Metalock design special internal grinder to regrind the internal bores of a double barrel extruder at a major chemical plant.
Over the years heat distortion and abrasion had caused the extruder barrels to become damaged resulting in operating difficulties.
The extruder is used to homogenize polymer melt by feeding them down the 281.3 mm diameter x 9 meter long bores with two archimedian screws.
The aim was to regrind both bores of the double barrel extrusion machine to restore parallelism and roundness along 1.4 meters at the hot end of the extruder.
Metalock Engineering designed and built a special purpose grinding machine based on one of its 115mm portable boring machines.
What was special about the extrusion machine, was that the bores formed a figure 8 with a gap along their length at the interface.
Metalock took advantage of this gap and designed its grinding machine to set up the boring bar in bore 1 then fit the extension arm, carrying the grinding attachment, through the gap between the two bores and regrind bore 2 by traversing the grinding head along the boring bar using a leadscrew. A separate drive mechanism turned the grinding wheel at high speed at the hot end.
Once Metalock had ground the first bore, the machine was transferred to the second bore and the exercise repeated to leave the hot end of both bores in a round and parallel state and allow the refitting modified screws.
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