How to reduce the aluminum factory product cost

[China Aluminum Network] core tips: aluminum defects is a factor that causes waste, a small defect in the aluminum will eliminate the entire length cut sawing aluminum. Due to the high added value of aluminum profiles, extrusion manufacturers should do their utmost to reduce defects in aluminum profiles.

1. Non-squeeze cycle time - Assuming that aluminum extrusion presses produce 30 aluminum rods per hour and each non-squeeze cycle saves 10 seconds, then you can increase the extrusion time by 2 hours per day for 2 hours. This means more than 8% of production, which is equivalent to a 8% reduction in conversion costs per kilogram of profile.

2. Downtime (Operational Interruption) - Losses due to downtime are significant (in our example, the downtime loss is 48.00 yuan per minute), not to mention the lost production capacity during the downtime due to no output.

3. Extrusion speed - The production efficiency of the purchased high-tech aluminum profile molds should be carefully considered. If the aluminum dies that you purchase and the extruding dies themselves can produce faster squeezing speeds, then a moderate amount of orders can make up for the additional costs of buying dies. For example, assume that the normal cost is 2,860.00 yuan/hour, because the additional cost incurred for purchasing high-tech molds is 10,000.00 yuan. As long as the extrusion speed increases by 50% and the basic production efficiency reaches 800 kg/hour, then an order of less than 10 tons is obtained. It can make up for the extra costs of using expensive molds.

4. Using porous molds, the extrusion speed can be increased by 200% (2-hole mold) or even 300% (3-hole mold), resulting in higher economic benefits.

One of the great benefits of using a modern aluminium profile hauler is that the haul-off machine has the function of controlling the extrusion of the extruder when the aluminum profile reaches the correct extrusion length. This is similar to the non-extrusion cycle, but since the extruded aluminum profile is exactly the required length, no wastage of the extrusion time is caused. As a result, more costs can be saved, as the waste reduction process also saves the transportation and recycling of the already-exposed waste.

After extruding aluminum extrusions from the extruder, the more important goal is to increase production and shipment rates by reducing scrap, and send more products to customers. Any waste that is generated after extrusion will be very costly, so waste should be minimized in subsequent processes. To reduce the waste to a small extent, sawing must be done at the stop mark (stop marks are marks left on the profile during the non-extrusion cycle).

There are only two technologies that can achieve sawing at the parking mark - ie, flying saw cutting and dual length systems. Flying saw cutting technology refers to sawing in the extrusion process. Using flying saw cutting technology, it is possible to cut the profile at the stop mark after the stop mark emerges from the extruder. The double-length system means that after the second profile has been extruded, it is cut between the front and the second profile in the non-extrusion cycle.

Both technologies have their own advantages. The two-length system can provide air cooling for two squeeze cycles, which is very beneficial for building alloys. However, the flying saw cutting system has lower costs (equipment costs and plant space costs) and allows one-shot multi-cut mode operation without stopping the extruder.

Both technologies can increase the yield by 1% to 2% (the original 1%-2% of waste, now converted to qualified products can be issued to customers). The conversion of waste into deliverables is a direct conversion of high value-added profiles and the resulting economic benefits are enormous. If this increase is counted as 1%, using our previous example of the cost of 2,860.00 yuan per hour, we can save more than RMB 1,000,000.00 in a 5-year payback period compared with a tractor system that cannot be sawed at the track. the cost of.

Aluminum profiles move on the extruder's conveyor system - any movement on the extruder's conveyor system can damage the aluminum profiles. For example: the modern transmission system uses a tractor to place the aluminum profile directly in line with the head of the stretcher so that it is not necessary to push and pull the aluminum profile on the belt table so that the aluminum profile and the stretcher jaws Align. Therefore, the possibility of the profile being scratched can be reduced.

Adjust the aluminum gap - the profiles are squeezed together and easily scratch each other. Modern transmission systems maintain proper clearance between profiles and profiles. In the process of arranging or collecting materials, it is not necessary to use a baffle to snap profiles.

Industrial aluminum mold operators operate manually - any time the operator comes in contact with the profile increases the probability of damage to the profile. Profiles are prone to damage on the transport system, but are more susceptible to damage when profiles are loaded into the hourglass frame and are unloaded from the chronobox and packaged for shipment. In these links, it is necessary to strengthen the training of operators and raise employees' awareness of their prudent operation.

Maintenance of aluminum extrusion presses - The maintenance status of aluminum extrusion presses has a significant impact on whether aluminum extrusion defects will occur. The quality of the aluminum profile can be affected by the alignment of the aluminum extrusion press, the condition of the ingot and the extrusion pad.

Residual air during the squeezing - if there is air in the squeezing force brought into the susceptor and then pressed against the air, the air is compressed to a small volume and the temperature rises. The air heated by compression will melt the surrounding aluminum alloy and generate air bubbles in the aluminum profile, or the air bubbles will open after being out of the working belt of the mold, thereby forming pores on the surface of the aluminum profile. The occurrence of either of the two conditions will cause defects in the aluminum profile and lead to waste. There are three factors that can cause air to be carried in:

1. Gas residue caused by upsetting - The column bar can only be loaded into the ingot when the diameter of the ingot is greater than the diameter of the bar. After the column rods in the ingots are pressed and the rods are extended to the diameter of the ingots, the carried air must be discharged. This air is released through the "exhaust cycle". The normal operation of the squeeze pad is very important for successful exhaust.

2. Gas sticking caused by long rod hot shear - The shear plane produced by the hot shear of the rod is not perfect and vertical. A simple long rod hot shear can cause severe distortion of the rod, resulting in oval cross-sections and large rounded corners of the sheared end. Even if it is a more advanced long bar heat shear, the corners of the sheared bar will always appear rounded. This rounding can easily cause air to remain when the rod is upset in the ingot.

Long bar hot saws can replace long bar hot shears. The vertical bar surface can be sawed using a long hot saw. No deformation will not bring in air. However, some aluminum manufacturers do not want to use hot rod saws because sawing produces aluminum chips. From the perspective of the economics of aluminum extrusion, it is very important that the sawdust produces aluminum scraps that have not taken any squeezing time and can not reduce the production efficiency of aluminum and aluminum profiles. These aluminum scraps are low-value scraps and will not increase the cost of any value-added processes. What is needed to deal with these wastes is the cost of the remelting process.

If the long hot saw can increase the aluminum utilization by 0.5%, then the cost of sawdust will be lower than the value of aluminum scrap. In North American installed heating equipment, more than 90% of manufacturers have turned their sights from long rod hot shears to long rod hot saws. There are also many users who had previously used long bar hot shears to upgrade their equipment to hot rod saws precisely because they saw the fact that the use of long hot saws would greatly reduce the defects of aluminum profiles.

3. Gas residue due to two-segment splicing rods - Because the surface of two short rods is almost flat, there is little possibility of air entrainment. The quality of the sawing directly affects how much air is drawn between the two short rods. There is now a new technology to avoid the emergence of two splicing rods. This is a bar-spinning welding machine. Prior to cutting out the required length of the bar, the bar-spinning welder can weld the remaining less than the set length of the bar to the next entire long bar, eliminating the need to bring air through the two sections of the bar. The possibility.

Solid contaminants - As with air in extrusion, defects caused by contamination also destroy the entire length of the aluminum profile. There are two main sources of solid pollutants:

1. Warehousing - It is important to keep the factory clean. Long bar storage locations, long bar heating equipment, bar transfer equipment for aluminum bar extruders, aluminium profiler loaders, and aluminum extrusion presses must be kept clean to avoid contamination of aluminium profiles . Over-lubrication is an important cause of contamination. Excessive lubrication can easily contaminate aluminum profiles. It is necessary to train operators on how to perform reasonable but not excessive lubrication. Excessive lubrication is harmful and unhelpful to the process.

2. Long bar hot-shear contamination - Many contaminants (such as oxides or dirt) on the surface of the long bar will enter the short bar when the long bar is cut. One of the characteristics of the hot shear is that it does not remove any material. But hot bar sawing can eliminate this source of pollution.

Holland Mesh Fence

Holland Mesh Fence