"A porous" is commonly known as "porous mold" in the industry. Extrusion of “one-mode porous†technology is an advanced production process that improves the yield, production efficiency and profile quality. It has significant effects in terms of energy saving, saving people, saving land and cost, and is in line with national energy conservation and consumption reduction policy guidance. Sustainable development plays a pivotal role.
1. Mold design and manufacturing "one-mode porous" mold design, in order to achieve the optimization effect, when placing the porous, it is necessary to consider the strength of the steel, to avoid the hole spacing is too large or too small, on the basis of adhering to the layout symmetry, it is recommended Holes are in the form of a horizontally placed one. If you really need a top and bottom layout, you need to have the holes staggered. In the process of processing molds, high-precision advanced mold processing instruments are the prerequisite for ensuring mold qualification. For example, the splitting hole and the welding chamber are preferably CNC machining centers to achieve the corresponding accuracy, while the cavity is cut by slow wire cutting to ensure the verticality, parallelism and smoothness of the working belt.
2. Extrusion production process control 2.1 Process parameters 2.1.1 The bar temperature control range of the bar temperature porous die is generally between 390 and 480 ° C. The specific bar temperature control adopts the step cooling method, and the general initial bar temperature adopts the control range. The upper limit of the bar temperature, after which the temperature of each bar is controlled to decrease by 10 ° C until the bar temperature is controlled to the lower limit of the range.
The rod temperature control range of the porous split mode is generally between 430-500 ° C, and the specific rod temperature control is the same as the above flat mold.
2.1.2 Mold temperature Normally the mold temperature should be controlled between 430-480 °C.
2.1.3 Ingot cylinder temperature (material bile temperature) Under normal circumstances, the cylinder temperature is controlled between 410-440 °C, and the cylinder temperature can be controlled at the upper limit according to actual production conditions.
2.1.4 Outlet port temperature Under normal circumstances, the outlet temperature is controlled between 520-580 °C. The temperature of the discharge port is too low and too high, which will affect the hardness and quality of the material and profile.
2.2 Process operation requirements 2.2.1 Aluminum rod heating aluminum rod heating through the rod furnace, according to the current bar furnace heating method is basically partition control heating, from high to low or low to high.
In order to ensure that the aluminum rod is heated and transparent, the heating mode of the porous mold is generally controlled from high to low, that is, the temperature of the aluminum rod from the furnace zone to the tapping zone is controlled from high to low. Generally, the temperature setting is decremented according to the number of furnace zones.
2.2.2 mold heating mold heating time is generally controlled within 6 hours, to ensure the heart, the mold should be heated together with the mold pad, mold sleeve, but can not overtime, otherwise the surface quality and material production of the profile influences.
When the mold is placed in the mold furnace for heating, the mold can not be placed close to the furnace wall and the fan tuyere position, as far as possible to the middle position, to ensure sufficient clearance between the molds, under normal circumstances not less than 5CM.
The mold furnace should be clean and free of dust, avoiding a large amount of dust falling on the mold working belt during the heating process, resulting in various surface quality problems in the profile when discharging.
2.3 Extrusion process control 2.3.1 The time from the removal of the mold to the extrusion of the mold shall not exceed 3 minutes, otherwise the output will be different.
2.3.2 The first rod produced on the machine is not exhausted, and it must be squeezed with a short rod. The length of the rod is controlled at 200-300mm.
2.3.3 The first rod should be pressed with the “0†section, and the extrusion speed should be slowly accelerated after the material is produced.
2.3.4 Use high-temperature pad to ensure the bottom surface is scratch-proof, wipe, etc., each material is separated by graphite plates to prevent the quality problems such as rubbing, bumping and concave of the profiles.
2.3.5 Intermittent adjustment of the pulling force of the tractor to ensure that the geometry of the profile meets the tolerance requirements. The first few sticks should increase the traction pull, and the pull force can be slowly adjusted after the normal output.
2.3.6 Under normal circumstances, the output speed can be controlled at 30-40m/min.
2.3.7 During the production process, quenching, air cooling or water cooling shall be carried out strictly according to the requirements of the alloy state.
2.3.8 During the normal production process, it is not allowed to stop at random. If there is a shutdown due to equipment failure, the machine will stop for more than 3 minutes. The mold must be unloaded and returned to the furnace for heating. The temperature of the upper mold must be guaranteed to reach 500 °C. However, in order to ensure the quality of the profile, it is recommended that the mold be unloaded and sent to the machine for production again. Because the porous mold has high requirements on the temperature, etc., the case where the mold is returned to the machine again causes the profile to be biased and the die is pressed.
2.4 Outlet Profile Temperature and Speed ​​Control 2.4.1 Adjust the heating temperature of the aluminum rod according to the temperature of the outlet profile.
2.4.2 The normal control range of the profile of the discharge port is between 520-580 °C, and the profile is lower than 520 °C. The profile is easy to cause insufficient hardness and can not reach the corresponding mechanical properties. Above 580 °C, rags and dies may occur at any time. phenomenon.
2.4.3 After the material is discharged, the surface of the profile is visually observed to become black. The temperature of the bar and the extrusion speed must be reduced immediately to prevent the temperature of the discharge profile from being too high.
2.4.4 During the production process of the porous mold, the operator must always observe the rod temperature, the profile temperature of the discharge port, the surface of the profile, and the operation of the equipment. Once an accident occurs, it must be stopped immediately, otherwise the mold damage rate is extremely high, and the service life of the mold is have a great impact.
3. "One-mode porous" extrusion equipment aluminum extrusion is a systematic project, to achieve the "one-mode porous" technology, to achieve the purpose of improving extrusion yield and production efficiency, and enhancing the stability of the output, in addition to paying attention to In addition to the stability of the extruder and the quality of the mold, it is also essential to equip advanced equipment such as twin-tractor machines with flying saws, molds, aluminum rod heating furnaces, and long-spindle hot-shear technology. .
4. Conclusion Squeeze the "one-mode porous" technology With the continuous improvement of the extrusion production process, its production efficiency and yield are continuously improved. Due to the differences in equipment, mold materials and extrusion processes used by enterprises, the development of “one-mode porous†technology is also different.
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Label: Squeeze "a porous" technology
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