform | Copper Specification | Aluminum Specification |
|---|---|---|
| Diameter of the extrusion wheel | Ø300 mm | Ø300 mm |
| Speed range | 0-13 rpm | 0-22.5 rpm |
| Power of main motor | 90 kW | 90 kW |
| Diameter of the workpiece | Ø8 mm; Ø12.5 mm | Ø9.5 mm; Ø12 mm |
| Product cross section | 5-200 mm2. | 5-150 mm2. |
| Maximum width (diameter) | Tire, 50 mm; Bar Ø25 mm |
Tire, 50 mm; Tube, Ø25 mm |
| Average productivity | 500 kg/h | 180 kg/h |
Characteristics of YJ350 Conform Extruder
| YJ350 Conform | Copper Specification | Aluminum Specification |
|---|---|---|
| Diameter of the extrusion wheel | Ø350 mm | Ø350 mm |
| Speed range | 0-12.5 rpm | 0-20 rpm |
| Power of main motor | 160kW | 160kW |
| Diameter of the workpiece | Ø12.5 mm; Ø16 mm | Ø9.5 mm; Ø12 mm; Ø15 mm |
| Product cross section | 20-1000 mm2. | 10-600 mm2. |
| Maximum width (diameter) | Tire, 100 mm; Bar, Ø36 mm |
Tire, 60 mm; Tube, Ø35 mm |
| Average productivity | 850 kg/h | 300 kg/hr |
Characteristics of YJ400 Conform Extruder
| YJ400 Conform | Copper Specification | Aluminum Specification |
|---|---|---|
| Diameter of the extrusion wheel | Ø400 mm | Ø400 mm |
| Speed range | 0-12 rpm | 0-20 rpm |
| Power of main motor | 250 kW | 250 kW |
| Diameter of the workpiece | Ø16 mm; Ø20 mm | Ø15 mm; Ø20 mm; |
| Product cross section | 100-2400 mm2. | 100-1500 mm2. |
| Maximum width (diameter) | Tire, 170 mm; Bar, Ø80 mm |
Tire, 120 mm; |
| Average productivity | 1300 kg/hr | 450 kg/hr |
Characteristics of YJ400S Conform Extruder
| YJ400S Conform | Copper Specification | Aluminum Specification |
|---|---|---|
| Diameter of the extrusion wheel | Ø400 mm | Ø400 mm |
| Speed range | 0-12 rpm | 0-16 rpm |
| Power of main motor | 250 kW | 250 kW |
| Diameter of the workpiece | Ø20 mm | 2 x Ø15 mm; |
| Product cross section | 100-3000 mm2. | 100-2400 mm2. |
| Maximum width (diameter) | Tire, 210 mm; Bar, Ø90 mm |
Tire, 200 mm; |
| Average productivity | 1200 kg/h | 600 kg/h |
Characteristics of YJ550 Conform Extruder
| YJ550 Conform | Specification |
|---|---|
| Diameter of the extrusion wheel | Ø550 mm |
| Speed range | 1-8.5 rpm |
| Power of main motor | 450 kW |
| Diameter of the workpiece | Ø20 mm Ø25 mm |
| Product cross section | 300-5000 mm2. |
| Maximum width (diameter) | Tire, 300 mm; |
| Average productivity | 2000 kg/hr |
Characteristics of YJ700 Conform Extruder
| YJ700 Conform | Specification |
|---|---|
| Diameter of the extrusion wheel | Ø700 mm |
| Speed range | 1-8.5 rpm |
| Power of main motor | 450 kW |
| Diameter of the workpiece | Ø32 mm |
| Product cross section | 600~9000 mm2 |
| Maximum width (diameter) | Tire, 425 mm; Bar, Ø140 mm |
| Average productivity | 3000 kg/hr |
Conform operating principle and configuration
The main operating principle was to increase the temperature inside the deformed area up to the recrystallization leve due to the large extrusion and friction force of non-ferrous metal, therefore, the workpiece in the form of a bar / pin doesn’t need to be heated. The workpiece is extruded through the die. Low-melting metals such as aluminum (alloy), pure copper (alloy), can be formed continuously and manufactured in long lengths mouldings.
A copper/aluminum workpiece, in the form of a bar / pin, is given away in coils. Coils have a large length and weight, about 2 ~ 4 tons, which allows to produce products continuously, excluding dwells for the products ends splicing.
The workpiece is continuously passed into the channel of the rotating wheel, pulled out by the friction of the wheel carrying roller. The stretched material is blocked by aт anvil, that inserted into the recess, and at the same time extrusion pressure is created as soon as the saddle covers the recess. Through this process, due to internal friction, the metal is heated to cold flow temperatures, completely recrystallized and pressed into the die chamber and can be extruded into any die and sections.
The continuous extrusion machine consists of the following elements:
- wheel with a powder feed hopper;
- coining roll
- shoe (hinged lid where the tool is installed);
- shoe position control;
- entry block;
- support, which guides the extruded material;
- the tool (die) and the chamber in which the die is located.
- scraper for cleaning the wheel channel of excess waste material
After leaving the main unit, the extruded product is cooled in the bath by using a water-based cooling fluid. After the manufacturing, the actual length of products is calculated by the meterage counter. Depending on the type of product, the taking-up operation is carried out on a technological drum or in a coil.
Conform line components
The Conform continuous extrusion line is an additional equipment, that designed for high-quality and precise molding of metal products. The configuration of the line can be individually adapted to your needs. The line allows to provide high molding accuracy and effective process control.
Usually, the line consists of the following modules:
- Pay-off device for smooth material feed;
- Realignment, cutting and feeding units for the precise size control;
- Conform, that used for step-by-step metal molding with high precision;
- Coolant and anti-oxidation bath, that used for providing the high-quality surface of the products;
- Meterage counter for precise estimate of manufacturing products;
- Tension table and spreader device stand for stable process;
- Take-up device for convenient packaging of finished products.
Q&A for Conform line
Yes, it is possible. If you already have some part of the equipment, but you would like to supplement or update your existing line, we are ready to manufacture the line components or parts that you need. If you need the fully functional Conform line with integrated components, we can also manufacture it on the plug-and-produce basis.
We design and manufacture customized equipment solutions, that specially adapted to the limited space of your workshop or the production specific character.
The Conform continuous extrusion method provides a number of significant advantages:
- The ability to produce long continuous products without connecting welds, which increases the durability and reliability of products.
- Production cost optimization due to reducing material waste and production cycle time.
- Flexibility in the manufacturing of products with different shapes and sizes, which makes it easy to adapt to the customer’s varied needs.
The Conform method ensures high manufacturing quality and precision due to:
- Carefully engineered dies and molding tools, that ensure precision sizes and shapes of products.
- Temperature and pressure control during the extrusion process, which allows to avoid deformations and defects.
- Using of advanced technologies and equipment that provide a high automation degree and operation accuracy.
The Conform method allows to process different metal types, including stainless steel, aluminum, titanium, copper, brass and other alloys.
The Conform method is used in different industries, including aviation, aerospace industry, electronics manufacturing, construction, cable production and other spheres where it is required high-quality and long metal products.
Information about the Conform lines, its device and operation principles can be read in the article, if you click on this link
Conform line is a continuous extrusion equipment for the manufacture of fabricated shape, pins, trapezoidal pins, tubes, bars, flat wire, cable sheaths of optical systems and other long length products.