~ \ <::)

n~>~< BULLETIN 93-A

I TubeUpselling
Machines
 'II
""
iI'

An
Inlrodulltl
'""'
.w

Internal-External Upset

Tube upsetters are used to hotfQrgethe operations are completed for the pro- This results in a relatively long punch
ends of tubes. This increases the wan duction lot, then the tooling is changed which must be retracted from the tube
thickness to provide the machinihg in the tube upsetter and the tubes are after upsetting. This requires not only a
stock and strength necessary for joining again processed for the third and, if long headerslide stroke, but also, provi-
the tubes together. The configuration of necessary, fourth operations. sions to grip the tube in the dies during
the tube end may be classified as EX. Forging of tubes generates tremendous a large portion of the headerslide
TERNAL UPSET, INTERNAL UPSST, forces across the dies. The forces are stroke. Compared to conventional forg-
or INTERNAL.EXTERNAL UPSET as ing machines, Ajax tube upsetters have
substantially more severe than those
shown in the illustration. substantially longer headerslide stroke,
generally resulting from the forging of
The dimensions of the upsetends for oil solid bar stock because greater die stock gather and hold-on.
country tubes are those speCitiedby area is used to back up the forging The available die length on Ajax tube
API, Hydril, or others. Depending upon operation. This forge area on tube up- upsetters is considerably longer than
the type of upset, .in one operationthe sets is normally about 3 to 10 times that on a standard forging machine.
wall thickness may be increased,gener- greater when compared to conven- This provides for the increased grip
ally, by a maximum of 50% tor EXTER. tional forging machines. The forces length required when forging tubes-
NAL or INTERNAL-EXTERNAL UP- required to prevent the dies from open- 4 to 6 times the tube diameter as
SETS, and by a maximumofJOO%iO[ ing during the forging operations compared to 3 to 4 times the solid stock
INTERNAL UPSETS. Basedl1ponthese impose high loads to the toggles and diameter for conventional forging ma-
~ the machine frame. Ajax tube upsetters chines. the result is a more reliable grip.
limits, some of the API upsets canbe
forged in one operationbutmostoftge are designed and constructed to with-
Ajax has helped industry produce the
t API upsets require two operations, . stand these forces and to provide re-
highest quality forgings for more than a
while most Hydril upsets require more liable performance and minimal
downtime. century, and its machines are the result
I' than two forging operations. Ajaxtube of years of problem solving and innova-
upsetters are designedto accommo- In tube upsetting, it is necessary that tive engineering. We invite you to review
date tooling for two operations which is the heading tool is long enough that the the special features which have helped
the practical limit for a single heat. For leading end is past the heated portion make Ajax the leader in modern forging
those tube ends that requi remorethaQ of the tube prior to the start of upsetting. machines.
~ two forging operations, thefirsttwo
,
,.

Ii
f;
"I

i
I
I

~t

Ajax 5V2"
"
Tube Upsetter

f. 1
I " >
 BasicComponenls
ollheAjax
TubeUpseller

HIGH MAIN TOp. MULTIPLE

TOGGLE SUSPENDED OPERATION DIES
AND ALLOY DIE SLIDE can upset or extrude hot or
STEEL PINS is outboard-guided for perfect cold stock. Exceptional
provide backing alignment with the stationary die. machine rigidity assures
throughout the A long fully backed shuttle plate supports precise die alignment.
entire die height the moving die urder heading load.

2
 -r
I
II
V.BELT MOTOR DRIVE
is best for forging equipment
because it adapts to a variety of
motors and transmits full motor
torque,

AIR CLUTCH
POWERFUL DIE GRIP AND BAND BRAKE
keeps dies closed under load without auxiliary offer fast, smooth starting and
~
means. A self-contained safety can throw out stopping, Conservative design
anywhere In the closing stroke to protect the assures long life and accuracy
machine and tooling.
)

CRANKSHAFT
Forged alloysteel crankshaft
has large diameter eccentric
pin, fulldiameter arms
and long, large diameter
journals. Crankshaft can be
removed without disturbing ALLOY
the header slide,
STEEL PITMAN MAIN AND PINION GEARS
has an exclusive are alloy steel and have machined
nose bearing that teeth, Pinion shaft has anti-friction
takes the forging bearings and the main gear is double-
load and minimizes keyed to the crankshaft,
stress at the wrist pin,

TOP-SUSPENDED
HEADER SLIDE
is extension-guided to produce
accurate forgings under any load
conditions,

RIGID STEEL BED

is a one-piece steel casting with thick wall and heavy
ribbing, Continuous crankshaft bearing housings are
Integrally cast to minimize crankshaft deflection,

3
. -----

&~@]~
SpeCial
Features
,- Die Grip
'I

POWERFUL
DIE GRIP
The cam actuated, double toggle, die
grip mechanism is ruggedly constructed
and provides effective gripping without
the use of backstops or auxiliary gripping
means. The complimentary cam is
mounted on the crankshaft. The cam
profile is designed to impart smooth mo-
tion to the die slide during the opening DOUBLE EXTENSION
and closing motions, and assures definite TOGGLES GUIDED DIE SLIDE
end positions of the die slide stroke. This
Double toggles are used to provide great- Two bearing lips faced with bronze liners
simplifies tooling set-up, since the align- er bearing area to distribute the forces operating on hardened steel shelf liners
ment between the dies and punches created by the gripping and upsetting in the bed amply support the top sus-
does not vary after installation.
loads. Large diameter, alloy steel toggle pended die slide. A rugged underarm
In the event of misplaced stock or other pins provide the necessary backing joins the main slide body and the out-
obstructions, the safety mechanism, con- through the entire die height and dis- board extension guide. The extension
tained within the cam slide, will throw out tribute the loads developed in closing the guide, operating in an unstressed area
anywhere in the closing stroke. This ac- dies and holding them closed. This, cou- on the right side of the bed, is supported
tion trips a limit switch, which stops the pled with the high strength of the frame on all four sides by bronze liners to keep
machine cycle. Inching procedure is results in reduced part flash, die wash, the moving die in perfect alignment with
used to automatically reset the safety and extended tool life. All toggle bearings the stationary die. This results in consis-
mechanism during the headerslide return are lubricated by the automatic pressure tently precise, well matched forgings.
stroke. system.
 ", ~~~ ~~~- -~-
Independent
Shuttle
Support
Platein
Open
Position

MOVING DIE SUPPORT EXTRA LENGTH DIES

The shuttle support plate extends across The available die length allows for extra
the backing plate and moves with the die long dies to provide ample gripping ca-
slide, on its own shelf liner, to back up the pacity for the entire diameter range of
moving die under the heading load. This each machine. Single long dies simplify
maintains the axial alignment of the alignment since both the grip and work-
moving and stationary dies. ing impression are in the same die. Also,
As an option, the shuttle support plate single long dies within the machine pro-
can be arranged to operate independ- vides maximum visibility for the operator.
ently from the die slide to also perform
pre-clamping and tube stripping
functions.

UNDERARM HEADERSLIDE AND PITMAN . .

The main body of the slidecarriesthe Underarmconstructionmakesall major
toolholder,the pitmanthrust bearing, and componentsvIsibleand readily
the wristpin connection.The slide is accessible. Progressive
Stepsin
ruggedly constructedto preventdistor- TheAjax exclusivepitmandesign fea- Forging
tion due to headingforces.The main turesa large thrust bearing on its nose OilField
body istop suspendedfrom two long, which distributesthe headingforce and Drilling Pipe
wide lipsfaced with bronzelinersoperat- minimizesstressconcentrationsat the
ing on hardenedsteelshelfliners in the wrist pin bore. Bushingsfor the wrist pin
bed. A strong underarmjoins the main are undercut so that the thrust bearing
body withthe extensionguide. The ex- takesthe full heading load. Large diame-
tensionguide: supported on all 4 sides ter pitman boltsare used to allowfor the
improvesforging accuracy regardlessof heavy pull-offloads encounteredIntube
load conditions.TheextensiongUide
linerscan be removedfor trulng and upsetting.
shimmingwithoutdisturbingthe slide.

Alloy Bronze
Lip Liners
Alloy Steel
PitmanCap

,
Pitman
Thrust
Large Diameter Bearing
Pitman Bolts

Extension GUided
Header Slide
Design with
Underarm
Construction

5
II
Other
Important
Features

The direct-acting air clutch and the heavy duty link

type band brake are smooth and responsive even at
high production cycle rates. The multiple friction disc
type clutch has integral ventilation and low unit pres-
sure which maximizes friction lining life. The torque
capacity of the clutch is controlled, and the clutch slips
in the event of an overload to act as a safety device.
The hinged multiple link type brake provides fast
response. The clutch is spring released while the
brake is spring set to provide for fail-safe operation in
the event of loss of air pressure or electrical power. A
separate auxiliary brake for stopping the flywheel is
also provided.
Special analysis, heat-treated steel main and pinion
gears have precision machined teeth. The main gear
is double keyed to the crankshaft. The pinion shaft
and the clutch plate are supported on anti-friction
bearings. The capped housings for the pinion shaft
bearings permit disassembly within the floor space of
the machine.

The bed frame is a one piece steel casting, com-

pletely strain relieved. Special care taken to assure
proper metal distribution results in unusually low stress
and high rigidity even in those frame sections which
support the high forces developed across the dies.
The frame strength across the dies is supplemented
by a side clamp assembly (optional on the 3-1/2:'
5-1/2" heavy duty and 7-5/8" sizes). The clamp is
independent of the machine bed frame and consists
of two massive steel castings connected by large
diameter tie rods both top and bottom. During upset-
ting, the clamp provides crosswise support to
minimize frame deflection, increasing die gripping
capability by approximately 50%.
Tooling is arranged vertically for easy tool setting, and
adequate die height is provided. The vertical die
parting line also allows for easier die and tool cooling,
and more efficient scale removal. Major components
are designed for easy removal which reduces
maintenance time.

Main and
Pinion Gears
of Heat Treated
AI/oySteel

6
&~@]w
Standard
Accessories
Slotted Tail
Die Clamps

The slotted tail die clamps hold the toggle assembly fit closely to prevent
stationary and moving dies securely entry of foreign material such as scale.
in place. These clamps facilitate die Along with the shield for the V-belt drive,
changes, since they need not be lifted the shields provide protection for shop
off the studs. personnel while permitting complete
The straddle type tool holder clamp has accessibility for inspection through con-
provisions for keying the tool holder at the veniently located access panels.
top. Combined with the bottom keying An automatic, centralized, metered, pres-
provided in the headerslide, this prevents sure fed oil lubrication system supplies all
the tool holder from shifting even under principal bearings, except the anti-friction
the heavy pull-off forces encountered in bearings of the clutch and pinion shaft
tube upsetting. Also, a wedge is provided which are pressure lubricated through
in the headerslide, at the back of the individual hand fittings as are minor bear-
tool holder, to provide full backing for the ings requiring infrequent lubrication.
heading load. The lubrication system is designed and
Ajax tube upsetters are powered by installed for dependable, troublefree
operation with convenient access for
individual motor drives through multiple
maintenance.
V-belts. The motor support bracket,
V-belts, and motor sheave are standard Pneumatic system accessories, including
equipment. The required motor with pressure regulators, pressure gauges,
adjusting rails can be furnished by the shut off and bleed valves, venturi air line
customer, or by Ajax at extra charge. lubricator, and air receiver tank are
Heavy steel shields for the gear and mounted on the frame permitting
pinion, the headerslide and pitman as- complete access for inspection.
sembly, and the cam slide and double

75fs"

12"

19 250
g~@Jw
Optional
Equipment

CONTROL & INSTRUMENTATION pies utilizing meters and/or recorders can be stroke and adjustment of ejector pin length
Electrical controls, including the starter for supplied. Tachometers, load monitors, and provide necessary ejection over the full
the upsetter drive motor, sequence and other recording or diagnostic instrumenta- range of tube diameters.
monitor the lubrication system and the two tion can also be furnished. RETRACTABLE STOCK GAUGE
modes of machine operation (SINGLE The Ajax engineering staff is ready to Located to the left side of the headerslide,
CYCLE and INCH) by a series of relays. custom design a control and instrumentation the stock gauge can travel into the space
With the control set for SINGLE CYCLE, the system to meet your specific needs and allowed by the open moving die. This per-
foot switch actuates control relays which interface with the complete production line. mits the entering tube to be stopped within
sequentially release the spring set brake and PRECLAMPING MECHANISM the die so that the punch is guided in the die
then engage the spring released clutch. The The shuttle support plate is operated inde- before upsetting begins. Prior to the start of
cycle is controlled by a rotary cam limit pendently from the die slide and is powered the headerslide stroke, the stock gauge is
switch, chain driven by the upsetter crank- by a large diameter air cylinder. The shuttle automatically retracted to clear the moving
shaft, which sequentially disengages the support plate and the stationary die thrust die. The gauging position is fully adjustable
clutch and then engages the brake to end block are arranged to accept matching grip- over a wide range by means of a handwheel
the cycle with the upsetter at back center per dies. The shuttle support plate operates at the operator's position.
position. Circuitry requires that the operator before the start of the header slide stroke so RIGID BED SIDE CLAMP
release the foot switch prior to starting that it clamps the tube against the stationary A side clamp assembly can be furnished
another cycle. Depending upon require- die. This preserves the stock gauge position withthe3V2:' 5112" heavyduty,or the 75/8"
ments, the foot switch can be replaced by a and aligns the tube with the punch, assuring tube upsetters. The clamp is independent of
pair of RUN push buttons. that the punch enters the tube cleanly. After the bed frame and provides substantial
With the control at INCH, the motor is used the forging is completed, the shuttle support crosswise support to minimize bed frame
to bring the flywheel to a speed suitable for plate maintains its grip on the tube until after deflections during upsetting. This greatly
inching. Two INCH push buttons actuate the the die slide starts to open, allowing the reduces the formation of fins to the extent
control relays, causing the upsetter to cycle punch to retract cleanly and stripping the that multiple passes on difficult tube upsets
slowly until the INCH push buttons are re- tube from the moving die. can be taken in the same heat.
leased. Inching is accomplished from the TUBE EJECTORS DIE AND TOOL COOLING
storedenergy of the flywheel - the motor is Air cylinder operated ejector pins, one for & LUBRICATION
not powered. each tube position, located at the stationary Systems for die and tool cooling, and for
Instrumentation to monitor the temperatures die thrust block, act directly on the tube to automatic die and tool lubrication can be
of critical bearings by means of thermocou- push it out from the stationary die. Ample provided.

Tube Ejectors Stock Gauge Side Clamp Assembly

DIE AND DESIGN
CAPABILITY
With over 100 years of experience in
designing and building forging equip-
ment, Ajax has the expertise to
design, build and develop dies and
tools necessary for the efficient pro-
duction of quality forgings.

Fullyautomated
tube upsetter
installation for
tubes 4 inches
through 103/4
Inches In diameter.

Ajax
12"
Tube Upsetter

C)
L.
~)~<
MANUFACTURING COMPANY
1441Chardon Rd., North. Cleveland, Ohio 44117
Telephone 216/531-1010

Pnnted In USA