Choosing the right extruder is the key to ensure the productivity and product quality of extruded aluminum profiles. This article will discuss how to choose the most suitable extruder according to the specific requirements of aluminum profiles.
The relationship between aluminum profile size and extruder selection
The size of the aluminum profile directly determines the specifica
tions and type of extruder required. When selecting an extruder, the cross-section size, wall thickness and other physical characteristics of the aluminum profile must be considered.
Extruder tonnage and aluminum profile cross-section diagonal
The tonnage of extruders is calculated according to the size of extrusion pressure, and the common ones are 500t, 630t, 800t, 1000t, 1200t, 1800t, 2500t and so on. The larger the extruder specification, the larger the diagonal of aluminum profiles that can be produced.
When selecting the tonnage of the extruder, the length of the diagonal of the aluminum profile section needs to be considered. For example, large extruders are usually used to produce aluminum profiles with larger diagonal dimensions. As shown in the figure: Large Extruder Outlet Size and Extruded Profile Diagonal Requirements.
Extruder Size and Aluminum Profiles
Extruder size and aluminum profile size must complement each other. The right extruder can only extrude the suitable range of aluminum profiles. Usually, the extrusion ratio is determined according to the cross-section drawing of the aluminum profile, and then the size of the extruder is decided.
The calculation of the extrusion ratio is also related to the specific requirements of the aluminum plant. For example, when the extrusion ratio of an aluminum profile is 5-15, the designer may suggest the aluminum plant to replace the press with a larger one for extrusion, but the aluminum plant may only ask the die plant to design without changing the press, in which case the die plant may continue to produce.
In practice, the extruder size must match the aluminum profile specification to ensure smooth production.
The relationship between the wall thickness of aluminum profiles and extrusion pressure
The wall thickness of an aluminum profile directly affects the pressure required during extrusion. Profiles with larger wall thicknesses require greater extrusion pressure to ensure that the profile is formed smoothly in the die. Selecting the appropriate extruder according to the different wall thickness of the profile can effectively improve production efficiency and ensure the quality of the finished product.
How to determine the aluminum profile with what tonnage of extruder production
When selecting the tonnage of the extruder, the extrusion ratio is usually calculated first. Extrusion ratio refers to the ratio of the cross-sectional area of the extrusion barrel to the total cross-sectional area of the aluminum profile, which is the main parameter to measure the deformation of aluminum alloy. The calculation formula is as follows:
λ = FtΣF1λ = \frac{Ft}{ΣF1}λ=ΣF1Ft
where Ft represents the cross-sectional area of the aluminum ingot after filling in the extrusion barrel, and ΣF1 represents the total cross-sectional area of the extruded profile. The size of the extrusion ratio determines the degree of deformation of the aluminum profile, i.e., the degree of deformation ε = λ – 1. Usually, the extrusion ratio needs to be greater than 8-12 in order to ensure the smooth progress of an extrusion.
When determining the tonnage of the extruder, it is also necessary to know the cross-section shape of the aluminum profile, so as to determine the size and structure of the die, and finally determine the required tonnage of the extruder. Different structures of profiles (such as hollow profiles and solid profiles) on the extruder tonnage requirements are different.
Relationship between extrusion ratio and deformation degree
The size of the extrusion ratio directly affects the ease of metal flow out of the die hole and the size of the extrusion pressure. When the extrusion ratio increases, the resistance of metal flow also increases, which leads to an increase in the difference between the internal and external metal flow rate, deformation is not uniform. How
ever, when the extrusion ratio increases to a certain degree, the shear deformation penetrates deep into the interior, and the deformation begins to transform to the uniform direction.
Studies have shown that when the degree of deformation ε reaches 85% to 90%, the extruded metal flows uniformly, and the mechanical properties of the inner and outer layers of the product tend to be consistent.
The selection of extrusion ratio needs to consider a variety of factors, including the type of alloy, extrusion method, product performance, extruder capacity, extrusion barrel inner diameter and ingot billet length. If the extrusion ratio is too large, may lead to extruder due to extrusion pressure is too large and “boring”, affecting the production efficiency; if the extrusion ratio is too small, can not make full use of the equipment capacity, it is difficult to obtain the organization and properties of uniform products.
The main types and functions of extruders
There are various types of extruders, each of which has its specific application scenarios and advantages and disadvantages.
Difference between single-action and double-action extruders
The main difference between single-acting and double-acting extruders lies in their operation modes and application areas. The single-action extruder is suitable for simple extrusion process, while the double-action extruder is more suitable for the production of complex cross-section aluminum profiles.
The single-action extruder operates with only one extrusion barrel, which is suitable for small batch production, while the double-action extruder has two extrusion barrels, which is able to produce more products in a shorter period of time.
Differences and application scenarios of hot extruder and cold extruder
There are significant differences between hot extruder and cold extruder in terms of temperature control and applicable materials. The hot extruder is suitable for extrusion of most aluminum alloys, especially when higher temperature is needed to maintain the plasticity of the metal during the production process; while the cold extruder is mainly used to produce high-precision thin-walled profiles, especially when the original mechanical properties of the material need to be maintained.
Analysis of the advantages and disadvantages of different extruders
Different types of extruders have their own advantages and disadvantages in terms of operation complexity, production efficiency, applicable materials and so on. Single-action extruder has a simple structure and is suitable for small-scale production; double-action extruder has a complex structure but high productivity and is suitable for mass production.
Hot extruder can handle a variety of aluminum alloys, applicable to a wide range, but high energy consumption; cold extruder although low energy consumption, but only for the production of some specific materials and products. Choosing the right type of extruder can effectively improve production efficiency and product quality.
Factors to be considered when selecting extruders
When choosing an extruder, you need to consider the aluminum specification, production capacity, energy consumption, cost, die and other factors.
Extruder selection cases in practical application
Different application scenarios of aluminum profile production have different requirements for extruder selection, the following are a few typical application case studies.
Extruder selection for construction aluminum profiles
Architectural aluminum profiles usually have large cross-section size and wall thickness, and the tonnage and pressure stability of the equipment need to be considered when selecting extruders. Large extruders are suitable for the production of architectural aluminum profiles, which can ensure the structural strength and quality of the products.
Selection of extruders for industrial aluminum profiles
Aluminum profiles for industrial use require high precision and strength, so it is necessary to choose extruders with high-pressure precision and stability. In addition, considering the high batch demand of industrial production, it is also necessary to select equipment with high efficiency to meet the production demand.
Selection of extruders for special-purpose aluminum profiles
Aluminum profiles for special applications, such as those in the aviation and military fields, usually have very high requirements for product precision and quality. For this reason, the selection of extruders needs to pay special attention to their high precision and stability to ensure that the aluminum profiles produced can meet the strict standards of special applications.
Conclusion
In summary, the selection of a suitable extruder requires comprehensive consideration of the size, wall thickness, production requirements and cost-effectiveness of the aluminum profile. Proper selection not only improves production efficiency, but also ensures the quality of the finished product, which in turn enhances the competitiveness of the enterprise in the market.
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