The key to improving the yield of aluminum profiles is to reduce and eliminate waste products.Although geometric waste is inevitable, it can be managed to minimize it.To this end, the following methods can be used to effectively control and improve the yield of extruded products.

Measures to reduce food waste

The correct choice of ingot length is the main measure to reduce process waste.The length of the ingot is not calculated before extrusion, but before extrusion.

At present, most companies use long-rod hot-cutting aluminum rod heating furnaces, which reduce the loss of aluminum sheets compared with short-rod heating furnaces.Due to the changes in the wall thickness of the mold, the control of the length of the casting is more flexible and accurate, and the yield is greatly improved.However, after using long-rod hot air furnaces, many companies ignore the calculation of the length of castings and directly hand over the work to the operator for control.The operator often observes the length of the material based on the experience of the lower rod. If the difference is large, continue to adjust. It usually takes about 3 rods to get the exact length.In this process, a large amount of waste is generated, which not only reduces production efficiency, but also reduces yield.

The correct method is that in the initial production of the mold, the length of the steel ingot is calculated by the process control department. When the mold is produced multiple times, the length of the last production rod recorded on the card is slightly increased by about 5×10 mm, and the length of the material is observed when the material is produced.If there are different fine-tuning, making the second stick is very accurate.The data show that the use of long rod hot shear can increase the output by 4 percentage points, and it is completely feasible to increase the output by 2 to 3 percentage points in actual production.

Measures to increase production from the technical level

Improving the level of mold design and manufacturing and reducing the number of mold tests is an important technical measure to increase product production.Under normal circumstances, the cost of the test mold is 1×3 ingots, and the output is reduced by 0.5% Due to the low level of mold design and manufacturing, some products can only produce finished products more than 4 times, and the yield is reduced by 2≤5%, which not only causes economic losses, but also extends the production cycle due to repeated mold tests.

Modern molds put forward the concept of zero mold testing, that is, after the mold is manufactured, there is no need to test the mold, it can be directly applied to the machine to produce qualified products.Using simulation design software and finite element analysis, the design can be completed on a computer.Through computer simulation, the mold cavity processing is completed in an automatic machining center, and the entire mold processing is completed with high precision, so the mold quality is very high, and the machine tool pass rate is more than 90%, which can increase the yield by 2≤6%.

Appropriately increase the extrusion coefficient of aluminum profiles and increase aluminum production

Each aluminum plant has a series of machines. Each factory determines that the product is produced on the corresponding machine according to the extrusion ratio of the product, the length of the cold bed, the outer part of the product, and the length and diameter of the extrusion cylinder.Practice has proved that products of the same specification are produced on different tonnage extruder. Due to the different extrusion coefficients, it has a great impact on the microstructure, performance and production efficiency of the product, and the output of the product will be different.When the tonnage of the extruder is large, the extrusion coefficient is large, the output is high, and the extrusion cost is close.

Improving the quality of ingots is a prerequisite for improving the yield

Ingots are raw materials for extrusion production.The steel ingot has uniform organization, fine grains, no slag, pores, segregation, cracks and other defects, which not only reduces the extrusion pressure, improves the extrusion speed, and improves the inherent quality of the product.It can also reduce surface air bubbles, pores, scratches, cracks, pitting and other defects.The smaller slag can be discharged through the slits of the mold working belt, but it will cause pear marks on the surface of the profile, resulting in a certain length of waste.However, larger slag inclusions will not be excluded from the slits of the working belt, which will cause the plug mold or product to crack and the mold to be replaced, which will seriously affect the output of the product.

When the profile is straightened, many companies do not design corresponding gaskets, especially some large wall-mounted profiles and hollow profiles, which cause excessive deformation of the head and tail of the profile. When the product is sawed off, the deformed part must be cut off, thereby reducing the yield.

The gasket can be made of hardwood or aluminum blocks, and the design minimizes the specifications of the gasket and increases the universality of the gasket.For special-shaped profiles with long and closed cross-sections of the hanging wall, when the gasket is inserted into the sealing chamber after straightening, the support frame should be placed on the part of the hanging wall.To reduce the deformation in the length direction.The fixture must be designed by special personnel, managed by special personnel, and used by workers.

At the same time, in order to prevent workers from using mats because they are too troublesome, it is necessary to establish a reward and punishment mechanism linked to product and wage output.