MULTI-AXIS SHEAR-ASSISTED EXTRUSION MACHINE

BACKGROUND

Extrusion is a machining process where raw material, such as a billet, can be forced or extruded through one or more openings to form extrudate. Metals, ceramics, polymers, and the like can be extruded into various shapes for various uses. Metal extrusion is a metal-forming manufacturing process in which a cylindrical billet inside a closed cavity is forced to flow through a die aperture. The process is commonly used to form pipes, tubes, and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

FIG. 1A illustrates a portion of a system for extruding a structure having a hollow circular cross section.

FIG. 1B illustrates a portion of a system for extruding a structure having a hollow circular cross section.

FIG. 2 illustrates a portion of a system for extruding a structure having a hollow circular cross section.

FIG. 3A illustrates a top isometric view of a porthole die.

FIG. 3B illustrates a bottom isometric view of a porthole die.

FIG. 4 illustrates a top schematic view of a multi-axis shear-assisted extrusion system.

FIG. 5 illustrates a cross-sectional schematic view of a multi-axis shear-assisted extrusion machine.

FIG. 6 illustrates a cross-sectional schematic view of a multi-axis shear-assisted extrusion machine.

FIG. 7 illustrates a cross-sectional schematic view of a multi-axis shear-assisted extrusion machine.

FIG. 8 illustrates a cross-sectional schematic view of a multi-axis shear-assisted extrusion machine.

FIG. 9 illustrates a cross-sectional schematic view of a multi-axis shear-assisted extrusion machine.

FIG. 10 illustrates an example of a flowchart of a method for extruding hollow cross-section pieces.

FIG. 11 illustrates a block diagram illustrating an example of a machine upon which one or more embodiments may be implemented.

DETAILED DESCRIPTION

In the field of energy conversion and energy transport, there is a need to develop materials (e.g., alloys, composites, etc.) with improved electrical performance, specifically higher electrical conductivity and current density. In electrical applications, such as in overhead conductors, motors, inverters, and generators, copper and aluminum, and various alloys thereof, are desirable materials. These alloys (such as C10100, C11000, C15000, AA1100, AA1350, AA8002) may seek to have minimal impurities, but occasionally can benefit from additives that can help improve one or more of mechanical performance, wear resistance, or corrosion resistance of the metal substrates, but certain approaches may involve sacrificing electrical conductivity. Introducing additives in a metal may increase charge scattering, which, in turn, can lead to detrimental electrical carrier transport properties. There is a need for technology in which one or more additives can be introduced into a metal such as to make an alloy or composite for improving electrical performance.

The present techniques can help address one or more of the challenges mentioned above, such as producing feedstock for other processing or producing finished components. For example, the present techniques can help enable extrusion of metal wires, bars, or tubes. Hollow structures can have an easily specifiable- or even variable-thickness within the same extruded product. This extrusion process can yield extrusion products from lightweight materials, such as magnesium and aluminum alloys, with improved mechanical properties. The extrusion process can go directly to extrudate from powder, flake, or billet feedstocks in as few steps as a single step. This can help reduce the overall energy consumption and processing time for extrusion. However, performing ShAPE can be relatively difficult due to the requisite axial and rotational forces required to extrude metallic components, such that testing of various techniques can be desired.

The present disclosure discusses various examples of a new machine for performing ShAPE in various configurations or arrangements. In particular, the present disclosure provides an example of one device that has multiple headstocks, with each one able to move translationally and each having its own spindle axis. This allows any combination of rotation and translation for the die, container, and stem and enables performance and configurations that have not been available in the past. In particular one configuration, this arrangement allows for non-rotating extrudates being produced from a ShAPE process via direct and indirect extrusion.

The above discussion is intended to provide an overview of subject matter of the present Patent Application. It is not intended to provide an exclusive or exhaustive explanation of the invention. The description below is included to provide further information about the present Patent Application.

FIGS. 1A and 1B illustrate, by way of example and not limitation, a system 100 for extruding a structure having a hollow cross section using a shear-assisted direct extrusion technique. FIGS. 1A and 1B are discussed together below. This can include using shear-assisted processing involving applying an axial compression force and a rotation-induced shear force. As shown in FIG. 1A, a die assembly 110 can include a die face 128 that can be thrust against and into a billet material 120 (or vice versa). The die face 128 can include one or more scrolls (e.g., a fluted or spiral topology defining surface contours that direct plasticized material inward as the die face 128 rotates relative to the billet material 120, illustrated further in FIG. 3A), the die face 128 can include other surface features, or it can even be flat. The billet material 120 can be held within a billet holder assembly 112 (or container assembly) that can include a container base 112A and a container sidewall 112B. The scrolls can include various fluted, spiral, or other patterns or styles of topology including constant curvature pitch and non-constant curvature pitch.

A die shank 114 of the die assembly 110 can be retained within a die holder 121 of the die assembly 110 and with the die face 128 operably engaged with the billet material 120 to create a high shear region 126 at the die face 128. The rotation (illustrated by the rotating arrow R, about a rotational axis 135) and the axial movement (illustrated by the double-sided arrow T) of the die assembly 110 including the die face 128 can induce shear to plasticize the billet material 120 at or adjacent to the interface (126) between the die face 128 and the billet material 120. The plasticized material can flow in a specified direction.

As shown in FIG. 1B, the system 100 can also be configured such that the billet holder assembly 112 and billet material 120 spin and the die face 128 can be translated axially into the billet material 120 such as to provide a combination of shear and compressive forces at the interface between the billet material 120 and the die face 128. Regardless of which structure is rotated or translated (rammed) in absolutely space relative to the other, the net effect is relative rotation and axial force between the die face 128 and the billet 120 which in turn cause an extrude 118 to flow out from the die orifice 138 of the die assembly 110.

Flow of the plasticized material can then be directed, such as through an extrusion aperture, to another location, such as an internal portion 111 of the die assembly 110. The die face 128 can define a die face orifice 138. A longitudinal axis (or “central longitudinal axis”) 135 can be defined to extend through a center of the die face orifice 38. The billet holder assembly 112 and the billet material 120 can rotate about the central longitudinal axis 135 to permit the die face 128 to engage the billet material 120. Reconstitution of plasticized material can occur defining a hollow-interior extruded structure 118 (also referred to as an “extrusion product” or an “extrudate”), such as can include one or more desired characteristics. Such characteristics can include grain structure or texture that are established using the extrusion through the die face orifice 138 or during down-stream processing such as controlled-temperature processing (e.g., quenching, annealing, or the like). Use of such down-stream processing is optional, and specified microstructure or other physical characteristics can be established using shear-assisted processing alone.

The mandrel 116 can be a part of the billet holder assembly 112 and can be in close proximity to the die face 128 (but can even be a portion of the die assembly as shown in other examples herein). Together with a die face orifice 138 in the die face 128, the mandrel 116 can form an annular extrusion aperture (e.g., annular extrusion aperture 137 shown in FIG. 4 for case of illustration) that the plasticized extrusion material is extruded through to form the extruded structure 118. The extrusion aperture can be formed when the mandrel 116 is extended through a die face orifice 138 in the die face 128. While the mandrel 116 is illustrated as protruding through a center of the billet material 120, examples are not so limited. One such other example of the mandrel 116 being rigidly affixed to the die face 128 is illustrated in FIG. 2.

FIG. 1B illustrates, by way of example and not limitation, a system 100 for extruding a structure having a hollow cross section. FIG. 1B, while having similar components to the system 100 of FIG. 1A, can configured to operate in a different way from the system 100 of FIG. 1A. For example, FIG. 1B illustrates an example of a die assembly 110 that moves or translates axially along the longitudinal axis 135 and a container sidewall 112B and container base 112A (of the billet holder assembly 112) that can rotate about the longitudinal axis 135. In this way, the die assembly 110 can provide movement to establish the axial extrusion force and the container provides movement to establish the rotation-induced shearing force. Such movement can be helpful to inhibit or prevent certain aspects of the extrusion system from rotating. For example, the extruded structure 118 in FIG. 1A can be extruded into the internal portion 111 within the die assembly 110 that is rotating. For this reason, the extruded structure 118 may be rotating within the die assembly 110 as well as the extruded structure 118 is being extruded. The rotation of the extruded structure 118 can cause malformation or warp when extruding extrudates of a particular shape. An extruded structure 118 with a non-circular shape may be more susceptible to such warping or malformation if it is rotating such as in FIG. 1A.

While the illustrations of FIG. 1A and FIG. 1B indicate total axial movement or total rotational movement from either the die assembly 110 or the container, examples are not so limited. A majority of the axial movement can occur with the die assembly 110 or a majority of rotational movement can occur with the container while the container may also have slight or lesser axial movement or the die may have slight or lesser rotational movement. That is, the die assembly 110 and the billet holder assembly 112 can move to a lesser degree within the discussed and shown range of movement. For example, one or more of the die assembly 110 or the 120 can move for or within a portion of their range of motion.

FIG. 2 illustrates, by way of example and not limitation, a system for extruding a structure having a hollow cross section. The system can include a die holder 121, a die shank 114, and a die face 128. The die holder 121, the die shank 114, and the die face 128 can be fixed to each other and can rotate (as the die assembly 110 rotates) about the longitudinal axis 135. The system can include a container base 112A and a container sidewall 112B that can be used to hold a billet material 120. As shown in FIG. 2, a liner 132 can be in direct contact with the billet material 120 and the container sidewall 112B. In some examples, the billet material 120 can be in direct contact with the container sidewall 112B without a liner 132.

The die face 128 can be part of a porthole die 122. The porthole die 122 can include portholes 117. The porthole die 122 can include a mandrel 116 that extends from the die face 128. The die face 128, porthole die 122, and mandrel 116 can move longitudinally (can translate) along the longitudinal axis 135, either away from or toward the billet material 120. Further the porthole die 122 can move rotationally around the longitudinal axis 135. In the alternative, the billet material 120 or container (112A/112B) can move rotationally around or axially along the longitudinal axis 135. Variations of such movement are discussed further below in association with FIGS. 4-7. Whichever way such movement occurs, as the die face 128 and billet material 120 can establish rotational shear and the axial extrusion force on the billet material 120, such that the billet material 120 can plasticize and be extruded through holes in the porthole die 122. The plasticized billet material extruded through the holes of the porthole die 122 can be extruded to surround the mandrel 116 behind the porthole die 122 and form an extruded structure, as will be further described below. The extruded structure can be extruded through an internal portion 111 of the die shank 114.

In an example, the container base 112A can be replaced with a stem or ram device (see FIGS. 5-6 below) that provides direct extrusion of the billet material 120. For example, a stem or ram device could be used to translate the billet material 120 axially toward the die face 128. In this example, the die face 128 may remain stationary. Alternatively, or additionally, the die face 128 can be translated toward the billet material 120.

FIGS. 3A and 3B illustrate, by way of example and not limitation, respective top and bottom isometric views of a porthole die with a modified scroll face and mandrel. FIG. 3A illustrates a top isometric view of the porthole die 122 showing the modified scroll face and FIG. 3B illustrates a bottom isometric view of the porthole die 122 showing the portholes and a mandrel. Grooves 113 and 115 can extend into the die face 128 of the porthole die 122 surface 124, extending into the die from an outer surface. The Grooves 113 and 115 can help direct plasticized billet material toward the portholes 117. The threaded holes 123 can be used to attach the die face to the die shank.

Plasticized billet material can then pass through the portholes 117 and across the mandrel 116. In this illustrative example, material flow can be separated into four distinct streams through the four portholes 117, as the billet material 120 and the porthole die 122 are forced against one another due to rotational and axial movement. In other examples, more or fewer portholes can be used. As an illustration, the outer grooves 115 on the die face 128 can feed material inward toward the portholes 117, and inner grooves 113 on the die face 128 can feed material radially outward toward the portholes 117.

In this illustrative example, one groove 113 can feed material radially outward toward each aperture port 117 for a total of four outward flowing grooves. The outer grooves 115 on the die face 128 can feed material radially inward toward the aperture port 117. In this illustrative example, two grooves can feed material radially inward toward each aperture port 117 for a total of eight inward feeding grooves 115. In addition to these two sets of grooves, the die 122 can include a perimeter scrolled groove 119 located radially or laterally outward on an outer perimeter surface 125 of the porthole die 122, shown in FIG. 3B. The perimeter scrolled groove 119 is oriented counter to the die rotation so as to provide back pressure thereby minimizing material flash between the liner 132 (or, in the absence of a liner, the container sidewall 112B) and die assembly 110 during extrusion.

In FIG. 3B, the porthole die 122 shows a series of full penetration of portholes 117. In use, streams of plasticized billet material can be directed by the inward 115 and outward 113 grooves described above can pass through these portholes 117 and can then be recombined and flow around a mandrel 116 to create a desired cross section. In this way, the grooves 113, 115, and 119 can be used to feed the portholes 117 during rotation to separate material flow of the feedstock (e.g., powder, flake, or billet) into distinct flow streams. This arrangement can help to enable formation of extruded products with hollow cross sections and, depending on the porthole die 122 configuration, non-circular interior or exterior profiles (or both). Whichever setup is used, such as the mandrel illustrated in FIGS. 1A-1B, the porthole die configuration in FIG. 3A-3B, or additional configurations not illustrated, the variation of rotational or axial movements described herein can be used with any number of die face configurations or associated mandrels.

FIG. 4 illustrates a top schematic view of a multi-axis shear-assisted extrusion system 400. The multi-axis shear-assisted extrusion system 400 can include a ShAPE machine 402 that can be similar to (or can in part or in whole include) the system 100 discussed above or can be or include any of the ShAPE machines discussed below. The multi-axis shear-assisted extrusion system 400 can also include a control cabinet 404 that can be connected to the ShAPE machine 402 or a housing thereof. The control cabinet 404 can be configured to at least partially support or enclosed one or more control devices for operating the multi-axis shear-assisted extrusion system 400, such as one or more controllers or the like.

The control cabinet 404 can be configured to include or support a controller 405 at least partially therein. The controller 405 can be connected or connectable to one or more components of the system 100 (or the system 500 discussed below). For example, the controller 405 can be in communication with one or more sensors, motors (e.g., spindle motors or actuators) or the like. The controller 405 can be a programmable controller, such as a single or multi-board computer, a direct digital controller (DDC), a programmable logic controller (PLC), printed circuit board (PCB), or the like. In other examples the controller 405 can be any computing device, such as a handheld computer, for example, a smart phone, a tablet, a laptop, a desktop computer, or any other computing device including a processor, memory, and communication capabilities.

The multi-axis shear-assisted extrusion system 400 can include a front guarding 406 and a rear guarding 408 (such as cabinet or fencing) that can be connected or not connected to the ShAPE machine 402 and configured to at least partially surround an entrance and an exit to the multi-axis shear-assisted extrusion system 400 such as to help protect operators or users of the ShAPE machine 402 during operation (e.g., extrusion) of the ShAPE machine 402. The front guarding 406 can include one or more doors 410 for access to the front of the ShAPE machine 402, such as for retrieval of extrudate 414. The rear guarding 408 can also include one or more doors 412 for access to the rear of the ShAPE machine 402, such as for loading of feedstock material into the ShAPE machine 402 or the retrieval of extrudate 414.

The multi-axis shear-assisted extrusion system 400 can also include a lifting device such as a jib or other crane 416 that can be connected to the multi-axis shear-assisted extrusion system 400 or can be connected to another component near the ShAPE machine 402 (e.g., can be connected or secured to a floor or overhead support). The crane 416 can be operable to move within an area such as defined by the arc C such that the jib crane 416 can be used to lift the extrudate 414 produced by the ShAPE machine 402 or can be used to load feedstock material into the ShAPE machine 402 or to lift other tooling and fixtures such as, but not limited to, including in part or in whole the extrusion system 100.

FIG. 5 illustrates a cross-sectional schematic view of a multi-axis ShAPE machine 502. The multi-axis ShAPE machine 502 can be (or can be similar to) the ShAPE machine 402 discussed above or any of the other ShAPE machines discussed above or below, such that the features of the machine 502 can be included in any of the ShAPE machines discussed above or below.

The machine 502 can include a front fixed endstock 540, a rear fixed endstock 542, and a base 544. Optionally, the front fixed endstock 540 can be omitted. In other examples, the rear fixed endstock 542 can be omitted. The base can be a rigid platform configured to support the components of the machine 502, such as the headstocks, actuators, and the like. The fixed endstocks (540 and 542) can be rigid supports connected to and extending upwards from the base 544. The front fixed endstock 540 and the rear fixed endstock 542 can be configured to react linear and torsional forces of the machine 502, which may or may not be identical. As discussed in further detail below, the front fixed endstock 540 and the rear fixed endstock 542 can include holes or bores extending at least partially therein or therethrough to receive portions of rails 546 and 548 at least partially therein or therethrough. The rails 546 and 548 can include 2 rails, 3 rails, 4 rails, 5 rails, 6 rails, 7 rails, 8 rails, 9 rails, 10 rails, or the like. The rails 546 and 548 can be rigid or semi-rigid elongate members (e.g, rods, bars, tubes, or the like) configured to support movable headstocks and other components of the machine 502 and can be configured to react to torsional loads of the machine 502.

The machine 502 can also include a front movable headstock 543 and a rear movable headstock 545. The front movable headstock 543 and the rear movable headstock 545 can be connected to or supported by the rails 546 and 548 and the front movable headstock 543 and the rear movable headstock 545 can be movable (e.g., translatable) along the rails, such as along the central axis A. Though the front fixed endstock 540, the rear fixed endstock 542, the front movable headstock 543, and the rear movable headstock 545 are referred to as “front” and “rear” these terms are used merely to indicate relative positions of the recited elements with respect to each other, and not some other absolute frame of reference. The front and rear component orientation names can be reversed, or can be replaced by “first” and “second” or the like. While the front movable headstock 543 and rear movable headstock 545 are depicted as being substantially similar, they can also be identical or can be substantially different in form, size, capacity, stock, speed, power, or the like.

The machine 502 can also include shafts 550 and 552 and actuators 554 and 556. The actuators 554 and 556 can be connected to or in communication with the controller 405. The shafts 550 and 552 can connect to the front fixed endstock 540 and the rear fixed endstock 542 and can engage with the (or be connected to) the front movable headstock 543 or the rear movable headstock 545. The actuators 554 and 556 can be motors such as electric, hydraulic, or combustion motors operable to move the shafts 550 and 552. For example, the actuators 554 and 556 can be rotary motors, such as electric servos or variable frequency drive driven electric motors, but can be other motor types such as hydraulic or the like. The actuators 554 and 556 can be rigidly attached to the machine 502, or can be physically separate from the machine and directly connect to the machine 502 via a hydraulic hose, drive shaft, or other power transmission device. The shafts 550 and 552 can be screws, such as lead screws, roller screws, electric cylinders, ball screws, or hydraulic actuation devices such as hydraulic rams.

In operation, the actuators 554 and 556 can be operated to generate rotational output to rotate the shafts 550 and 552, which can cause translation or movement of one or more of the front movable headstock 543 and the rear movable headstock 545, such as along the central axis A, as guided by the rails 546 and 548. In some examples, the actuator 554 can be operated to drive the front movable headstock 543 to translate or move along the rails 546 and 548, and the actuator 556 can be operated to drive the rear movable headstock 545 to translate or move along the rails 546 and 548, such that the front movable headstock 543 and the rear movable headstock 545 are independently movable relative to the front fixed endstock 540, the rear fixed endstock 542, and to each other. Though the shafts 550 and 552 are discussed as being rotatable to translate the front movable headstock 543 and the rear movable headstock 545, in an example where the actuators 554 and 556 are hydraulic, the shafts 550 and 552 may not rotate and may only translate to effect translation of the front movable headstock 543 and the rear movable headstock 545.

The machine 502 can also include a front spindle 560 connected to the front movable headstock 543. The front spindle 560 can be translatable with the front movable headstock 543 to generate an axial extrusion force. Similarly, the machine 502 can also include a rear spindle 562 connected to the rear movable headstock 545. The rear spindle 562 can be translatable with the rear movable headstock 545 to generate an axial extrusion force. That is, one or more of the front movable headstock 543 and the rear movable headstock 545 can be used to generate the axial extrusion force during shear-assisted extrusion. Also, one or more of the front movable headstock 543 and the rear movable headstock 545 can be translated between (or before or after) extrusion operations for preparation and service of the machine 502, such as insertion of feedstock material, removal of material, cleaning of the machine 502, or the like.

The front spindle 560 and the rear spindle 562 can also each include a gear, gear box, or other drivetrain that can be configured to be driven to rotate the spindles. The front spindle 560 can rotate about the central axis A (as indicated by the arrow R1) relative to the front fixed endstock 540, the rear fixed endstock 542, the front movable headstock 543, and the rear movable headstock 545. The rear spindle 562 can rotate about the central axis A (as indicated by the arrow R2) relative to the front fixed endstock 540, the rear fixed endstock 542, the front movable headstock 543, and the rear movable headstock 545. The front spindle 560 and the rear spindle 562 can be independently driven such that the front spindle 560 and the rear spindle 562 can rotate together (e.g., at the same speed) or independently (e.g., at different speeds).

The front fixed endstock 540 can define a bore 564, the front spindle 560 can define a bore 566, the rear spindle 562 can define a bore 568, and the rear fixed endstock 542 can define a bore 570. Each of the bores 564, 566, 568, and 570 can be central bores sharing a common axis (the central axis A). Together the bores 564, 566, 568, and 570 can effectively define one continuous bore configured to receive feedstock material or a billet at least partially therein for extrusion thereof. The bores 564, 566, 568, and 570 can be of same or different diameters, lengths, other defining features, or can be omitted.

The machine 502 can also include one or more tooling plates. For example, a tooling plate 572 can be secured to a rear portion of the front fixed endstock 540. The machine 502 can also include a tooling plate 574 secured to a front portion of the front spindle 560 and the machine 502 can include a tooling plate 576 secured to a front portion of the rear spindle 562. The tooling plate 574 can be rotatable with the front spindle 560 and the tooling plate 576 can be rotatable with the rear spindle 562. Any of the tooling plates can be configured to receive a die tool, and any of the tooling plates can be of identical or different size, design, bolt patterns, or other functional features.

The machine 502 can also include a first rotary union and slip ring 578 connected to the front spindle 560 and can include a second rotary union and slip ring 580 connected to the rear spindle 562. The first rotary union 578 (which can be a rotary coupler) can be translatable with the front movable headstock 543 but the front spindle 560 can rotate with respect to all or part of the first rotary union 578. Similarly, the second rotary union 580 can be translatable with the rear movable headstock 545 but the rear spindle 562 can rotate with respect to all or part of the second rotary union 580. The first rotary union 578 can be configured to deliver power (e.g., electricity) to the front spindle 560 and the first rotary union 578 can be configured to deliver cooling fluid to the front spindle 560 as discussed in further detail below. The machine 502 can also include junction boxes 582 connected to each of the headstock(s) or endstock(s), where terminations (such as electrical terminations for power and control wiring) can be made. The rotary union and slip ring functionalities can be both incorporated in both devices, or can be selectively used such that one or more rotary unions or slip rings are present or absent.

As discussed in further detail below, in operation of some examples, feedstock material can be loaded into one or more of the bores 564-570 and a die tool can be secured to one or more of the tooling plates. When the feedstock material is loaded, an extrusion process can begin where one or more of the front spindle 560 and the rear spindle 562 can establish a rotation-induced shear force at an interface between the die tool and the feedstock material. And, one or more of the front movable headstock 543 and the rear movable headstock 545 can establish an axial extrusion force between the die tool and the billet or feedstock material to allow ShAPE to be performed to generate extrudate in a desired shape. Because the machine 502 can operate one or more of the spindles 560 and 562 to rotate or translate independently, the front spindle 560 and rear spindle 562 can each provide the requisite rotation to establish the shear force and can each operate as a ram or provide linear force such that the machine 502 can be used to perform direct or indirect extrusion without rebuilding (or with only re-tooling) the machine 502.

FIG. 6 illustrates a cross-sectional schematic view of the multi-axis shear-assisted extrusion machine 502 (referred to as the machine 502) in use. The machine 502 can be consistent with FIG. 5 discussed above and the machine 502 can include any other features of any of the machines discussed above or below. Similarly, any of the machines discussed above or below can include the components of the machine 502.

FIG. 6 shows the machine 502 configured with a die tool 584 that includes an opening 586 extending through the die tool 584. The die tool 584 also includes a die face 588. The die tool 584 can be secured to the tooling plate 572 of the front fixed endstock 540 such that a rotational position and an axial position of the opening 586 can be fixed or non-moving. FIG. 6 also shows a ram 590 secured to the tooling plate 576 such that the ram 590 is configured to extend at least partially into the bore 566 of the front spindle 560. FIG. 6 further shows a billet 592 (or feedstock material) located at least partially within the bores 566 of the front spindle 560. The billet 592 can be located at least partially within the front spindle 560 as shown, or the billet 592 can be located within a separate liner or container (e.g., the liner 597) as shown in FIG. 8 below.

In operation of some examples, the machine 502 can be started up by initiating spindle rotation, such as rotation of the front spindle 560 and the rear spindle 562 as indicated by the arrows R1 and R2, respectively. An axis of the ram 590 can be moved from an offset position to a contact position where the ram 590 engages a rear portion of the billet 592 and where the ram 590 is aligned along the central axis A, as shown in FIG. 6.

Once the components are in alignment and positioned accordingly, contact between the ram 590 and the billet 592 can occur and ramp up can be performed where an axial velocity of the ram 590 can be slowly increase (through adjusting the velocity of the rear spindle 562), resulting in a rapid increase in force, power, and temperature of various components of the machine 502, such as the billet 592. Rotational speed of the front spindle 560 and the rear spindle 562 can be controlled (e.g., raised or lowered) to bring a process temperature to or near a desired process temperature.

After ramp up and obtaining a desired temperature, ramp up can be complete and steady state can be entered where the speed of the front spindle 560 and the rear spindle 562 can be maintained and the axial velocity of the rear spindle 562 and the ram 590 can be maintained, which can result in near-constant process temperatures and near-constant axial forces. In some examples, rotational speed of the front spindle 560 or the rear spindle 562 can be adjusted or varied to maintain the desired process temperature while axial velocity of the rear spindle 562 and the ram 590 is maintained to maintain the desired axial force. During ramp up and steady state operation, the billet 592 can engage with the die face 588 to perform shear-assisted extrusion to generate extrudate through the die tool 584. That is, the combination of the axial and the rotating forces can plasticize the billet 592 at the interface with the die face 588.

Flow of the plasticized material can then be directed, such as through an extrusion aperture, to another location, such as the opening 586 of the die tool 584. The plasticized material can be formed to include a hollow-interior extruded structure (e.g., the extruded structure 118), such as can include one or more desired characteristics. Such characteristics can include grain structure or texture that are established using the extrusion through the opening 586 or during down-stream processing such as controlled-temperature processing (e.g., quenching, annealing, or the like). Use of such down-stream processing is optional, and specified microstructure or other physical characteristics can be established using shear-assisted processing alone. Optionally, the materially can be formed into solid (non-hollow) structures.

After the billet 592 is consumed or nearly consumed, an axial velocity of the ram 590 and the rear spindle 562 can be relatively quickly reduced to zero and then the velocity of the ram 590 and the rear spindle 562 can be reversed to back the ram 590 out of the bore 566. During stopping of extrusion and backing out of the ram 590, speeds of the front spindle 560 and rear spindle 562 can be reduced by not stopped, which can help to reduce adherence of the billet 592 to the other components of the machine 502. Once the ram 590 is clear of the remaining billet 592, rotation of the front spindle 560 and the rear spindle 562 can be stopped. While the above describes one example of an extrusion process, these steps do not describe all extrusions. For example, a very slow extrusion may not need a ramp-up phase. And, the machine 502 can provide flexibility in its programming to accommodate various differences of operation.

The machine 502 can also be used for other types of extrusion. For example, the die tool 584 can be secured to the tooling plate 576 and the rear spindle 562 can be held rotationally stationary. In such an example, the ram 590 can be secured to the tooling plate 574 and the rear spindle 562 can be translated relative to the front spindle 560 and endstock 540 to deliver axial force to the billet 592. The rear spindle 562 can also rotate to rotate the die 584 to cause rotation-induced shear force between the billet 592 and the die tool 584 to perform ShAPE where extrudate can enter the bore 568 or the bore 570.

In another example, the machine 502 can be configured such that the die tool 584 can be secured to the tooling plate 576 and the rear spindle 562. In such an example, the ram 590 can be connected to the tooling plate 572 such that the front spindle 560 and the rear spindle 562 can translate toward the tooling plate 572 and the die tool 584 to generate or sustain an axial force for extrusion. And, the rear spindle 562 and the die tool 584 can rotate to cause rotation-induced shear force between the billet 592 and the die tool 584 to perform ShAPE where extrudate can enter the bore 568 or the bore 570. Though only three examples are described herein, the die tool 584 and the ram 590 can be secured to any of the tooling plates 572, 574, and 576 to create multiple configurations for performing ShAPE.

FIG. 7 illustrates a front cross-sectional schematic view of a multi-axis shear-assisted extrusion machine. The machine 502 can be consistent with FIGS. 5-6 discussed above. FIG. 7 shows additional details of the machine 502. For example, FIG. 7 shows that the front movable headstock 543 of the machine 502 can include bores 594A-594D (collectively referred to as bores 594), which can be threaded bores, roller nuts, or another mechanism to connect the headstocks to the shafts 550. The bores 594 can receive shafts 550A, 550B, 552A, and 552B at least partially therethrough such that the shafts 550 and 552 can cause translation of the front movable headstock 543. In some examples, the shafts 550A and 550B can be threadably (or otherwise) engaged with the front movable headstock 543 and the shafts 552A and 552B can be engaged with the rear movable headstock 545 allowing the shafts 550 to translate the front movable headstock 543 and the shafts 552 to translate the rear movable headstock 545. In such an example, the bores 594B and 594D can be non-threaded such that rotation of the shafts 552 does not cause movement or translation of the front movable headstock 543, thus allowing the front movable headstock 543 and the rear movable headstock 545 to be translated independently. Though four of the shafts 550 and 552 are discussed, the machine 502 can include more or fewer shafts, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or the like. Accordingly, the machine 502 can include a complementary number of coupling threads, nuts, or other fasteners to match the number of shafts.

To effect translation of the front movable headstock 543, the shafts 550 and 552 can be threaded such that the shafts 550 and 552 can be rotated (such as powered by a rotating actuator). Optionally, the shafts 550 and 552 can be non-threated such that the shafts 550 and 552 can be translated (such as powered by a linear motor or actuator such as a hydraulic motor or actuator).

FIG. 7 also show that the front movable headstock 543 can include cars 596 and 598 extending laterally outward from opposing sides of the movable headstock 543. The cars 596 and 598 can each include a lower surface and linear bearing that can be relatively flat or planar and can be engaged with the rails 546 and 548, respectively, allowing the front movable headstock 543 to be supported by the rails 546 (at least in part) and to allow the front movable headstock 543 to translate along the rails 546.

FIG. 7 also shows that the machine 502 can include a spindle motor 591 that can be connected to or mounted on (or supported by) the front movable headstock 543 such that the spindle motor 591 can translate with the front movable headstock 543. The spindle motor 591 can be connected to or in communication with the controller 405. FIG. 7 also shows a gearbox 593 that can include one or more gears, belts, chains, or other drive mechanism engaged with the motor 591 (or a shaft thereof) and engaged with the front spindle 560 such as to transfer rotation of the spindle motor 591 or a shaft thereof to the front spindle 560. Though FIG. 7 is discussed with respect to the front movable headstock 543, the rear movable headstock 545 can be similarly configured. However, the size, placement, capacity, mass, etc. of the rear movable headstock 545 can be similar to the front movable headstock 543 or can be different. For example, a rear spindle motor can be engaged with the rear spindle 562 and a rear spindle motor can be connected to or in communication with the controller 405.

FIG. 8 illustrates a cross-sectional schematic view of the machine 502. The machine 502 can be consistent with FIGS. 5-7 discussed above. FIG. 8 shows additional details of the machine 502. For example, FIG. 8 shows that the machine 502 can include a container 595 located at (or connected to or adjacent to) a radially inner surface of the front spindle 560 or the front tooling plate 574. The container 595 can be connected to the tooling plate 574 to secure the container 595 to the front spindle 560 such that the container 595 can be rotatable with the front spindle 560 and translatable with the front movable headstock 543.

FIG. 8 also shows that the machine 502 can include a liner 597 that can include a bore 599, where the bore 599 can extend along the central axis A. The liner 597 can be located at (or connected to or adjacent to) a radially inner surface of the container 595. The liner 597 can be configured to engage and support the billet 592 within the bore 599 of the liner 597. The liner 597 can be releasably securable or secured to the container 595 such that the liner 597 is relatively easily replaceable. Because the billet 592 and the ram can engage the liner 597 during extrusion operations, the liner 597 can become damaged. Because the liner 597 can be easily replaced, damage of the machine 502 can be limited and maintenance or repair can be relatively low cost. In some examples, the liner 597 can be excluded and the container 595 can receive the feedstock or the billet 592 directly. In such an example, the container 595 can be relatively easily replaced.

In some examples, the container 595 and the liner 597 can be cooled during operation, such as by a cooled or chilled fluid (e.g., refrigerant, water, a glycol/water mixture, or the like). In such an example, the container 595 can include one or more channels, passageways, or the like configured to receive chilled fluid from the first rotary union 578 so that the container 595 can receive cooled fluid even when the front spindle 560 is rotating. The fluid can reduce a temperature of the container 595 during operation before returning to the first rotary union 578 to be delivered to an external cooling source or a cooling source of the machine 502.

Optionally, the container 595 can also receive headed fluid in a case where the container 595, the liner 597, or the billet 592 need to be heated such as leading up to, or during, a process operation (e.g., during ramp up). Optionally, the container 595 can include one or more heating elements (e.g., resistive heating elements) to help heat the container 595, the liner 597, or the billet 592. Because the liner 597 can be connected to the container 595, the container 595 can cool (or reduce a temperature of) the liner 597 during operation. The container 595 can thereby be used to help obtain a desired process temperature of the container 595, the liner 597, and the billet 592 during process operations (e.g., extrusion).

FIG. 9 illustrates a cross-sectional schematic view of the machine 502. The machine 502 should have sufficient range of motion to allow for tooling (e.g., the die tool 584) and fixturing to be easily installed on the machine. However, several tooling dimensions are dependent up final dimensions of the machine 502. In particular, the ram 590 and the container 595 shown in FIG. 8 can be as long as the total spindle assembly length (a1 in FIG. 10), which means that a total free area that is larger than that will be needed for instillation of this tooling. The minimum range of motion that is necessary in order for installation and removal of tooling is parametrically defined herein based upon sizes of various machine elements, especially the total spindle assembly length (a1).

FIG. 9 shows the following dimensions: a1: a length from front of the front spindle 560 and the faceplate 574 to back of the first rotary union 578; a2: a distance of a1 minus the first rotary union 578; a3: a longitudinal dimension of the front movable headstock 543; b1: a distance between the tooling plate 572 and the tooling plate 574; b2: a distance between the first rotary union 578 and the tooling plate 576; b3: a distance from second rotary union 580 to rear fixed endstock 542; b0: a sum of b1 to b3, c1: same as b1; c2: a distance from a back of the front spindle 560 to the tooling plate 576; c3: a distance from a back of the rear spindle 562 to the rear fixed endstock 542; c0: a sum of c1 to c3; and d1: a total available travel space of headstocks. The “a”, “b0”, “c0”, and “d” dimensions can be fixed based upon geometry, whereas “b1-3” and “c1-3” dimensions can vary based upon position and operation of the machine 502.

When the first rotary union 578 or the second rotary union 580 are included in the machine 502, at minimum b0>a1, but ideally b0>1.5*a1. It is permissible but not particularly useful beyond b0>2*a1. When the machine 502 does not include a rotary union, c0>1.5*(x+a2), where x denotes the desired free space that may be later dedicated to a rotary union or other apparatus to be installed on the back of the spindle. The machine can be physically capable of moving the front movable headstock 543 and the rear movable headstock 545 such that c1 and c2 are both small (such as but not limited to 25 mm), with a large space at c3. In some examples, c1 and c3 can both be small, with a large space at c2. c2 and c3 can both be small, with a large space at c1. In some examples, c1, c2, or c3 can be 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 75 mm, 100 mm, 200 mm, or the like.

The machine 502 can have changeable limits (such as via software as confirmed by sensors), such that when a rotary union or similar is placed in the machine, b1 and b2 are both×mm, with a large space at b3, b1 and b3 are both×mm, with a large space at b2, b2 and b3 are both×mm, with a large space at b1, and where “x” is a definable limit, such as 10 mm. Similarly, user-level programmable limits can be used such that if tooling is added onto any of the three faceplates, the machine 502 can also be programmed such that a collision cannot inadvertently occur. User inputs can be used in these determinations: tooling length on both sides of the front movable headstock 543 and rear movable headstock 545, and one on the inside of each of the front fixed endstock 540 and rear fixed endstock 542.

In some examples, an area in c1, c2, and c3, exclusive of any rotary unions, can have a clearance radius, for example 250 mm, (centered on spindle) to allow for tools and work area to install tooling (e.g., die tools). In some examples, a maximum single-part length expected to be just over a1 can allow for access for installation and removal of any tooling on either faceplate. Machine surfaces in between the spindle frames can be flat and can be configured to support tooling being temporarily placed on flat area between end stocks, i.e. areas approximately corresponding to b1, b2, and b3 or c1, c2, and c3 is seen in FIG. 9.

FIG. 10 illustrates an example of a flowchart of a method 1000 for extruding pieces. The method 1000 can be a method of performing shear-assisted extrusion for extruding (for example) hollow cross-section pieces. More specific examples of the method 1000 are discussed below. The steps or operations of the method 1000 are illustrated in a particular order for convenience and clarity; many of the discussed operations can be performed in a different sequence or in parallel without materially impacting other operations. The method 1000 as discussed includes operations performed by multiple different actors, devices, or systems. It is understood that subsets of the operations discussed in the method 1000 can be attributable to a single actor, device, or system could be considered a separate standalone process or method. The method 1000 may be carried out using an extrusion system such as the systems described in association with FIGS. 1 to 9. Various examples are illustrated in the figures above. One or more features from one or more of these examples may be combined to form other examples.

At step 1002, a machine can be started up by initiating spindle rotation, such as rotation of the front spindle 560 and the rear spindle 562 as indicated by the arrows R1 and R2, respectively. At step 1004, the ram can be moved. For example, an axis of the ram 590 can be moved from an offset position to a contact position where the ram 590 engages a rear portion of the billet 592 and where the ram 590 is aligned along the central axis A.

At step 1006, the ram can be moved to contact a billet under force. For example, once the components are in alignment and positioned accordingly, contact between the ram 590 and the billet 592 can occur. At step 1008, ramp up can be performed. For example, an axial velocity or pressure of the ram 590 can be slowly increased (such as through adjusting the velocity of the rear spindle 562), resulting in a rapid increase in force, power, and temperature of various components of the machine 502, such as the billet 592. At step 1010, speeds of the spindles can be controlled. For example, rotational speed of the front spindle 560 and the rear spindle 562 can be controlled (e.g., raised or lowered) to bring a process temperature to or near a desired process temperature.

At step 1012, steady state can be entered. After ramp-up and obtaining a desired temperature, ramp up can be complete and steady state can be entered where the speed of the front spindle 560 and the rear spindle 562 can be maintained and the axial velocity of the rear spindle 562 and the ram 590 can be maintained, which can result in near-constant process temperatures and near-constant axial forces. In some examples, rotational speed of the front spindle 560 or the rear spindle 562 can be adjusted or varied to maintain the desired process temperature while axial velocity of the rear spindle 562 and the ram 590 is maintained to maintain the desired axial force. During ramp up and steady state operation, the billet 592 can engage with the die face 588 to perform shear-assisted extrusion to generate extrudate through the die tool 584.

At step 1014, velocities can be reduced following extrusion. For example, after the billet 592 is consumed or nearly consumed, an axial velocity of the ram 590 and the rear spindle 562 can be relatively quickly reduced to zero and then the velocity of the ram 590 and the rear spindle 562 can be reversed to back the ram 590 out of the bore 566. During stopping of extrusion and backing out of the ram 590, speeds of the front spindle 560 and rear spindle 562 can be reduced but not stopped, which can help to reduce adherence of the billet 592 to the other components of the machine 502. Once the ram 590 is clear of the remaining billet 592, rotation of the front spindle 560 and the rear spindle 562 can be stopped. While the above describes one example of an extrusion process, these steps do not describe all extrusions. For example, a very slow extrusion may not need a ramp-up phase. And, the machine 502 can provide flexibility in its programming to accommodate various differences of operation.

FIG. 11 illustrates a block diagram of an example machine 1100 upon which any one or more of the techniques (e.g., methodologies) discussed herein may perform. Examples, as described herein, may include, or may operate by, logic or a number of components, or mechanisms in the machine 1100. Circuitry (e.g., processing circuitry) is a collection of circuits implemented in tangible entities of the machine 1100 that include hardware (e.g., simple circuits, gates, logic, etc.). Circuitry membership may be flexible over time. Circuitries include members that may, alone or in combination, perform specified operations when operating. In an example, hardware of the circuitry may be immutably designed to carry out a specific operation (e.g., hardwired). In an example, the hardware of the circuitry may include variably connected physical components (e.g., execution units, transistors, simple circuits, etc.) including a machine readable medium physically modified (e.g., magnetically, electrically, moveable placement of invariant massed particles, etc.) to encode instructions of the specific operation. In connecting the physical components, the underlying electrical properties of a hardware constituent are changed, for example, from an insulator to a conductor or vice versa. The instructions enable embedded hardware (e.g., the execution units or a loading mechanism) to create members of the circuitry in hardware via the variable connections to carry out portions of the specific operation when in operation. Accordingly, in an example, the machine readable medium elements are part of the circuitry or are communicatively coupled to the other components of the circuitry when the device is operating. In an example, any of the physical components may be used in more than one member of more than one circuitry. For example, under operation, execution units may be used in a first circuit of a first circuitry at one point in time and reused by a second circuit in the first circuitry, or by a third circuit in a second circuitry at a different time. Additional examples of these components with respect to the machine 1100 follow.

In alternative embodiments, the machine 1100 may operate as a standalone device or may be connected (e.g., networked) to other machines. In a networked deployment, the machine 1100 may operate in the capacity of a server machine, a client machine, or both in server-client network environments. In an example, the machine 1100 may act as a peer machine in peer-to-peer (P2P) (or other distributed) network environment. The machine 1100 may be a personal computer (PC), a tablet PC, a set-top box (STB), a personal digital assistant (PDA), a mobile telephone, a web appliance, a network router, switch or bridge, or any machine capable of executing instructions (sequential or otherwise) that specify actions to be taken by that machine. Further, while only a single machine is illustrated, the term “machine” shall also be taken to include any collection of machines that individually or jointly execute a set (or multiple sets) of instructions to perform any one or more of the methodologies discussed herein, such as cloud computing, software as a service (SaaS), other computer cluster configurations.

The machine (e.g., computer system) 1100 may include a hardware processor 1102 (e.g., a central processing unit (CPU), a graphics processing unit (GPU), a hardware processor core, or any combination thereof), a main memory 1104, a static memory (e.g., memory or storage for firmware, microcode, a basic-input-output (BIOS), unified extensible firmware interface (UEFI), etc.) 1106, and mass storage 1108 (e.g., hard drive, tape drive, flash storage, or other block devices) some or all of which may communicate with each other via an interlink (e.g., bus) 1130. The machine 1100 may further include a display unit 1110, an alphanumeric input device 1112 (e.g., a keyboard), and a user interface (UI) navigation device 1114 (e.g., a mouse). In an example, the display unit 1110, input device 1112 and UI navigation device 1114 may be a touch screen display. The machine 1100 may additionally include a storage device (e.g., drive unit) 1108, a signal generation device 1118 (e.g., a speaker), a network interface device 1120, and one or more sensors 1116, such as a global positioning system (GPS) sensor, compass, accelerometer, or other sensor. The machine 1100 may include an output controller 1128, such as a serial (e.g., universal serial bus (USB), parallel, or other wired or wireless (e.g., infrared (IR), near field communication (NFC), etc.) connection to communicate or control one or more peripheral devices (e.g., a printer, card reader, etc.).

Registers of the processor 1102, the main memory 1104, the static memory 1106, or the mass storage 1108 may be, or include, a machine readable medium 1122 on which is stored one or more sets of data structures or instructions 1124 (e.g., software) embodying or utilized by any one or more of the techniques or functions described herein. The instructions 1124 may also reside, completely or at least partially, within any of registers of the processor 1102, the main memory 1104, the static memory 1106, or the mass storage 1108 during execution thereof by the machine 1100. In an example, one or any combination of the hardware processor 1102, the main memory 1104, the static memory 1106, or the mass storage 1108 may constitute the machine readable media 1122. While the machine readable medium 1122 is illustrated as a single medium, the term “machine readable medium” may include a single medium or multiple media (e.g., a centralized or distributed database, or associated caches and servers) configured to store the one or more instructions 1124.

The term “machine readable medium” may include any medium that is capable of storing, encoding, or carrying instructions for execution by the machine 1100 and that cause the machine 1100 to perform any one or more of the techniques of the present disclosure, or that is capable of storing, encoding or carrying data structures used by or associated with such instructions. Non-limiting machine readable medium examples may include solid-state memories, optical media, magnetic media, and signals (e.g., radio frequency signals, other photon based signals, sound signals, etc.). In an example, a non-transitory machine readable medium comprises a machine readable medium with a plurality of particles having invariant (e.g., rest) mass, and thus are compositions of matter. Accordingly, non-transitory machine-readable media are machine readable media that do not include transitory propagating signals. Specific examples of non-transitory machine readable media may include: non-volatile memory, such as semiconductor memory devices (e.g., Electrically Programmable Read-Only Memory (EPROM), Electrically Erasable Programmable Read-Only Memory (EEPROM)) and flash memory devices; magnetic disks, such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks.

The instructions 1124 may be further transmitted or received over a communications network 1126 using a transmission medium via the network interface device 1120 utilizing any one of a number of transfer protocols (e.g., frame relay, internet protocol (IP), transmission control protocol (TCP), user datagram protocol (UDP), hypertext transfer protocol (HTTP), etc.). Example communication networks may include a local area network (LAN), a wide area network (WAN), a packet data network (e.g., the Internet), mobile telephone networks (e.g., cellular networks), Plain Old Telephone (POTS) networks, and wireless data networks (e.g., Institute of Electrical and Electronics Engineers (IEEE) 802.11 family of standards known as Wi-Fi®, IEEE 802.16 family of standards known as WiMax®), IEEE 802.15.4 family of standards, peer-to-peer (P2P) networks, among others. In an example, the network interface device 1120 may include one or more physical jacks (e.g., Ethernet, coaxial, or phone jacks) or one or more antennas to connect to the communications network 1126. In an example, the network interface device 1120 may include a plurality of antennas to wirelessly communicate using at least one of single-input multiple-output (SIMO), multiple-input multiple-output (MIMO), or multiple-input single-output (MISO) techniques. The term “transmission medium” shall be taken to include any intangible medium that is capable of storing, encoding or carrying instructions for execution by the machine 1100, and includes digital or analog communications signals or other intangible medium to facilitate communication of such software. A transmission medium is a machine readable medium.

NOTES AND EXAMPLES

The following, non-limiting examples, detail certain aspects of the present subject matter to solve the challenges and provide the benefits discussed herein, among others.

Example 1 is a system for performing shear-assisted extrusion, the system comprising: a front fixed endstock and a rear fixed endstock; a front movable headstock located between the front fixed endstock and the rear fixed endstock and configured to translate therebetween in an axial direction; a rear movable headstock located between the front movable headstock and the rear fixed endstock and configured to translate therebetween in the axial direction to generate an axial extrusion force; a die tool connected to the front fixed endstock, the die tool comprising a face configured to engage and plasticize a face of feedstock material, the die tool defining an opening to receive plasticized feedstock material therethrough; a front spindle supported by the front movable headstock, the front spindle defining a front spindle bore extending along a longitudinal axis and configured to receive the feedstock material at least partially therein, the front spindle rotatable to rotate the feedstock material with respect to the front movable headstock; and a rear spindle connected to the rear movable headstock, the rear spindle rotatable with respect to the rear movable headstock and the die tool to generate, together with the front spindle and the feedstock material, a rotation-induced shear force between the feedstock material and the die tool to extrude the feedstock material through the opening of the die tool, and the rear spindle translatable with the rear movable headstock to generate the axial extrusion force.

In Example 2, the subject matter of Example 1 optionally includes wherein the die tool is connectable to the front fixed endstock, the rear fixed endstock, the front movable headstock, or the rear movable headstock.

In Example 3, the subject matter of any one or more of Examples 1-2 optionally include a plurality of rails connected to the front fixed endstock, the rear fixed endstock, the front movable headstock, and the rear movable headstock, the front movable headstock and the rear movable headstock translatable along the plurality of rails with respect to the front fixed endstock and the rear fixed endstock.

In Example 4, the subject matter of Example 3 optionally includes a plurality of shafts connected to the front fixed endstock, the rear fixed endstock, the front movable headstock, and the rear movable headstock; and one or more actuators operable to move the front movable headstock or the rear movable headstock along the plurality of shafts, held in alignment by the plurality of rails.

In Example 5, the subject matter of any one or more of Examples 1-4 optionally include a container connected to the front spindle and configured to support the feedstock material at least partially therein, the container rotatable with the front spindle.

In Example 6, the subject matter of Example 5 optionally includes a liner connected to a radially inner surface of the container, the liner configured directly engage and support the feedstock material at least partially therein.

In Example 7, the subject matter of any one or more of Examples 1-6 optionally include a front spindle motor connected to the front spindle and operable to drive the front spindle to rotate; and a rear spindle motor connected to the rear spindle and operable to drive the rear spindle to rotate.

In Example 8, the subject matter of any one or more of Examples 5-7 optionally include a first tooling plate connected to a rear face of the front fixed endstock; a second tooling plate connected to a front face of the front spindle; and a third tooling plate connected to a front face of the rear spindle.

In Example 9, the subject matter of Example 8 optionally includes wherein the die tool is secured to the first tooling plate and wherein the container is secured to the second tooling plate.

In Example 10, the subject matter of Example 9 optionally includes a ram connected to the third tooling plate, the ram configured to engage the feedstock material to generate the axial extrusion force.

In Example 11, the subject matter of Example 10 optionally includes wherein the ram is connectable to the first tooling plate, the second tooling plate, or the third tooling plate.

In Example 12, the subject matter of any one or more of Examples 8-11 optionally include wherein the die tool is securable to the first tooling plate, the second tooling plate, or the third tooling plate.

In Example 13, the subject matter of any one or more of Examples 5-12 optionally include wherein the container is configured to receive liquid from the front spindle to cool the container during extrusion.

In Example 14, the subject matter of Example 13 optionally includes a rotary union connected to the container and connected to the front spindle, the rotary union configured to deliver fluid to the front spindle during extrusion.

In Example 15, the subject matter of any one or more of Examples 1-14 optionally include wherein the front movable headstock is translatable with respect to the front fixed endstock and the rear fixed endstock to translate the front spindle and the feedstock material.

In Example 16, the subject matter of any one or more of Examples 1-15 optionally include wherein the front spindle is rotatable to rotate the feedstock material with respect to the front fixed endstock and the rear fixed endstock.

In Example 17, the subject matter of Example 16 optionally includes wherein the rear spindle is rotatable with respect to the front movable headstock, the front fixed endstock, and the rear fixed endstock to generate, together with the front spindle and the feedstock material, a rotation-induced shear force between the feedstock material and the die tool.

In Example 18, the subject matter of any one or more of Examples 1-17 optionally include a housing connected to the front fixed endstock and the rear fixed endstock; and a pair of movable doors connected to the housing and configured to at least partially enclose extrudate produced by the system from the feedstock material.

In Example 19, the subject matter of Example 18 optionally includes a crane connected to or near the machine, the crane operable to load feedstock material or tooling into and out of the system.

In Example 20, the subject matter of any one or more of Examples 18-19 optionally include a control system connected to the housing and configured to operate the front movable headstock, the rear movable headstock, the front spindle, and the rear spindle.

Example 21 is a system for shear-assisted extrusion, the system comprising: a front fixed endstock and; a front movable headstock located between the front fixed endstock and configured to translate therebetween in an axial direction; a rear movable headstock located between the front movable headstock and configured to translate therebetween in the axial direction to generate an axial extrusion force; a die tool connected to the front fixed endstock, the die tool comprising a face configured to engage and plasticize a face of feedstock material, the die tool defining an opening to receive plasticized feedstock material therethrough; a front spindle supported by the front movable headstock, the front spindle defining a front spindle bore extending along a longitudinal axis and configured to receive the feedstock material at least partially therein, the front spindle rotatable to rotate the feedstock material with respect to the front movable headstock; and a rear spindle connected to the rear movable headstock, the rear spindle rotatable with respect to the rear movable headstock and the die tool to generate, together with the front spindle and the feedstock material, a rotation-induced shear force between the feedstock material and the die tool to extrude the feedstock material through the opening of the die tool, and the rear spindle translatable with the rear movable headstock to generate the axial extrusion force.

In Example 22, the subject matter of Example 21 optionally includes a container connected to the front spindle and configured to support the feedstock material at least partially therein; and a liner connected to a radially inner surface of the container, the liner configured directly engage and support the feedstock material at least partially therein.

In Example 23, the subject matter of any one or more of Examples 21-22 optionally include a spindle motor connected to the front spindle and operable to drive the front spindle to rotate.

In Example 24, the subject matter of any one or more of Examples 21-23 optionally include a rear fixed endstock connected to the front fixed endstock; a plurality of rails connected to the front fixed endstock, the rear fixed endstock, the front movable headstock, and the rear movable headstock, the front movable headstock and the rear movable headstock translatable along the plurality of rails with respect to the front fixed endstock and the rear fixed endstock.

In Example 25, the subject matter of Example 24 optionally includes one or more shafts connected to the front fixed endstock, the rear fixed endstock, and front movable headstock, and the rear movable headstock; and one or more actuators operable to drive the one or more shafts to translate one or more of the front movable headstock and the rear movable headstock along the pair of rails.

In Example 26, the apparatuses or method of any one or any combination of Examples 1-25 can optionally be configured such that all elements or options recited are available to use or select from.

The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “examples.” Such examples can include elements in addition to those shown or described. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

In the event of inconsistent usages between this document and any documents so incorporated by reference, the usage in this document controls. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim.

In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. § 1.72 (b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as examples or embodiments, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

	Number	Date	Country
	63530733	Aug 2023	US
	63604041	Nov 2023	US

MULTI-AXIS SHEAR-ASSISTED EXTRUSION MACHINE

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CLAIM OF PRIORITY

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Provisional Applications (2)