How To Improve The Productivity Of Aluminum Extrusion?

When the sales price of aluminum profile remains unchanged, the higher the production cost, the lower the profit. At present, under the harsh environment of rising raw material prices, rising workers' wages, RMB appreciation, rising energy prices and increasing tax burden, the competition in the same industry has entered a "white hot", and the era of refined cost control has come. How can we improve the yield of aluminum profile, reduce aluminum scrap and improve productivity?

The waste products of aluminum alloy extruded profiles are divided into two categories: Geometric waste products and technical waste products.

Geometric waste is the inevitable waste of aluminum alloy profile in the extrusion process. For example, the extruded residues, the collets at both ends of the product during stretching, the fixed length materials discarded due to insufficient fixed length, cut the necessary samples, the aluminum blocks left in the shunting cavity in the shunting combined die, the aluminum chips consumed by the saw mouth for cutting the fixed length broken materials of ingots and products, and the aluminum ingots consumed during die testing.

Technical waste is the artificial waste produced in the production process of aluminum fabrication profile due to unreasonable process, equipment problems and improper operation of workers. It is different from geometric waste. Through technical improvement and strengthening management, it can effectively overcome and eliminate the generation of technical waste.

1. Before opening the aluminum profile mold, confirm the optimal extruder table in strict accordance with the unit weight per meter, structure and product requirements of the product, and grasp the yield from the source on the mold.
2. The mold design must be reasonable, which is mainly reflected in the stable discharge of the mold, good surface finish, practical and durable, and the shortened tail of the extruded interlayer.
3. Aluminum profile extrusion production should strictly arrange the production process. The temperature of the die and the temperature of the aluminum rod should be moderate. At the same time, during extrusion, the die should be unloaded when producing a certain output, so as to prevent metal fatigue and improve the service life of the die.
4. High quality aluminum ingots should be selected. Aluminum ingots are the raw materials for the production of aluminum profiles. The selection of high-quality aluminum ingots with alloying, refinement and homogenization can reduce the cracks, pores and pits on the product surface and improve the yield of products.
5. Properly increase the extrusion coefficient and improve the extrusion yield. Each aluminum factory has a series of extrusion machines. Each manufacturer reasonably determines which extruder the products will be produced on according to the extrusion ratio, length of cooling bed, diameter of circumscribed circle of products, length and diameter of extrusion barrel, etc. Practice has proved that when products of the same specification are produced on extruders with different tonnage, due to different extrusion coefficients, they will have a great impact on the organization, performance and production efficiency of products, and their yield will also be different.

The key to improve the yield of aluminum alloy profiles is to reduce and eliminate waste products. Although geometric waste is inevitable, we can try to minimize it. Technical waste is a human factor, which can be eliminated item by item or reduced to the lowest level.

Improving the level of mold design and manufacturing and reducing the number of mold trials are important technical measures to improve the yield. Generally, 1 ~ 3 ingots are consumed for each mold test, reducing the yield by 0.5 ~ 1%. Due to the low level of mold design and manufacturing, some products need to repair and test the mold for 3 ~ 4 times or even more to produce the finished product, which virtually reduces the yield by 2 ~ 5%, which will not only cause economic losses, but also prolong the production cycle due to repeated mold test.

Strengthen the management of aluminum profile extrusion die and original production records. The mold card and the original production record are very important. The mold card must be able to truly show the mold nitriding, maintenance and material production. The original record must be able to truly show the weight, casting length and quantity, so as to provide a reliable basis for the next production.

The first mock exam can improve the yield. Extrusion speed is an important process parameter in extrusion process, which is related to the quality of products and production efficiency. Extrusion speed is not like mastering the process temperature. For an alloy and a heat treatment process, it can basically choose an easy temperature, and extrusion speed is a highly empirical process parameter. The extrusion speed is different for profiles with different alloy States and different sections. The extrusion speed of the same product is also different before and after the extrusion process due to the influence of temperature change.

Reduce the generation of waste products by strengthening the first inspection and process inspection. Surface waste products, such as scratch, orange peel, tissue articles, black spots, bubbles, etc., often do not appear in every product. It is necessary to inspect each other through the sawing process of main machine operator, quality inspector and tensile finished products, and jointly supervise the transfer out of the waste products on the surface. Quality management is the management of the whole staff and the whole process. Each process must control the quality and achieve the combination of self inspection, mutual inspection and special inspection, so as to effectively eliminate the technical waste in the bud. Artificially control and improve the yield.

It is very important to buy aluminum from a reliable aluminium extrusion supplier. FOSHAN MAX ALUMINIUM CO.LTD is an aluminium supplier, welcome to contact.