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I TubeUpsellingMachines

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Tube upsetters are used to hotfQrgetheends of tubes. This increases the wanthickness to provide the machinihgstock and strength necessary for joiningthe tubes together. The configuration ofthe tube end may be classified as EX.TERNAL UPSET, INTERNAL UPSST,or INTERNAL.EXTERNAL UPSET asshown in the illustration.

The dimensions of the upsetends for oilcountry tubes are those speCitiedbyAPI, Hydril, or others. Depending uponthe type of upset, .in one operationthewall thickness may be increased,gener-ally, by a maximum of 50% tor EXTER.NAL or INTERNAL-EXTERNAL UP-SETS, and by a maximumofJOO%iO[INTERNAL UPSETS. Basedl1pontheselimits, some of the API upsets canbeforged in one operationbutmostoftgeAPI upsets require two operations, .while most Hydril upsets require morethan two forging operations. Ajaxtubeupsetters are designedto accommo-date tooling for two operations which isthe practical limit for a single heat. Forthose tube ends that requi remorethaQtwo forging operations, thefirsttwo

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Ajax 5V2"Tube Upsetter

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Internal-External Upset

operations are completed for the pro-duction lot, then the tooling is changedin the tube upsetter and the tubes areagain processed for the third and, ifnecessary, fourth operations.

Forging of tubes generates tremendousforces across the dies. The forces aresubstantially more severe than thosegenerally resulting from the forging ofsolid bar stock because greater diearea is used to back up the forgingoperation. This forge area on tube up-sets is normally about 3 to 10 timesgreater when compared to conven-tional forging machines. The forcesrequired to prevent the dies from open-ing during the forging operationsimpose high loads to the toggles andthe machine frame. Ajax tube upsettersare designed and constructed to with-stand these forces and to provide re-liable performance and minimaldowntime.

In tube upsetting, it is necessary thatthe heading tool is long enough that theleading end is past the heated portionof the tube prior to the start of upsetting.

This results in a relatively long punchwhich must be retracted from the tubeafter upsetting. This requires not only along headerslide stroke, but also, provi-sions to grip the tube in the dies duringa large portion of the headerslidestroke. Compared to conventional forg-ing machines, Ajax tube upsetters havesubstantially longer headerslide stroke,stock gather and hold-on.

The available die length on Ajax tubeupsetters is considerably longer thanthat on a standard forging machine.This provides for the increased griplength required when forging tubes-4 to 6 times the tube diameter ascompared to 3 to 4 times the solid stockdiameter for conventional forging ma-chines. the result is a more reliable grip.

Ajax has helped industry produce thehighest quality forgings for more than acentury, and its machines are the resultof years of problem solving and innova-tive engineering. We invite you to reviewthe special features which have helpedmake Ajax the leader in modern forgingmachines.

BasicComponenlsollheAjaxTubeUpseller

HIGH MAINTOGGLEAND ALLOYSTEEL PINSprovide backingthroughout theentire die height

TOp.SUSPENDEDDIE SLIDEis outboard-guided for perfectalignment with the stationary die.A long fully backed shuttle plate supportsthe moving die urder heading load.

MULTIPLEOPERATION DIEScan upset or extrude hot orcold stock. Exceptionalmachine rigidity assuresprecise die alignment.

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POWERFUL DIE GRIPkeeps dies closed under load without auxiliarymeans. A self-contained safety can throw outanywhere In the closing stroke to protect themachine and tooling.

CRANKSHAFTForged alloysteel crankshafthas large diameter eccentricpin, fulldiameter armsand long, large diameterjournals. Crankshaft can beremoved without disturbingthe header slide, ALLOY

STEEL PITMANhas an exclusive

nose bearing thattakes the forgingload and minimizesstress at the wrist pin,

TOP-SUSPENDEDHEADER SLIDEis extension-guided to produceaccurate forgings under any loadconditions,

RIGID STEEL BED

is a one-piece steel casting with thick wall and heavyribbing, Continuous crankshaft bearing housings areIntegrally cast to minimize crankshaft deflection,

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V.BELT MOTOR DRIVEis best for forging equipmentbecause it adapts to a variety ofmotors and transmits full motor

torque,

AIR CLUTCHAND BAND BRAKEoffer fast, smooth starting andstopping, Conservative designassures long life and accuracy

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MAIN AND PINION GEARSare alloy steel and have machinedteeth, Pinion shaft has anti-frictionbearings and the main gear is double-keyed to the crankshaft,

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,-'I Die Grip

POWERFULDIE GRIPThe cam actuated, double toggle, diegrip mechanism is ruggedly constructedand provides effective gripping withoutthe use of backstops or auxiliary grippingmeans. The complimentary cam ismounted on the crankshaft. The camprofile is designed to impart smooth mo-tion to the die slide during the openingand closing motions, and assures definiteend positions of the die slide stroke. Thissimplifies tooling set-up, since the align-ment between the dies and punchesdoes not vary after installation.

In the event of misplaced stock or otherobstructions, the safety mechanism, con-tained within the cam slide, will throw outanywhere in the closing stroke. This ac-tion trips a limit switch, which stops themachine cycle. Inching procedure isused to automatically reset the safetymechanism during the headerslide returnstroke.

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SpeCialFeatures

DOUBLETOGGLESDouble toggles are used to provide great-er bearing area to distribute the forcescreated by the gripping and upsettingloads. Large diameter, alloy steel togglepins provide the necessary backingthrough the entire die height and dis-tribute the loads developed in closing thedies and holding them closed. This, cou-pled with the high strength of the frameresults in reduced part flash, die wash,and extended tool life. All toggle bearingsare lubricated by the automatic pressuresystem.

EXTENSIONGUIDED DIE SLIDETwo bearing lips faced with bronze linersoperating on hardened steel shelf linersin the bed amply support the top sus-pended die slide. A rugged underarmjoins the main slide body and the out-board extension guide. The extensionguide, operating in an unstressed areaon the right side of the bed, is supportedon all four sides by bronze liners to keepthe moving die in perfect alignment withthe stationary die. This results in consis-tently precise, well matched forgings.

MOVING DIE SUPPORTThe shuttle support plate extends acrossthe backing plate and moves with the dieslide, on its own shelf liner, to back up themoving die under the heading load. Thismaintains the axial alignment of themoving and stationary dies.

As an option, the shuttle support platecan be arranged to operate independ-ently from the die slide to also performpre-clamping and tube strippingfunctions.

IndependentShuttleSupportPlateinOpenPosition

EXTRA LENGTH DIESThe available die length allows for extralong dies to provide ample gripping ca-pacity for the entire diameter range ofeach machine. Single long dies simplifyalignment since both the grip and work-ing impression are in the same die. Also,single long dies within the machine pro-vides maximum visibility for the operator.

UNDERARM HEADERSLIDE AND PITMAN . .The mainbody of the slidecarriesthe Underarmconstructionmakesall majortoolholder,the pitmanthrust bearing,and componentsvIsibleand readilythe wristpin connection.The slide is accessible.

ruggedlyconstructedto preventdistor- TheAjax exclusivepitmandesign fea-tion due to headingforces.The main turesa large thrustbearingon itsnosebody istop suspendedfromtwo long, which distributesthe headingforce andwide lipsfacedwith bronzelinersoperat- minimizesstressconcentrationsat theing on hardenedsteelshelfliners in the wristpin bore. Bushingsfor the wristpinbed.A strongunderarmjoins the main are undercutso that the thrust bearingbody withthe extensionguide. The ex- takesthe full heading load. Large diame-tensionguide: supported on all4 sides ter pitman boltsareused to allowfor theimprovesforging accuracy regardlessof heavypull-offloadsencounteredIntubeloadconditions.TheextensiongUide upsetting.linerscan be removedfor trulng andshimmingwithoutdisturbingthe slide.

AlloySteelPitmanCap

Large DiameterPitman Bolts

Extension GUidedHeader SlideDesign withUnderarmConstruction

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ProgressiveStepsinForgingOilFieldDrilling Pipe

Alloy BronzeLip Liners

,PitmanThrustBearing

OtherImportantFeatures

The direct-acting air clutch and the heavy duty linktype band brake are smooth and responsive even athigh production cycle rates. The multiple friction disctype clutch has integral ventilation and low unit pres-sure which maximizes friction lining life. The torquecapacity of the clutch is controlled, and the clutch slipsin the event of an overload to act as a safety device.The hinged multiple link type brake provides fastresponse. The clutch is spring released while thebrake is spring set to provide for fail-safe operation inthe event of loss of air pressure or electrical power. Aseparate auxiliary brake for stopping the flywheel isalso provided.

Special analysis, heat-treated steel main and piniongears have precision machined teeth. The main gearis double keyed to the crankshaft. The pinion shaftand the clutch plate are supported on anti-frictionbearings. The capped housings for the pinion shaftbearings permit disassembly within the floor space ofthe machine.

The bed frame is a one piece steel casting, com-pletely strain relieved. Special care taken to assureproper metal distribution results in unusually low stressand high rigidity even in those frame sections whichsupport the high forces developed across the dies.The frame strength across the dies is supplementedby a side clamp assembly (optional on the 3-1/2:'5-1/2" heavy duty and 7-5/8" sizes). The clamp isindependent of the machine bed frame and consistsof two massive steel castings connected by largediameter tie rods both top and bottom. During upset-ting, the clamp provides crosswise support tominimize frame deflection, increasing die grippingcapability by approximately 50%.

Tooling is arranged vertically for easy tool setting, andadequate die height is provided. The vertical dieparting line also allows for easier die and tool cooling,and more efficient scale removal. Major componentsare designed for easy removal which reducesmaintenance time.

MainandPinion Gearsof Heat Treated

AI/oySteel

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&~@]wStandardAccessories

Slotted TailDie Clamps

The slotted tail die clamps hold thestationary and moving dies securelyin place. These clamps facilitate diechanges, since they need not be liftedoff the studs.

The straddle type toolholder clamp hasprovisions for keying the toolholder at thetop. Combined with the bottom keyingprovided in the headerslide, this preventsthe toolholder from shifting even underthe heavy pull-off forces encountered intube upsetting. Also, a wedge is providedin the headerslide, at the back of thetoolholder, to provide full backing for theheading load.

Ajax tube upsetters are powered byindividual motor drives through multipleV-belts. The motor support bracket,V-belts, and motor sheave are standardequipment. The required motor withadjusting rails can be furnished by thecustomer, or by Ajax at extra charge.

Heavy steel shields for the gear andpinion, the headerslide and pitman as-sembly, and the cam slide and double

toggle assembly fit closely to prevententry of foreign material such as scale.Along with the shield for the V-belt drive,the shields provide protection for shoppersonnel while permitting completeaccessibility for inspection through con-veniently located access panels.

An automatic, centralized, metered, pres-sure fed oil lubrication system supplies allprincipal bearings, except the anti-frictionbearings of the clutch and pinion shaftwhich are pressure lubricated throughindividual hand fittings as are minor bear-ings requiring infrequent lubrication.The lubrication system is designed andinstalled for dependable, troublefreeoperation with convenient access formaintenance.

Pneumatic system accessories, includingpressure regulators, pressure gauges,shut off and bleed valves, venturi air linelubricator, and air receiver tank aremounted on the frame permittingcomplete access for inspection.

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OptionalEquipment

CONTROL & INSTRUMENTATIONElectrical controls, including the starter forthe upsetter drive motor, sequence andmonitor the lubrication system and the twomodes of machine operation (SINGLECYCLE and INCH) by a series of relays.With the control set for SINGLE CYCLE, thefoot switch actuates control relays whichsequentially release the spring set brake andthen engage the spring released clutch. Thecycle is controlled by a rotary cam limitswitch, chain driven by the upsetter crank-shaft, which sequentially disengages theclutch and then engages the brake to endthe cycle with the upsetter at back centerposition. Circuitry requires that the operatorrelease the foot switch prior to startinganother cycle. Depending upon require-ments, the foot switch can be replaced by apair of RUN push buttons.With the control at INCH, the motor is usedto bring the flywheel to a speed suitable forinching. Two INCH push buttons actuate thecontrol relays, causing the upsetter to cycleslowly until the INCH push buttons are re-leased. Inching is accomplished from thestoredenergy of the flywheel- the motor isnot powered.

Instrumentation to monitor the temperaturesof critical bearings by means of thermocou-

Tube Ejectors

pies utilizing meters and/or recorders can besupplied. Tachometers, load monitors, andother recording or diagnostic instrumenta-tion can also be furnished.

The Ajax engineering staff is ready tocustom design a control and instrumentationsystem to meet your specific needs andinterface with the complete production line.PRECLAMPING MECHANISMThe shuttle support plate is operated inde-pendently from the die slide and is poweredby a large diameter air cylinder. The shuttlesupport plate and the stationary die thrustblock are arranged to accept matching grip-per dies. The shuttle support plate operatesbefore the start of the header slide stroke sothat it clamps the tube against the stationarydie. This preserves the stock gauge positionand aligns the tube with the punch, assuringthat the punch enters the tube cleanly. Afterthe forging is completed, the shuttle supportplate maintains its grip on the tube until afterthe die slide starts to open, allowing thepunch to retract cleanly and stripping thetube from the moving die.TUBE EJECTORSAir cylinder operated ejector pins, one foreach tube position, located at the stationarydie thrust block, act directly on the tube topush it out from the stationary die. Ample

Stock Gauge

stroke and adjustment of ejector pin lengthprovide necessary ejection over the fullrange of tube diameters.RETRACTABLE STOCK GAUGELocated to the left side of the headerslide,the stock gauge can travel into the spaceallowed by the open moving die. This per-mits the entering tube to be stopped withinthe die so that the punch is guided in the diebefore upsetting begins. Prior to the start ofthe headerslide stroke, the stock gauge isautomatically retracted to clear the movingdie. The gauging position is fully adjustableover a wide range by means of a handwheelat the operator's position.RIGID BED SIDE CLAMPA side clamp assembly can be furnishedwiththe3V2:' 5112" heavyduty,or the 75/8"tube upsetters. The clamp is independent ofthe bed frame and provides substantialcrosswise support to minimize bed framedeflections during upsetting. This greatlyreduces the formation of fins to the extentthat multiple passes on difficult tube upsetscan be taken in the same heat.DIE AND TOOL COOLING& LUBRICATIONSystems for die and tool cooling, and forautomatic die and tool lubrication can be

provided.

Side Clamp Assembly

DIE AND DESIGNCAPABILITYWith over 100 years of experience indesigning and building forging equip-ment, Ajax has the expertise todesign, build and develop dies andtools necessary for the efficient pro-duction of quality forgings.

Fullyautomatedtube upsetterinstallation fortubes 4 inchesthrough 103/4Inches In diameter.

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Ajax12"Tube Upsetter

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~)~<MANUFACTURING COMPANY1441Chardon Rd., North. Cleveland, Ohio 44117Telephone 216/531-1010

Pnnted In USA