Multi-axis shear-assisted extrusion machine

Abstract

A system for performing shear-assisted extrusion can include a front fixed endstock and a rear fixed endstock. The system can include a front movable headstock and a rear movable headstock. The system can include a die tool connected to the front fixed endstock. The die tool can include a face configured to engage and plasticize a face of feedstock material. The die tool can define an opening to receive plasticized feedstock material therethrough. The system can include a front spindle supported by the front movable headstock. The front spindle can be rotatable to rotate the feedstock material with respect to the front movable headstock. The system can include a rear spindle connected to the rear movable headstock, the rear spindle rotatable with respect to the rear movable headstock and the die tool.

1 . A system for performing shear-assisted extrusion, the system comprising:
 a front fixed endstock and a rear fixed endstock;   a front movable headstock located between the front fixed endstock and the rear fixed endstock and configured to translate therebetween in an axial direction;   a rear movable headstock located between the front movable headstock and the rear fixed endstock and configured to translate therebetween in the axial direction to generate an axial extrusion force;   a die tool connected to the front fixed endstock, the die tool comprising a face configured to engage and plasticize a face of feedstock material, the die tool defining an opening to receive plasticized feedstock material therethrough;   a front spindle supported by the front movable headstock, the front spindle defining a front spindle bore extending along a longitudinal axis and configured to receive the feedstock material at least partially therein, the front spindle rotatable to rotate the feedstock material with respect to the front movable headstock; and   a rear spindle connected to the rear movable headstock, the rear spindle rotatable with respect to the rear movable headstock and the die tool to generate, together with the front spindle and the feedstock material, a rotation-induced shear force between the feedstock material and the die tool to extrude the feedstock material through the opening of the die tool, and the rear spindle translatable with the rear movable headstock to generate the axial extrusion force.   
     
     
         2 . The system of  claim 1 , wherein the die tool is connectable to the front fixed endstock, the rear fixed endstock, the front movable headstock, or the rear movable headstock. 
     
     
         3 . The system of  claim 1 , comprising:
 a plurality of rails connected to the front fixed endstock, the rear fixed endstock, the front movable headstock, and the rear movable headstock, the front movable headstock and the rear movable headstock translatable along the plurality of rails with respect to the front fixed endstock and the rear fixed endstock.   
     
     
         4 . The system of  claim 3 , comprising:
 a plurality of shafts connected to the front fixed endstock, the rear fixed endstock, the front movable headstock, and the rear movable headstock; and   one or more actuators operable to move the front movable headstock or the rear movable headstock along the plurality of shafts, held in alignment by the plurality of rails.   
     
     
         5 . The system of  claim 1 , comprising:
 a container connected to the front spindle and configured to support the feedstock material at least partially therein, the container rotatable with the front spindle.   
     
     
         6 . The system of  claim 5 , comprising:
 a liner connected to a radially inner surface of the container, the liner configured directly engage and support the feedstock material at least partially therein.   
     
     
         7 . The system of  claim 1 , comprising:
 a front spindle motor connected to the front spindle and operable to drive the front spindle to rotate; and   a rear spindle motor connected to the rear spindle and operable to drive the rear spindle to rotate.   
     
     
         8 . The system of  claim 5 , comprising:
 a first tooling plate connected to a rear face of the front fixed endstock;   a second tooling plate connected to a front face of the front spindle; and   a third tooling plate connected to a front face of the rear spindle.   
     
     
         9 . The system of  claim 8 , wherein the die tool is secured to the first tooling plate and wherein the container is secured to the second tooling plate. 
     
     
         10 . The system of  claim 9 , comprising:
 a ram connected to the third tooling plate, the ram configured to engage the feedstock material to generate the axial extrusion force.   
     
     
         11 . The system of  claim 10 , wherein the ram is connectable to the first tooling plate, the second tooling plate, or the third tooling plate. 
     
     
         12 . The system of  claim 8 , wherein the die tool is securable to the first tooling plate, the second tooling plate, or the third tooling plate. 
     
     
         13 . The system of  claim 5 , wherein the container is configured to receive liquid from the front spindle to cool the container during extrusion. 
     
     
         14 . The system of  claim 13 , comprising:
 a rotary union connected to the container and connected to the front spindle, the rotary union configured to deliver fluid to the front spindle during extrusion.   
     
     
         15 . The system of  claim 1 , wherein the front movable headstock is translatable with respect to the front fixed endstock and the rear fixed endstock to translate the front spindle and the feedstock material. 
     
     
         16 . The system of  claim 1 , wherein the front spindle is rotatable to rotate the feedstock material with respect to the front fixed endstock and the rear fixed endstock. 
     
     
         17 . The system of  claim 16 , wherein the rear spindle is rotatable with respect to the front movable headstock, the front fixed endstock, and the rear fixed endstock to generate, together with the front spindle and the feedstock material, a rotation-induced shear force between the feedstock material and the die tool. 
     
     
         18 . The system of  claim 1 , comprising:
 a housing connected to the front fixed endstock and the rear fixed endstock; and   a pair of movable doors connected to the housing and configured to at least partially enclose extrudate produced by the system from the feedstock material.   
     
     
         19 . A system for shear-assisted extrusion, the system comprising:
 a front fixed endstock and;   a front movable headstock located between the front fixed endstock and configured to translate therebetween in an axial direction;   a rear movable headstock located between the front movable headstock and configured to translate therebetween in the axial direction to generate an axial extrusion force;   a die tool connected to the front fixed endstock, the die tool comprising a face configured to engage and plasticize a face of feedstock material, the die tool defining an opening to receive plasticized feedstock material therethrough;   a front spindle supported by the front movable headstock, the front spindle defining a front spindle bore extending along a longitudinal axis and configured to receive the feedstock material at least partially therein, the front spindle rotatable to rotate the feedstock material with respect to the front movable headstock; and   a rear spindle connected to the rear movable headstock, the rear spindle rotatable with respect to the rear movable headstock and the die tool to generate, together with the front spindle and the feedstock material, a rotation-induced shear force between the feedstock material and the die tool to extrude the feedstock material through the opening of the die tool, and the rear spindle translatable with the rear movable headstock to generate the axial extrusion force.   
     
     
         20 . The system of  claim 19 , comprising:
 a container connected to the front spindle and configured to support the feedstock material at least partially therein;   a liner connected to a radially inner surface of the container, the liner configured directly engage and support the feedstock material at least partially therein;   a spindle motor connected to the front spindle and operable to drive the front spindle to rotate;   a rear fixed endstock connected to the front fixed endstock; and   a plurality of rails connected to the front fixed endstock, the rear fixed endstock, the front movable headstock, and the rear movable headstock, the front movable headstock and the rear movable headstock translatable along the plurality of rails with respect to the front fixed endstock and the rear fixed endstock.