Towards the flexible and near-net-shape production of three-dimensionally curved extrusion profiles

The present paper describes the new developments in continuous extrusion of curved profiles by a flexible production method which is composed of a short process chain starting with the extrusion press, a deflection tool, one robot for the flying cutting of the profile and another robot for supporting and handling the profile. Because of the flexibility of this complete system according to the profile curvature it is convenient for small-volume production. In order to reach high profile accuracy all kinematic systems in the process chain have to be synchronized with the profile speed caused by the extrusion process. The results of the investigation of different existing synchronization methods identify the need for an additional measuring system to compensate the large deviation of the cut profile length. By adjusting parameters of the synchronization the accuracy of the profile length could be strongly improved. Furthermore influencing parameters like die deformation during the extrusion process are measured and combined with the results of the cut profile length over the process time.