Improving the yield of aluminum extrusion can ensure the production efficiency. In the aluminum production process must pay attention to detail. This extrusion USES an aluminum extruder. What does an aluminum extruder look like? Today we will talk about the aluminum profile production yield improvement of the process and the modification of the aluminum extruder.
Aluminum extrusion process
1. Appropriately increase the extrusion coefficient to improve the extrusion yield
Each aluminum factory has a series of extrusion models, each manufacturer according to the extrusion ratio of the product, the length of the cold bed, the diameter of the circumference of the product, the length and diameter of the extrusion barrel, reasonable to determine the product will be produced on which extrusion press. It has been proved in practice that when the products of the same specification are produced on extruders of different tonnage, the different extrusion coefficients have great influence on the organization, performance and production efficiency of the products, and the yield of the products will also be different. According to the production statistics of a certain enterprise in 2009, the annual average yield range of three different tonnage extruders is shown in Table 1.
2. Improving ingot quality is the premise to ensure extrusion yield
Ingots are raw materials for extrusion production. When the ingot has uniform structure, fine grain and no defects such as slag inclusion, porosity, segregation and crack, it can not only reduce the extrusion pressure, increase the extrusion speed and improve the internal quality of the product, but also reduce the surface defects such as bubbles, pores, scratches, cracking and pitting on the extruded products. For example, the smaller slag can be discharged through the narrow slot of the mold working belt, but it will cause the plough mark on the profile surface and produce a certain length of geometric waste. The larger slag will be stuck in the slot of the working belt and cannot be discharged, causing the plug die or extrusion products cracking and forced to replace the mold, which will seriously affect the yield.
3. Strengthen production management and accurately calculate ingot length
The application of aluminum profiles in construction, transportation, electronics, tourism, machinery is more and more, so the product variety of aluminum plant is also increasing, bringing the increase of molds, to the production plan arrangement increased the difficulty. The production plan of aluminum profile shall calculate the quantity and length of the ingot used according to the specification, single weight, length, quantity and length of the cold bed required by the customer, using the principle of equal volume or equal mass. The calculation of ingot length is more by using equal mass method. This is because with the use and repair of the mold, the wall thickness of each part of the change is not synchronous, it is difficult to accurately calculate the sectional area of the product, and its theoretical line density and the actual line density obtained by machine test mold is not small difference.
4. Use clamping pad to reduce the length of cutting head and tail
After extrusion cooling, the defects such as bending and twisting should be eliminated by tension straightening. Most companies are still using tension straightening straightening machine, but the key question is due to the material variety and straightening work too trouble operation, many companies don't use the clamping pad, with jaw clip flat profile at both ends, directly cause tensile deformation of the two ends of the profile after often in 0.4 m to 1.2 m in length, cross section of large section deformation length is longer, the deformation part must be cut off, otherwise unable to remove the profile cross section deformation due to straighten, thus increases the geometric waste and compressive yield decline.
5. Use non-pressure residual extrusion to reduce geometric waste
Non-excess extrusion of fixed pad means that the extrusion pad is fixed on the extrusion rod and some modifications are made to both of them. At the end of extrusion, the extrusion cylinder can easily detangle the aluminum ingot without backing up, and then the second ingot is directly pushed into the extrusion cylinder and pressed together with the remaining ingot last time to complete the extrusion. This method avoids the single shear surplus of each ingot extruded, and the number of extruded ingot can be determined according to the quality requirements and the quantity of orders. In general, the number of civil profiles can be 40-50.
6. Use hot shear bar furnace to control ingot length
In recent years, more and more enterprises replace the chain type short ingot heating furnace with hot shear long ingot heating furnace (short for hot shear casting bar furnace). Hot cut casting rod furnace can avoid the ingot sawing, reduce the loss caused by aluminium crumbs, extrusion of host hand according to the dynamic single weight of mould with hot cut casting rod furnace on shear device adjust shearing length, for any length of aluminum billet, thus make long extruded profiles of the cutting head cutting tail to achieve the shortest, further improve the yield.
Some enterprises ignore the accurate calculation of ingot length and the management of this work after using the hot shear bar casting furnace, and leave it to the operators to handle by themselves. Operators tend to die extrusion, first by the standard of mould trial extrusion wall thickness shear a ingot casting, and observe whether the total length of extrusion profile in meeting the requirements of The Times the feet and cutting head cutting tail length, is improper to cut roughly test ingot casting, the second try, again and again 2 ~ 3 times to find the suitable length of the ingot, but produced in the process of trying to squeeze is not short of the waste, this a try to squeeze process not only reduce the production efficiency, but also reduce the rate of finished product.
7. Strengthen mold management to accurately record the dynamic weight of single profile
The importance of original production records in management is self-evident, in the aluminum extrusion production, accurate records each die extrusion profiles of linear density (weight) or a single profile is ready to yield, cost accounting and the mould management is an important work, it for the next this set of mold function provides the basis for accurate to find the right length of ingot casting. Therefore, an electronic scale with high accuracy should be provided for each extrusion production line, regular calibration, supervision and reinspection should be conducted, and operators or technicians should be urged to fill in the weight of single profile on the mold production card, so as to accurately record the weight of each profile in the extrusion process, so as to prepare for the next production.
Modification of aluminum extruder
The aluminum extruder can be transformed by servo system. The aluminum extruder is equipped with high pressure pump and medium pressure pump. Two kinds of functions need to be considered in the process of transformation, and two sets of servo systems should be supported. Transformation requires very professional technicians, otherwise the machine will run unstable, the probability of defective products greatly increased.
Through the production process control and the transformation of aluminum extruder introduced above, the probability of defective products can be greatly reduced, product quality can be improved, and higher economic benefits can be obtained.
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