Aluminum defects are a major cause of waste in the production process. Even a small flaw in an aluminum profile can lead to the entire length being discarded, especially during cutting. Given the high value of aluminum profiles, extrusion manufacturers must make every effort to minimize such defects and improve overall efficiency.
One key factor affecting production is the non-extrusion cycle time. If an extrusion press produces 30 rods per hour, and each non-extrusion cycle saves 10 seconds, this could add up to two extra hours of production daily. This increase can result in over an 8% rise in output, effectively reducing conversion costs by 8% per kilogram of profile produced.
Downtime is another costly issue. In our example, each minute of downtime results in a loss of 48 yuan. Beyond the direct financial impact, the lost production capacity during these periods further increases costs. Therefore, minimizing machine stoppages is crucial for maintaining profitability.
Extrusion speed also plays a significant role. High-tech molds can significantly boost productivity. For instance, if a mold allows for a 50% increase in extrusion speed, it can offset its higher initial cost within a relatively small order volume. Assuming an hourly cost of 2,860 yuan, even a 10-ton order can cover the added expense of advanced molds.
Using multi-hole dies, such as 2-hole or 3-hole molds, can increase extrusion speed by 200% or even 300%, leading to substantial economic benefits. Modern haul-off machines also contribute by ensuring that the extruded profile reaches the correct length without unnecessary waste, thus saving on both material and transportation costs.
After extrusion, reducing scrap becomes essential. Any waste generated after the process is expensive, so it's important to cut at the "stop marks" left during non-extrusion cycles. Two technologies—flying saw cutting and dual-length systems—allow precise cutting at these marks. The flying saw system enables faster, continuous operation, while the dual-length system offers better cooling for certain alloys.
Both methods can increase yield by 1–2%, converting previously wasted material into saleable products. For example, a 1% improvement in yield could save over 1 million yuan over five years, depending on production scale.
The conveyor system used in extrusion can also damage profiles. Modern systems use tractors to align profiles with stretchers, reducing the risk of scratches. Proper clearance between profiles during transport prevents damage, and operators should be trained to handle materials carefully, especially when loading and unloading.
Maintaining extrusion presses is critical. Poor alignment, faulty ingots, or worn-out pads can all introduce defects. Additionally, residual air during the extrusion process can create bubbles in the final product, leading to surface imperfections. Three main causes of air entrapment include improper upsetting, long rod hot shearing, and splicing of two segments.
Long rod hot saws are a more effective alternative to hot shears, as they don’t deform the rod and prevent air from entering. Although some manufacturers avoid them due to chip production, the resulting scraps are low-value and do not affect the extrusion process significantly. In fact, many North American manufacturers have switched to hot saws to reduce defects and improve material utilization.
Solid contaminants, such as oxides or dirt, can also harm the quality of the final product. Keeping storage areas, heating equipment, and conveyors clean is essential. Over-lubrication should be avoided, as it can lead to contamination. Similarly, using hot saws instead of shears helps eliminate surface contaminants during the cutting process.
By focusing on reducing defects, improving extrusion speed, and implementing efficient cutting and handling techniques, aluminum extrusion companies can significantly enhance their productivity and profitability.
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