The key to improving the yield of industrial aluminum alloy profiles is to reduce and eliminate waste products. Geometry waste, while unavoidable, can be managed to be minimized. Technical waste is a human element that can be eliminated or minimized on a case-by-case basis. To this end, the following methods can be taken to effectively control and improve the yield of extruded products.
Measures to reduce geometric waste:
1. The correct selection of ingot length is the main measure to reduce process waste. The length of the ingot is not calculated after extrusion, but calculated first and then extruded. Calculate the reasonable ingot length according to the cut-to-length product to ensure the highest production efficiency and yield.
In addition to carefully calculating the length of the ingot, it is not necessary to know whether the mold used for the product is a new mold or an old mold. Because the wall thickness of the profile produced by the new mold generally starts with a negative tolerance, and the old mold is often a positive tolerance. Some molds are even close to out-of-tolerance. It is necessary to know the usage and detailed data of the mold from the computer mold file, and then correct the calculated ingot length.
If it is more necessary to produce short ingots, when using long ingots for heating, the extruded length of the first material can be used to confirm whether the length of the extruded product is appropriate, and then adjust the length of the ingot. If the ingot length is selected properly, the yield of aluminum alloy profiles can be increased by 1%-10%, which is a great potential for improving economic benefits.
In addition, when selecting the number of fixed lengths or the length of the product, on the premise that the extrusion machine can be extruded smoothly, and the length of the cooling bed is long enough, the aluminum alloy profile should increase the number of fixed lengths or the length of the product as much as possible, that is, choose the longest ingot as much as possible. This is an effective way to reduce the geometric waste ratio and increase the yield.
2. Long ingot heating, using hot shear technology is a good measure to reduce geometric waste. Not only can it not produce waste when cutting the cast rod into short rods, but also can cut a short rod that is only enough for the trial mold during the mold trial, thereby reducing the geometric waste of the mold trial. At the same time, the correct hot-shear short rod can also appropriately reduce the length of the extrusion residue. This geometric waste can be reduced by 1%-3%.
3. Improving the internal and external quality of the ingot can make most alloy casting rods do not need to be covered, even if the alloys such as duralumin and super duralumin must be peeled, the depth of the casing can be reduced. This reduces the geometric waste of the wagon. Due to the good internal and external quality of the ingot, the residual length can also be appropriately shortened.
Through the above measures, the geometric waste of aluminum alloy profiles can be reduced by a maximum of 18%, that is, the minimum geometric waste is about 9%, and the finished product rate can reach 91% (the technical waste is zero). It can be seen that reducing geometric waste is an important technical quality management measure for enterprises, and it has great significance for improving economic benefits.
4. One-die multi-hole extrusion can improve the yield. When some products are suitable for multi-hole extrusion, multi-hole extrusion can be used as much as possible, which can not only reduce the extrusion coefficient and extrusion force, but also increase the yield. In the case of zero technical waste, the yield of double-hole extrusion can be increased by 3%-4% compared with single-hole extrusion.
Most tissue waste products and waste products with unqualified mechanical properties are related to the process temperature.