The Tube Scarfing Experts

Transcription

1 PRODUCTS 2011 The Tube Scarfing Experts Experience since 1982 in Tube ID Scarfing Systems and Tools for Longitudinal Welded Tubes Tube ID Scarfing Hydraulic Tools Mechanical Tools Cutting Rings PREMIUM QUALITY Made in Germany Tube Cutoff Clamp Jaw Sets Cutoff Blades NEW Tube Welding Tube OD Scarfing Chip Handling Strip Edge Conditioning Integral Impeders Cluster Impeders Disposable Impeders Ferrite Cores Impeder Casings Insert Holders OD Scarfing Inserts Rotoscarf OD Bead Chopper ID Notching Tools Strip Shaving Unit Alpha Metall GmbH & Co. KG Matthias-Erzberger-Str Ensdorf Germany Phone: Fax:

2 2011 Table of content Page Content: Table of content Hydraulic ID Scarfing Tools ID Scarfing Systems ID Scarfing Systems Mechanical ID Scarfing Tools Cutting rings Impeders (Standard, Cluster Impeder, Monoferrite-Impeder) Ferrite cores (Standard & Special) Impeder casing & Disposable Impeders, Ceramic Impeders OD Tube Scarfing: SNMG cutting inserts & accessory/spare parts OD Tube Scarfing: SNMX cutting inserts & accessory/spare parts OD Tube Scarfing: Rotoscarf (Oscillating/Revolving) Strip Edge Shaving Unit for Aluminized/Galvanized Strip Material Chip Treatment (Chip Shredder) Cutoff Blades & Clamp Jaws 2

3 Hydraulic ID Scarfing Tools Single and double lower leg type IS-HN8 Tube ID Scarfing Tool mm tube I.D. new IMproved Design Extended Range IST-HB 1 inside tube deburring tool 21-26mm tube I.D. Hydraulic Double Lower Leg ID Scarfing Tool (IS-DB-Types) with integrated NOTCHING FUNCTION The NOTCHING FUNCTION weakens the weld bead by notches in order to break after scarfing Standard tool Tube I.D. range Hydraulic Tube ID Scarfing Tool Cutting ring holder Standard tool Tube I.D. range Hydraulical inside tube weld seam removal tool Cutting ring holder 21-26mm 26-34mm 32-50mm 40-60mm 48-72mm IST-HB 1 IST-DB-HB 1 IST-HB 2 IST-DB-HB 2 IST-HB 3 IST-DB-HB 3 IST-HB 3/4 IST-DB-HB 3/4 IS-HB 4 IS-DB-HB 4 1-CRHT 6,5 1-CRHT 1 2-CRHT 1 2-CRHT 2 3-CRHT 1 3-CRHT 2 3-CRHT 3 3-CRHT 1 3-CRHT 2 3-CRHT 3 4-CRH 2 4-CRH 3 4-CRH 4 tilted cutting ring holder profile mm mm mm mm mm mm IS-HB 5 IS-DB-HB 5 IS-HB 6 IS-DB-HB 6 IS-HB 7 IS-DB-HB 7 IS-HN 8 IS-HN 9 IS-DB-HN 9 5-CRH 3 5-CRH 4 5-CRH 5 6-CRH 4 6-CRH 5 6-CRH 6 6-CRH 5 6-CRH 6 6-CRH 7 6-CRH 6 6-CRH 7 6-CRH 8 6-CRH 6 6-CRH 7 6-CRH mm IS-HN 4/5 IS-DB-HN 4/5 4-CRH 2 4-CRH 3 4-CRH mm IS-HN 10 IS-DB-HN 10 6-CRH 6 6-CRH 7 6-CRH 8 3

4 Customized Tube ID Scarfing Systems Hydraulic and Mechanic Cutting ring holder as wear part exchangeable also at smallest size fits for standard cutting rings available in different special designs applications precise height adjustment Modular Impeder high efficient because of selected materials Water spray nozzle avoids building up melting loss ID Scarfing tool easy to maintain rolls equipped with wear discs cutting ring cooling pass though Tow bar offset adapts the scarfing tool to the impeder diameter 4

5 Turn key projects long & short version available Sample picture shows long hydraulic system with tow bar support on last Fin pass stand Tow Bar Support for stable scarfing conditions The Unit is normally mounted on the exit of FinPass 3 Mounting Unit allows +/- 15 rotational adjustment The Unit is normally mounted on the entry of FinPass 1 Connector Terminal the Position upstream allows: large rotating capability high cross sectional area of coolant tubes easy access and retrofit Tow bar with integrated coolant supply tubes Quick coupling system 5

6 Mechanical ID Scarfing Tools Single and double lower leg type new IMproved Design Extended Range All our mechanical tools are delivered: In a high quality multiplex wooden box With a set of metric allen keys With complete set of wear parts Assembly drawing with parts list With 10 pcs of cutting rings of your choice fitting into the chosen cutting ring holder. Hook coupling to attach the tool to a tow bar.! Adjustment Instruction Guide Standard tool Tube I.D. range Mechanical Tube ID Scarfing Tool Cutting ring holder Standard tool Tube I.D. range Mechanical inside tube deburring tool Cutting ring holder 9,5-12mm IST-ME mm IST-ME 2 IST-DB-ME 2 2-CRHT 1 2-CRHT mm IST-ME IST-DB-ME mm IST-ME 3 IST-DB-ME 3 3-CRHT 1 3-CRHT 2 3-CRHT mm IST-ME 014 IST-DB-ME CRHT 4, mm IS-ME 4 IS-DB-ME 4 4-CRH 1 4-CRH 2 4-CRH 3 4-CRH mm IST-ME 017 IST-DB-ME CRHT 4,5 017-CRHT 6, mm IS-ME 5 IS-DB-ME 5 5-CRH 3 5-CRH 4 5-CRH mm IST-ME 1 IST-DB-ME 1 1-CRHT 6,5 1-CRHT mm (up to 175mm with modified lower leg) IS-ME 6 IS-DB-ME 6 6-CRH 4 6-CRH 5 6-CRH 6 6

7 PREMIUM QUALITY Carbide Cutting Rings and Cutting Ring Holders for mechanical and hydraulic inside tube scarfing systems Different Coating Systems Available TiN (PVD) CvD-TiC/TiN TiAlN Supercoatings for Special Applications Hyperlox Exxtral Premium carbide quality for long service life. H other cutting geometries available upon request i.e. former ALU type rings. special cutting geometry for high strength materials available upon request. Cutting Ring D [mm] d1 [mm] H [mm] Cutting Ring Holder Cutting Ring Holder 0-AL-4,5 (SR0/AR4,5) 4,0 0-AL 5,5 (SR0/AR5,5) 8,0 5,0 0-AL-6 (SR0/AR6) 5,5 0-AL 6,5 (SR0/AR6,5) 6 10,0 0-AL 7 (SR0/AR7) 6,5 0-AL 8 (SR0/AR8) 7, ,5 4,5 4,5 4,5 014-CRH 4,5 (SH0/SR4,5) 014-CRHT 4,5 017-CRH 6,5 (SH0/SR6,5) 1-CRH 6,5 (SH1/SR6,5) 017-CRHT 6,5 1-CRHT 6,5 1-AL 7 (SR1/AR7) 1-AL 8 (SR1/AR8) 1-AL 9 (SR1/AR9) 1-AL 10 (S1R/AR10) 13,0 6,0 7,0 8,0 9, CRH 1 (SH1/SR1) 2-CRH 1 (SH2/SR1) 3-CRH 1 (SH3/SR1) 1-CRHT 1 2-CRHT 1 3-CRHT 1 2-AL 10 (SR2/AR10) 2-AL 11 (SR2/AR11) 2-AL 12 (SR2/AR12) 19,0 9,0 10,0 11, CRH 2 (SH2/SR2) 3-CRH 2 (SH3/SR2) 2-CRHT 2 3-CRHT 2 3-AL 14 (SR3/AR14) 3-AL 17 (SR3/AR17) 22,0 12,0 15, CRH 3 (SH3/SR3) 4-CRH 3 (SH4/SR3) 3-CRHT 3 4-AL 23 (SR4/AR23) 5-AL 25 (SR5/AR25) 5-AL 28 (SR5/AR28) 30,0 20, ,0 22,0 25, CRH 4 (SH4/SR4) 5-CRH 4 (SH5/SR4) 5-CRH 5 (SH5/SR5) 6-CRH 5 (SH6/SR5) The above "CRHT" cutting ring holders fit only in our IST type Scarfing Tools. 6-AL 34 (SR6/AR34) 45,0 30, CRH 6 (SH6/SR6) 7-AL 39 (SR7/AR39) 50,0 35, CRH 7 (SH6/SR7) 8-AL 46 (SR7/AR39) 55,0 40, CRH 8 (SH6/SR8) 7

8 Integral Impeders // Throughflow & Returnflow for tube ID range: 8-600mm Standard Tow Bar Impeders! Available in through-flow & return-flow design! Non-standard diameters are available on request! Hydraulic through-flow Impeder available starting at 12mm Impeder diameter Cluster Impeders (Saddle design) Available starting at 85mm up to 460mm Impeder diameter for Tube ID mm Standard Impeder Diameters: 85mm 105mm 125mm 140mm 160mm 180mm 200mm 220mm 240mm 260mm 360mm 460mm Easy and fast changeable ferrite cores. Integral mandrel design for heavy tube walls & small diameter tubes *Maximum ferrite content* Mono-Ferrite Impeder! Special cover for Waterflow over the coated epoxy tube & cap to reduce weld spatter adhesion.! Maximum ferrite content for increased welding speed.! Rigidity of the Impeder assembly according to perfect fit between the Impeder Body and the epoxy tube. Available diameters: 8mm up to 90mm 8

9 PREMIUM QUALITY Impeder Ferrite Cores for HF welding applications Standard Ferrite Cores AMV AMH AMVS AMHS Alpha Metall Ferrite Cores (Type ZR) (Type ZRH) (Type ZRS) (Type ZRSH) 3x200 4x200 5x200 6x200 7x200 8x200 9x200 10x200 11x200 12x200 13x200 14x200 15x200 16x200 18x200 19x200 20x200 22x200 6x3x200 7x3x200 8x3x200 8x4x200 9x4x200 10x4x200 10x5x200 11x5x200 12x5x200 12x6x200 12x7x200 13x6x200 13x7x200 13x8x200 14x5x200 14x7x200 15x6x200 15x7x200 16x8x200 17x8x200 18x9x200 19x9x200 20x8x200 20x10x200 21x10x200 22x11x200 25x12x200 26x13x200 28x14x200 30x15x200 3x200 4x200 5x200 6x200 7x200 8x200 9x200 10x200 11x200 12x200 13x200 14x200 15x200 16x200 18x200 19x200 20x200 22x200 23x200 24x200 25x200 30x200 For dimensions and lengths not listed below please feel free to send us your inquiry IMPORTANT NOTE: ALL FERRITE DIAMETERS ARE EXTRUDED IN ONE PIECE (no glued rings for best performance) 10x3x200 10x5x200 11x3x200 11x5x200 12x3x200 12x4x200 13x5x200 14x4x200 14x5x200 14x7x200 15x4x200 15x5x200 15x6x200 15x7x200 16x5x200 16x6x200 16x7x200 16x8x200 17x5x200 17x6x200 17x7x200 18x5x200 18x6x200 18x9x200 19x6x200 20x6x200 20x10x200 21x6x200 21x10x200 22x6x200 22x10x200 23x6x200 23x11x200 24x6x200 25x10x200 26x10x200 28x13x200 29x10x200 32x13x200 33x10x200 40x20x200 50x20x200 60x27x200 80x35x200 AMHU (Type ZRHU) 7x3x200 9x4x200 11x5x200 13x6x200 15x6x200 16x6x200 18x9x200 AMHSU (Type ZRSHU) 9x4x200 11x5x200 13x6x200 15x6x200 16x6x200 18x9x200 Premium Ferrite Cores 9

10 Impeder Jackets & Disposable Impeders Disposable Impeders Throughflow & Returnflow Available from 8-90mm Diameter with different types of connectors. Quick coupling CERAMIC IMPEDER Compression Fitting (Metric) new SAE45 Flared Fitting JIC37 Flared Fitting new Ceramic Impeder Jackets available on request Dimension O.D. / I.D [mm] 10 / 8 11 / 9 12 / / / / / / / / / / / / / / / / / / / / / / / / / / / / /104 Standard length 1050mm 10 All Impeder Casings can be delivered ready cut to customer's length. Other diameters on request. Coatings available on request.

11 OD Tube Scarfing Holders and Inserts Indexable Inserts, 8 Cutting Edges, CVD-TiN-Coated (Standard) SNMG Dimensions [mm] Holder Insert d R l s HPH [R/L/N] Option [R] - RIGHT Option [L] - LEFT Option [N] - STRAIGHT Spare parts: Carbide support plate Lever Clamp screw Round Clip Assembly Pin SNMG 15 R7 R9 R10 R13 R15 R18 R20 R22 R25 R27 R30 R35 R40 R45 R50 R55 R60 15,90 R7 R9 R10 R13 R15 R18 R20 R22 R25 R27 R30 R35 R40 R45 R50 R55 R60 10,00 9,15 HPH [R/L/N] Option [R] - RIGHT Option[L] - LEFT Option[N] - STRAIGHT Spare parts: Carbide support plate Lever Clamp screw Round Clip Assembly Pin SNMG 19 R10 R12 R15 R20 R25 R35 R45 R55 R60 R80 R90 19 (3/4") R10 R12 R15 R20 R25 R35 R45 R55 R60 R80 R90 12,70 (1/2") 8,0 (5/16") HPH [R/L/N] Option [R] - RIGHT Option[L] - LEFT Option[N] - STRAIGHT Spare parts: Carbide support plate Lever Clamp screw Round Clip Assembly Pin SNMG 25 R50 R80 R90 R100 R120 R200 R250 R00 25,4 (1") R50 R80 R90 R100 R120 R200 R250 R0 14,3 (9/16") 12,7 (1/2") 11

12 OD Tube Scarfing Holders and Inserts Indexable Inserts, 8 Cutting Edges, TIN-Coated (Standard) Holder Insert SNMX HPS 20 x 150 [R/L/N] Option [R] - RIGHT Option [L] - LEFT Option [N] - STRAIGHT Spare parts: Carbide support plate (a) Lever (b) Clamp screw ( c) (a) (c) (b) SNMX 15 R7 R9 R11 R13 R15 R18 R20 R22 R25 R27 R30 R35 R40 R42 R45 R50 R60 R70 R75 R90 HPS 25/19x150 [R/L/N] Option [R] - RIGHT Option[L] - LEFT Option[N] - STRAIGHT Spare parts: Carbide support plate Lever Clamp screw SNMX 19 R30 R35 R40 R50 R60 R70 R80 R90 12

13 Outside Tube Scarfing System Rotoscarf An outside tube scarfing system with regrindable carbide inserts or indexable carbide inserts for tube O.D. starting at 12,7mm up to 101,6mm (1/2"-4") optional up to 168mm The objective for this unit was to provide the user a system that will run at least one shift without manual tool change. Furthermore our intention is to supply high quality and performance at the best price per cutting edge. The Princip is simple: Three carbide cutting blades are located in a circular tool head. Each of the cutting blades oscillates with the complete length of its cutting edge over the tube surface. The result is a perfect surface finish and a long tool life. Performance and Advantages: Average blade lifetime: 120m/min weld speed. Non Stop O.D. deburring for one shift. Tool change between the 3 inserts only by pressing a push button; a tool change is done in 2 seconds. The carbide cutting blades can be reground up to 30 times Easy regrinding: Only the front surface needs to be reground. The average costs to regrind a blade are between 2 and 3 euros. The simplicity of the regrinding process allows the user to try out different angles to optimize the cutting process and not least to increase performance. Perfect surface finish of the deburred area. Easy and fast tool cassette change. Cassettes with different relief angles are available (for aluminized or galvanized strips). Connection to the tube mill for automatic tool lifting or starting in automatic mode. 3 O.D. range tool heads: 12,7-40mm; 25-72mm and ,6mm (other sizes on request). Cutting heads also availabe for indexable inserts of the SNMX/G-type (see page 11+12) 13

14 Tube Mill Entry Equipment Strip Shaving Unit Perfect strip edge preparation increases welding quality and prevents rejects. Strip width (standard) Welding aluminized strips is very difficult because of many reasons: Aluminium melts at the strip edges and interferes the welding process and decreases the quality of the weld. Drops of liquid aluminium may destroy the impeders and can also built up weld beads, which can get loose and destroy the tooling downstream. I.D. and O.D. tube deburring is sometimes difficult and costly due to many tube mill stops caused by a untreated strip.we have designed our STRIP EDGE SHAVING MACHINE which will not only shave the edges... The Alpha Metall Strip Shaving Unit is specially designed to shave off the coatings also from the upper and lower side of the strip. All 3 Stations of the Strip Shaving Unit are equipped with standard TiN-coated TCMT carbide cutting inserts. The Strip Edge Shaving Unit is supplied with 3 stations featuring: Lead in and exit rollers. Side guide rollers adjustable through an excentric bolt. Top and bottom guide rails. One horizontal main adjustment to set the 6 tool stations to the strip width (95-300mm, other sizes on request). Horizontal adjustment for the strip centerline (+/- 12,5mm) First station shaves the upper part of the strip. Second station shaves the edges of the strip. Third station shaves the lower part of the strip. Micrometer adjustment of the cutters. Automatic sequence for opening and closing the side guide rollers, the top guide rails and the cutting tools to free the strip when the weld butt passes or for fast strip size change. 14

15 Chip Treatment Bead Chopper / Chip Shredder During the outside diameter scarfing process a continuous chip is being produced which is either reeled up or falls on the floor. The control and the removal of this chip is a problem due to the risk of accidents. The problem increased with the development of tube mills operating at weld speeds up to 200 metres per minute. view on the cutting blades The chips are guided into the weld seam shredder which can be placed in front of the scarfing station(s) without interfering tube mill operation. During the cutting progress the chip is slightly pulled into the shredder. That means less danger for the tube mill operator. Our Weld seam shredder is capable to process chips with a cross section up to 40mm². The main advantage is, that the chip volume is 20 times less than that of reeled chips and staff is no longer involved in chip removing. The feeding hole of the shredder is equipped with an additional feeding hopper. The feeding hopper is installed facing its opening towards the O.D. deburring units and the chip flow where the operator has no access. The feeding hopper can be equipped with a safety shutter which can be opened or closed by hand. The purpose of this unit is to avoid contact between the operator and the cutting blades during tool change at the O.D. deburring units. The shutter is also available in a aircontrolled modification. For better access during the O.D. deburring tool change the weld seam shredder can be mounted on guiding rails to make it possible to move it sideways or backwards. Also a Belt conveyor is possible Our cutting inserts have two cutting edges. Each edge can be reground up to 10 times. One cutting egde should last approximately 350 hours of operation. 15

16 Cutoff Knives and Clamp Jaws i.e. for Thermatool Alpha flying cutoffs and similar Customized High Precision Jaws and Blades for excellent service llife Please send us your Inquiry 16