Aluminium Extrusion
The aluminum extrusion process provides virtually unlimited opportunities to the product designer with the added benefit of low tooling costs and short lead times.
It is not just in new product design where aluminum extrusions are leading the way. In existing products, substitution of other materials and process by aluminum extrusions can result in major cost savings through fewer components, reduced finishing, simplified asmbly and improved supply chain logistics.
Clip-fits, screw-ports and circuit-board location grooves are just a few ways of reducing components and simplifying asmbly at no additional cost.
Aluminum’s excellent corrosion resistance means that often no finishing is required. However, if additional corrosion resistance or aesthetics are important, there is a whole range of suitable finishing process from polishing and brushing through to anodizing and painting.
The anodizing process offers unique benefits in terms of protection with almost no impact on the components eventual recyclability.
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It can be that the low cost tooling, quick turnaround and the ability to produce a range of different length components from stock lengths can transform the supply chain. A leading supplier of electric motors shifted his production from aluminum castings. This not only revolutionid the production process but also resulted in incread strength, improved thermal conductivity and reduced risk for corrosion for the housings.
Different length motor housings can be produced from stock lengths, new designs can now go from the drawing board to production in 4 to 6 weeks at only a fraction of the tooling costs.
Extrusion Process
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The whole manufacturing and production process starts with the design. It is here that the extrusion takes shape and features are built in to reduce weight, simplify asmbly, add functionality and minimi finishing costs. Here we take advantage of the unique benefits of aluminum, in combination with the extrusion process, to make a cost-effective product with optimal functionality and an attractive appearance.
Direct Extrusion
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The direct extrusion process can be clearly en in the schematic diagram below. Cylindrical aluminum alloy billets of cast or extruded manufacture are heated to between 450º and 500º before being loaded into a container and the billet squeezed through a die orifce using ram pressures of up to 680MPa. The die is supported by a ries of back dies and bolsters so that the main press load is transferred to a front platen.
On leaving the die the temperature of the ction is more than 500ºC and with heat treatable alloys the quenching, or solution heat treatment, takes place in the production line. This can be by water ba
th, water spray or forced-draught air, with the latter being particularly uful for thin ction. The approximate temperature drop during the transver of the quench box 250ºC. To avoid distortion care has to be exercid in handling ctions with extreme aspect ratios and large cariations in thickness.
After extrusion the ction is guided down the table by a puller on to a slatted moving belt. Modern Pullers are bad on linear motor systems and operate on tables up to 40 meters long. On completion of an extruded length, the ction is sheared at the press end and lifted from the slatted table by eccentric pivoted arms. It is then transferred by a walking beam or multi-belt transfer table to the stretcher bay where it is given a controlled stretch to straighten and remove minor miss-alignments. The ction is then taken and cut to ordered lengths on high speed tungsten carbide tipped saws.
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If the material is required in the solution heat treated condition (T4) it is relead at this stage. If the full strength aged material (T6) is required, it is given a precipitation treatment before relea. In the ca of the T5 temper, there is limited cooling at the press exit and the material goes directly to precipitation treatment.
Indirect Extrusion
In the traditional direct method of extrusion, as described above, the die is stationary and the press ram applies pressure on to the billet. In the indirect method, the ram carries the die and applies pressure on to the stationary billet, in the opposite direction of extrusion. There can be variation to this basic concept, but in every ca the billet remains stationary in relation to the container, there by keeping friction loss to a bare minimum.
There are basically two main types of extruded shapes or profiles;
Solid extrusions without cavities – e.g. round bar
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题龙阳县青草湖Hollow extrusions with cavities – e.g. round tube
Nearly, if not all, commercial extrusion plants u a cylindrical feedstock, (aluminum billet) that is pushed through the centre of a cylindrical
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container. This impos certain size restrictions and is often expresd in terms of the diameter of the circumscribing circle, (DCC). This is a measure of the extrusion’s overall size in cross-ction and has a bearing on the material thickness and tolerances.
Below are the measurement limits within which most extrusion plants can supply aluminium extrusions bad on the DCC.
胸罩英语The smallest aluminum profiles have a minimum circumscribed circle of 5 mm and a minimum weigh
t of 30 gr/m. Application fields of the tiny profiles : car luggage covers, sunroof and sunshade guides, automotive trims, shower cabins, interior furniture…
