The Tube Scarfing Experts · 2014. 9. 23. · 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

20112011

Experience since 1982 in Tube ID Scarfing Systems and Tools for Longitudinal Welded Tubes

The Tube Scarfing Experts

PREMIUM QUALITY

Made in Germany

Tube ID Scarfing

Hydraulic ToolsMechanical Tools

Cutting Rings

Tube Welding

Integral ImpedersCluster Impeders

Disposable ImpedersFerrite Cores

Impeder Casings

Chip Handling

OD Bead Chopper

ID Notching Tools

Strip EdgeConditioning

Strip Shaving Unit

Tube OD Scarfing

Insert HoldersOD Scarfing Inserts

Rotoscarf

Tube Cutoff

Clamp Jaw SetsCutoff Blades

Alpha Metall GmbH & Co. KG • Matthias-Erzberger-Str. 13 • 66806 Ensdorf • GermanyPhone: +49 6831 506956 • Fax: +49 6831 506958 • [email protected]

www.alpha-metall.de

Alpha Metall GmbH & Co. KG • Matthias-Erzberger-Str. 13 • 66806 Ensdorf • GermanyPhone: +49 6831 506956 • Fax: +49 6831 506958 • [email protected]

www.alpha-metall.de

NEW

PRODUCTSPRODUCTS

20112011

Page Content:

Table of contentHydraulic ID Scarfing ToolsID Scarfing SystemsID Scarfing SystemsMechanical ID Scarfing ToolsCutting ringsImpeders (Standard, Cluster Impeder, Monoferrite-Impeder)Ferrite cores (Standard & Special)Impeder casing & Disposable Impeders, Ceramic ImpedersOD Tube Scarfing: SNMG cutting inserts & accessory/spare partsOD Tube Scarfing: SNMX cutting inserts & accessory/spare partsOD Tube Scarfing: Rotoscarf (Oscillating/Revolving)Strip Edge Shaving Unit for Aluminized/Galvanized Strip MaterialChip Treatment (Chip Shredder)Cutoff Blades & Clamp Jaws

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Table of contentTable of content

Alpha Metall GmbH & Co. KG • Matthias-Erzberger-Str. 13 • 66806 Ensdorf • Germany • [email protected] • www.alpha-metall.de2

Hydraulic ID Scarfing ToolsSingle and double lower leg type

IS-HN8Tube ID Scarfing Tool180-280mm tube I.D.

new IMproved Design Extended Range

IS-HB 7IS-DB-HB 7

6-CRH 56-CRH 66-CRH 7

135-220mm

IS-HB 6IS-DB-HB 6


95-167mm

IS-HB 5IS-DB-HB 5


70-100mm

IS-HN 86-CRH 66-CRH 76-CRH 8

180-240mm200-280mm

IS-HN 9IS-DB-HN 9


230-400mm

IS-HN 10IS-DB-HN 10


400-600mm

Standard toolTube I.D.

range

Cutting ringholder

HydraulicTube ID

Scarfing Tool

IS-HN 4/5IS-DB-HN 4/5


57-82mm

IS-HB 4IS-DB-HB 4


48-72mm

IST-HB 3/4IST-DB-HB 3/4

3-CRHT 13-CRHT 23-CRHT 3

40-60mm

IST-HB 3IST-DB-HB 3


32-50mm

IST-HB 2IST-DB-HB 2

26-34mm2-CRHT 12-CRHT 2

IST-HB 1IST-DB-HB 1

21-26mm1-CRHT 6,51-CRHT 1


range

Cutting ringholder

Hydraulicalinside tube weld

seam removal tool

tilt

ed

cu

ttin

g r

ing

ho

lde

r p

rofi

le

IST-HB 1inside tube deburring tool21-26mm tube I.D.

Hydraulic Double Lower LegID Scarfing Tool (IS-DB-Types)

with integrated NOTCHING FUNCTION

Alpha Metall GmbH & Co. KG • Matthias-Erzberger-Str. 13 • 66806 Ensdorf • Germany • [email protected] • www.alpha-metall.de 3

The NOTCHING FUNCTION weakens the weld bead bynotches in order to break after scarfing

Customized Tube ID Scarfing SystemsHydraulic and Mechanic

Alpha Metall GmbH & Co. KG • Matthias-Erzberger-Str. 13 • 66806 Ensdorf • Germany • [email protected] • www.alpha-metall.de

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

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

4

Turn key projectslong & short version available


Sample picture shows long hydraulic systemwith 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 Terminalthe Position upstream allows:• large rotating capability• high cross sectional area of coolant tubes• easy access and retrofit

Quick coupling system

Tow bar with integrated coolant supply tubes

5



range

Cutting ringholder

MechanicalTube ID

Scarfing Tool


range

Cutting ringholder

Mechanicalinside tube

deburring tool

IS-ME 6IS-DB-ME 6


98-135mm(up to 175mm with modified lower leg)

IS-ME 5IS-DB-ME 5


70-100mm

IST-ME 3IST-DB-ME 3


32-50mm

IS-ME 4IS-DB-ME 4

4-CRH 14-CRH 24-CRH 34-CRH 4

48-72mmIST-ME 014

IST-DB-ME 014014-CRHT 4,514-17mm

IST-ME 017IST-DB-ME 017

017-CRHT 4,5017-CRHT 6,5

17-21mm

IST-ME 1IST-DB-ME 1

1-CRHT 6,51-CRHT 1

21-26mm

IST-ME 2IST-DB-ME 2

2-CRHT 12-CRHT 2

26-34mm

! 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

All our mechanical tools are delivered:

IST-ME 010 ---9,5-12mm

IST-ME 012IST-DB-ME 012

12-14mm ---

new IMproved Design Extended Range

Mechanical ID Scarfing ToolsSingle and double lower leg type

6

PREMIUM QUALITY Carbide Cutting Rings

• TiAlN• CvD-TiC/TiN

Different Coating Systems Available

• TiN (PVD)

Supercoatings for Special Applications

• Hyperlox® • Exxtral®

H

• Premium carbide quality for long service life.

• other cutting geometries available upon requesti.e. former „ALU“ type rings.

• special cutting geometry for high strengthmaterials available upon request.


and Cutting Ring Holders for mechanical and hydraulic inside tube scarfing systemsand Cutting Ring Holders for mechanical and hydraulic inside tube scarfing systems

7

Cutting Ring Cutting Ring Holder Cutting Ring Holderd1 [mm]D [mm]

The above "CRHT"cutting ring holders fit only in our IST

type Scarfing Tools.

H [mm]

6-AL 34 (SR6/AR34) 6-CRH 6 (SH6/SR6)30,045,0 15

7-AL 39 (SR7/AR39) 6-CRH 7 (SH6/SR7)35,050,0 15

8-AL 46 (SR7/AR39) 6-CRH 8 (SH6/SR8)40,055,0 18

014-CRH 4,5 (SH0/SR4,5) 014-CRHT 4,50-AL-4,5 0-AL 5,5 (SR0/AR5,5)

(SR0/AR4,5) 4,05,08,0

44

1-AL 7 (SR1/AR7)1-AL 8 (SR1/AR8)1-AL 9 (SR1/AR9)

1-AL 10 (S1R/AR10)

6,07,08,09,0

13,01-CRH 1 (SH1/SR1)2-CRH 1 (SH2/SR1)3-CRH 1 (SH3/SR1)


5555

2-AL 10 (SR2/AR10)2-AL 11 (SR2/AR11)2-AL 12 (SR2/AR12)

9,010,011,0

19,02-CRH 2 (SH2/SR2)3-CRH 2 (SH3/SR2)

2-CRHT 23-CRHT 2

888

3-AL 14 (SR3/AR14)3-AL 17 (SR3/AR17)

12,015,0

22,03-CRH 3 (SH3/SR3)4-CRH 3 (SH4/SR3)

3-CRHT 31010

4-AL 23 (SR4/AR23)4-CRH 4 (SH4/SR4)5-CRH 4 (SH5/SR4)

20,030,0 12

5-AL 25 (SR5/AR25)5-AL 28 (SR5/AR28)

5-CRH 5 (SH5/SR5)6-CRH 5 (SH6/SR5)

22,025,0

35,01212

017-CRH 6,5 (SH0/SR6,5)1-CRH 6,5 (SH1/SR6,5)

017-CRHT 6,51-CRHT 6,5

0-AL-6 0-AL 6,5 (SR0/AR6,5)

0-AL 7 (SR0/AR7)0-AL 8 (SR0/AR8)

(SR0/AR6) 5,56

6,57,5

10,0

4,54,54,54,5

Integral Impeders // Throughflow & Returnflowfor tube ID range: 8-600mm


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 reduceweld spatter adhesion.

! Maximum ferrite content for increasedwelding speed.

! Rigidity of the Impeder assemblyaccording to perfect fit between the Impeder Body and the epoxy tube.

Available diameters:8mm up to 90mm

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

Easy and fastchangeable ferrite cores.

Cluster Impeders (Saddle design)Available starting at 85mm up to 460mm Impeder diameterfor Tube ID 98-600mm

85mm105mm125mm140mm160mm180mm200mm220mm240mm260mm360mm460mm

Standard Impeder Diameters:

8

PREMIUM QUALITY Impeder Ferrite Coresfor HF welding applications


Pre

miu

m F

err

ite

Co

res

Pre

miu

m F

err

ite

Co

res

Pre

miu

m F

err

ite

Co

res

3x2004x2005x2006x2007x2008x2009x20010x20011x20012x20013x20014x20015x20016x20018x20019x20020x20022x20023x20024x20025x20030x200

AMVS

10x3x20010x5x20011x3x20011x5x20012x3x20012x4x20013x5x20014x4x20014x5x20014x7x20015x4x20015x5x20015x6x20015x7x20016x5x20016x6x20016x7x20016x8x20017x5x20017x6x20017x7x20018x5x20018x6x20018x9x20019x6x20020x6x20020x10x20021x6x20021x10x20022x6x20022x10x20023x6x20023x11x20024x6x20025x10x20026x10x20028x13x20029x10x20032x13x20033x10x20040x20x20050x20x20060x27x20080x35x200

AMHS

3x2004x2005x2006x2007x2008x2009x20010x20011x20012x20013x20014x20015x20016x20018x20019x20020x20022x200

AMV

6x3x2007x3x2008x3x2008x4x2009x4x20010x4x20010x5x20011x5x20012x5x20012x6x20012x7x20013x6x20013x7x20013x8x20014x5x20014x7x20015x6x20015x7x20016x8x20017x8x20018x9x20019x9x20020x8x20020x10x20021x10x20022x11x20025x12x20026x13x20028x14x20030x15x200

AMH

AMHU AMHSU

7x3x2009x4x20011x5x20013x6x20015x6x20016x6x20018x9x200

9x4x20011x5x20013x6x20015x6x20016x6x20018x9x200

Standard Ferrite CoresStandard Ferrite Cores

Alpha Metall Ferrite Cores

For dimensions and lengths not listed belowplease feel free to send us your inquiry

IMPORTANT NOTE:

ALL FERRITE DIAMETERS AREEXTRUDED IN ONE PIECE

(no glued rings for best performance)

(Type ZRS) (Type ZRSH)(Type ZR) (Type ZRH)

(Type ZRHU) (Type ZRSHU)

9

Impeder Jackets & Disposable Impeders


DimensionO.D. / I.D

[mm]

DisposableImpeders

Throughflow & Returnflow

10 / 811 / 912 / 1014 / 1216 / 1316 / 1418 / 1518 / 1620 / 1620 / 1722 / 1923 / 2024 / 2225 / 2225 / 2328 / 2534 / 3034 / 3139 / 3545 / 4150 / 4655 / 5160 / 5665 / 5970 / 6475 / 6980 / 7485 / 7990 / 84100 / 94110 /104

1050mm

All Impeder Casings can be delivered ready cut to customer's length.Other diameters on request.

Coatings available on request.

new

Available from 8 - 90mm Diameter with different typesof connectors.

Quick coupling Compression Fitting(Metric)

SAE45° Flared FittingJIC37° Flared Fitting

CERAMICIMPEDER

Standardlength

new

Ceramic Impeder Jackets available on request

10


R7R9R10R13R15R18R20R22R25R27R30R35R40R45R50R55R60

R10R12R15R20R25R35R45R55R60R80R90

R50R80R90R100R120R200R250R00

15,90

d

19(3/4")

25,4(1")

R7R9R10R13R15R18R20R22R25R27R30R35R40R45R50R55R60

R

R10R12R15R20R25R35R45R55R60R80R90

R50R80R90R100R120R200R250R0

10,00

l

12,70(1/2")

14,3(9/16")

9,15

s

8,0(5/16")

12,7(1/2")

Option - RIGHTOption [L] - LEFTOption [N] - STRAIGHT

Spare parts:Carbide support plateLeverClamp screwRound ClipAssembly Pin

[R]

Option - RIGHT Option[L] - LEFTOption[N] - STRAIGHT


[R]

Option - RIGHTOption[L] - LEFTOption[N] - STRAIGHT


[R]

SN

MG

15

SN

MG

19

SN

MG

25

HPH

2020-1

5 [

R/L

/N]

HPH

2525-1

9 [

R/L

/N]

HPH

3232-2

5 [

R/L

/N]

Holder Insert

Dimensions [mm]

SNMG

OD Tube Scarfing Holders and InsertsIndexable Inserts, 8 Cutting Edges, CVD-TiN-Coated (Standard)Indexable Inserts, 8 Cutting Edges, CVD-TiN-Coated (Standard)

11


R7R9R11R13R15R18R20R22R25R27R30R35R40R42R45R50R60R70R75R90

Option - RIGHTOption [L] - LEFTOption [N] - STRAIGHT

Spare parts:Carbide support plate (a)Lever (b)Clamp screw ( c)

[R]

SN

MX 1

5

HPS 2

0 x

150 [

R/L

/N]

R30R35R40R50R60R70R80R90

Option - RIGHT Option[L] - LEFTOption[N] - STRAIGHT

Spare parts:Carbide support plateLeverClamp screw

[R]

SN

MX 1

9

HPS 2

5/1

9x1

50 [

R/L

/N]

Holder Insert

(a)

(b)

(c)

SNMX

OD Tube Scarfing Holders and InsertsIndexable Inserts, 8 Cutting Edges,

TIN-Coated (Standard)

12


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.

An outside tube scarfing system withregrindable 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

Performance and Advantages:

à Average blade lifetime: 3hours @ 120m/min weld speed.

à Non Stop O.D. deburring for one shift.

à Tool change between the 3 inserts only by pressing a push button; a tool change is done in 2

seconds.

à The carbide cutting blades can be reground up to 30 times

à Easy regrinding: Only the front surface needs to be reground.

à The average costs to regrind a blade are between 2 and 3 euros.

à 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.

à Perfect surface finish of the deburred area.

à Easy and fast tool cassette change.

à Cassettes with different relief angles are available (for aluminized or galvanized strips).

à Connection to the tube mill for automatic tool lifting or starting in automatic mode.

à 3 O.D. range tool heads: 12,7-40mm; 25-72mm and 65-101,6mm (other sizes on request).

à Cutting heads also availabe for indexable inserts of the SNMX/G-type (see page 11+12)

Outside Tube Scarfing SystemRotoscarf

13


à Lead in and exit rollers.

à Side guide rollers adjustable through an excentric bolt.

à Top and bottom guide rails.

à One horizontal main adjustment to set the 6 tool stations to the strip width (95-300mm, other sizes on request).

à Horizontal adjustment for the strip centerline (+/- 12,5mm)

à First station shaves the upper part of the strip.

à Second station shaves the edges of the strip.

à Third station shaves the lower part of the strip.

à Micrometer adjustment of the cutters.

à 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.

The Strip Edge Shaving Unit is supplied with 3 stations featuring:

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 Unitare equipped with standard TiN-coated TCMT carbide cutting inserts.

Perfect strip edge preparationincreases welding quality

and prevents rejects.

Strip width55-300(standard)

Tube Mill Entry EquipmentStrip Shaving Unit

14


Chip TreatmentBead 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.

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.

view on the cutting blades

15


Cutoff Knives and Clamp Jawsi.e. for Thermatool Alpha flying cutoffs and similar

Customized High Precision Jaws and Bladesfor excellent service llife

Please send us your Inquiry

16

Documents

The Tube Scarfing Experts · 2014. 9. 23. · 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