Aluminum Profile Extrusion Process and Future Technological Trends
1 The definition of extrusion process Aluminum Extrusion (or aluminum extrusion forming) is the process of applying strong pressure to the aluminum billet placed in the mold cavity (or extrusion barrel), forcing the aluminum billet to undergo directional plastic deformation, and then extruding it out from the mold hole of the extrusion mold to obtain the required cross-sectional shape, size and certain mechanical properties of parts or semi-finished products through plastic processing. Its working principle is similar to "extruded toothpaste". This metal forming method has the following remarkable advantages.
1.1 One of the most remarkable advantages of durable aluminum is its resistance to corrosion, which is inherent and natural. Aluminum does not require any additional treatment to corrode naturally and resist corrosion. This is because there is a thin, naturally formed protective oxide aluminum film on its surface. Through anodized, its corrosion resistance becomes stronger. For instance, in outdoor environments, anodized of 25 microns can be carried out, which not only enhances corrosion resistance but also improves surface smoothness. Moreover, aluminum does not require maintenance and in most cases, there is no need to worry about corrosion.
1.2 The weight of the lightweight and sturdy aluminum is more than 33% lighter than that of steel while retaining most of its strength. The tensile strength of most Aluminum Alloys ranges from 70 to 700 megapascal, and its density is two-thirds less than that of steel. Product design engineers need not worry about the strength of aluminum extrusion parts. They can be used as structural components in both the construction and automotive industries, and are the best alternative to other metal materials. To achieve light weighting and reduce energy consumption, the automotive industry is making extensive use of aluminum alloy.
1.3 The thermal conductivity of aluminium is very similar to that of copper, but it is much lighter. Aluminium is an excellent thermal conductor. The extruded contour design of aluminium can maximize the thermal conductive surface area and form thermal channels. A typical example is the CPU cooler of a computer, where aluminium is used to remove heat from the CPU.
1.4 Aluminum extrusion parts that are convenient for secondary processing can be easily formed, cut, drilled, machined, stamped, bent and welded to meet specific purposes.
1.5 The processing cycle of the molds is short and the cost is low. The molds for aluminum extrusion are simple and the processing cycle is short with low cost. This is the comparison made by AEC between aluminum extrusion and other metal forming processes.
2 The structure of the extruder
2.1 The structure of the extruder mainly consists of three major parts: mechanical part, hydraulic part and electrical part. The mechanical part is composed of the base, prestressed frame-type tension column, front crossbeam, movable crossbeam, X-shaped guide for extrusion cylinder seat, extrusion shaft,supply mechanism, residual material separation shear, sliding mold seat, etc. The hydraulic system mainly consists of the main cylinder, side cylinder, locking cylinder, punching cylinder, large-capacity axial piston variable pump, electro-hydraulic proportional servo valve (or electro-hydraulic proportional regulating valve)， position sensor， oil pipe， oil tank and various hydraulic switches. The electrical part mainly consists of power cabinet， operation console， PLC programmable controller， upper-level industrial control computer and display screen， etc.
3 Future Technology Trends
Based on an in-depth analysis of the current development status of the world's mainstream manufacturers and my own years of accumulated practical experience, combined with the future market trends of the aluminum processing industry, it is expected that the mainstream new technologies in the field of extrusion equipment in the coming years will continue to be optimized around the latest "Eco-Plant" equipment concept. This concept has recently begun to gradually emerge in Europe. The core concept of this concept is to create an "environmentally friendly, efficient, and cost-effective production line" based on sustainable development. At the same time, this concept will be gradually integrated into the design and manufacturing of equipment. Therefore, in order to implement this concept, the future new trends in extrusion technology will focus on further optimizing equipment extrusion pressure and improving energy and operation efficiency in the following aspects for in-depth optimization.
3.1 Further Enhancement of Equipment's Extrusion Force When the equipment possesses greater extrusion force, it implies a further breakthrough of the current limitations of aluminum extrusion product processing technology, opening up a broader space for the birth of new aluminum products and even the manufacturing of new materials. Besides, greater extrusion force leads to an increase in the efficiency of the extrusion cycle and a further improvement of the existing production capacity, which also means an improvement in economic efficiency. To achieve this goal, it is necessary to continuously enhance the rigidity of the extrusion machine frame and the structural design to withstand stronger extrusion prestress.
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