[China Aluminum Network] We all know that in the production of aluminum profiles, profits = sales minus production costs. The total cost of aluminum profiles is divided into fixed costs and variable costs. Fixed costs such as factory rent, machine depreciation, etc. It is fixed. The variable cost is a very flexible space.
In the case of unchanged sales prices of aluminum products, the higher the cost of aluminum products, the lower the profit. At present, raw material prices have risen, workers’ wages have risen steadily, and in the harsh environment such as the appreciation of the renminbi, rising energy prices, and increasing burden on taxes and fees, competition with the industry has entered a “white fever†today. The era of cost control refinement has come.
Cost control is the key and core of business management. Only by constantly discovering weak links, tapping internal potentials, using all means and ways to reduce costs, and engaging all employees, starting from the details, starting from reducing waste, and finely implementing aluminum profile cost control can effectively expand the space for business survival. , improve the state of business management, so that companies continue to develop and remain invincible.
Aluminium profile cost control is guided by the value chain and divides cost control into design cost, purchase cost, manufacturing cost, sales cost and service cost. Due to cost control involves a wide range of content. From the perspective of manufacturing, I talked about how to increase production yield and reduce production costs.
Through data analysis and practice, it is proved that improving the yield of aluminum alloy profiles is one of the more direct and effective methods for reducing the production cost. Taking the extrusion workshop as an example, the production rate per ton of aluminum material will be reduced by 25 percent for every one percent increase in the yield rate. 30 yuan, and this part of the reduction is the company's net profit. To increase the yield of extrusion, the task of production is to reduce extrusion waste.
How to increase the yield of aluminum profiles to reduce aluminum scrap, increase productivity, and reduce the production costs of aluminum profiles, we have summarized extrusion products:
The aluminum alloy extrusion waste is divided into two categories: geometric waste and technical waste. Geometric waste products are inevitable waste products in the extrusion process of aluminum alloy profiles. For example, the extruded residue, the chucks at both ends of the product at the time of stretching, and the material discarded when the length of the sizing material is not enough for the fixed length, the necessary sample is cut out, and the aluminum block remaining in the diverting chamber in the split mold is split. The product is used to cut out the aluminum chips consumed by the slicing cuts of the cut-off length, and the aluminum ingots consumed during the die test.
Technical waste products are considered waste products due to irrational processes and equipment problems in the production of aluminum alloy profiles. It is different from geometric waste products. Through technical improvement and strengthening of management, it can effectively overcome and eliminate the production of technical waste products. Technical waste can be divided into:
Organized waste products: over-burned, coarse-grained rings, coarse grains, shrinking tails, inclusions, etc.
Unqualified mechanical properties waste: strength, hardness is too low, does not meet national standards: or plasticity is too low, not fully softened does not meet technical requirements.
Surface waste products: layers, bubbles, extrusion cracks, orange peel, tissue text, dark spots, longitudinal weld lines, transverse weld lines, scratches, metal presses, etc.
Geometry scrap: waves, twists, bends, plane gaps, oversizes, etc.
The yield is divided into process yields and integrated yields.
The finished product aluminum ratio generally refers to the main process and is usually calculated on a shop floor basis. Casting process (casting plant), extrusion process (extrusion process), oxidation coloring process (oxidation plant), dusting process (spraying plant). It is defined as the ratio of the qualified output of the workshop to the input of the raw materials (or semi-finished products) in the workshop.
The rate of finished product is related to the quality of the equipment, the quality of the ingot, the product structure, the frequency of the variety specification, the advanced level of the process technology, the level of the enterprise management, and the quality of the operator.
The key to improving the yield of aluminum alloy profiles is to reduce and eliminate waste products. Although geometric waste is unavoidable, it can be managed to lower it. Technical waste is a human factor that can be eliminated on a case-by-case basis and can be reduced to a lower level. For this purpose, the following can be used to effectively control and increase the yield of extruded products.
6.1.3.1 Reducing geometric scraps is an important prerequisite for improving the yield. Reducing geometric scraps The correct choice of ingot length is the main measure to reduce scrap. The length of the ingot is not calculated after the first extrusion, but must be calculated before extrusion.
Most companies now use a long rod hot shear aluminum rod heating furnace, compared to a short rod heating furnace, reducing the loss of aluminum scrap, due to the use of mold thickness changes in the mold, casting length control more flexible and accurate, greatly improving the yield. However, many companies have neglected the calculation of the cast length after using the long hot bar shears, and directly hand over this work to the operator to control. Operators are often based on experience, the next bar, observe the length of the material, if the difference is large, continue to adjust, it usually takes about 3 bars to get the exact length. In this process, no short-term waste has been produced, which has reduced the production efficiency and reduced the yield.
The correct approach is that when the mold is initially produced, the length of the ingot is calculated by the process control department. When the mold is produced many times, the length of the last production rod recorded on the mold card is about 5 to 10 MM. Observe the length of the material when it is out. Fine-tune if there is a difference. This way the second stick is accurate. According to statistics, the use of long rod heat shear can increase the yield rate by 4 percentage points, and it is entirely feasible to increase 2-3 percentage points in actual production.
In addition, when selecting the number of lengths or the length of the product, under the premise of ensuring the smooth extrusion of the extruder. When the length of the cooling bed is long enough, the number of lengths or product lengths should be increased as much as possible. That is, longer ingots may be selected. This is also an effective way to reduce the percentage of process geometry waste and increase the yield.
The measures to increase the yield from the technical level to improve the mold design, manufacturing level, and reduce the number of trials are important technical measures to increase the yield. In general, this trial mode consumes 1-3 ingots, which reduces the yield by 0.5-1%. Due to the design of the mold, the manufacturing level is low, and some products need to be repaired, tried out three or four times or even more times. Only when finished products can be produced, the yield will be reduced by 2-5%, which will not only cause economic losses, but also prolong the production cycle due to repeated trials.
The modern mold proposes the concept of zero test mold, that is, after the mold is manufactured, there is no need to try the mold, and it can directly produce qualified products on the machine. Using analog design software, finite element analysis, the design can be completed in the computer. Can also be simulated by computer simulation. The cavity processing is completed in the automatic machining center, and the entire mold processing is performed with high precision, so the quality of the mold is very high. The machine qualification rate is above 90%. Can improve the yield 2-6%.
Appropriately increase the extrusion coefficient of aluminum materials to increase the yield. Each aluminum factory has a series of machines. Each factory determines the product according to the extrusion ratio of the product, the length of the cooling bed, the outer circle of the product, and the length and diameter of the extrusion cylinder. Placed on the corresponding machine production. Practice has proved that products of the same specifications are placed on extruders of different tonnages. Due to the different extrusion coefficients, they have a great influence on the organizational performance and production efficiency of the products, and their yields will also be different. When the tonnage of the extruder is large, the extrusion coefficient is large, the yield is high, and the extrusion cost is close.
Increasing the quality of ingots is the prerequisite for increasing the yield. Ingots are the raw material for extrusion production, uniform ingot structure, fine grain, no slag inclusion, porosity, segregation, cracks and other defects, not only can reduce the extrusion force, improve extrusion Pressing speed, improve product intrinsic quality. And can reduce the surface of products, air bubbles, scratches, cracks, pits 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 profile surface, resulting in a certain length of waste. Larger slags will be stuck in the slits of the working belt and cannot be excluded, causing cracks in the plugs or products, and the replacement of molds, which will seriously affect the yield. Use the corresponding bolster when straightening and straightening to reduce the cutting length of the head and tail material. When the profile is straightened during stretching, many companies do not design the corresponding bolsters, especially some large-walled profiles and hollow profiles. Lead to deformation of the head and tail of the profile is too large, and when the finished product is sawed, the deformed part must be cut off. This results in a decrease in the yield.
Hardwood or aluminum blocks can be used for the pad, and the pad size can be reduced as much as possible during design to increase the versatility of the pad. For profiles with long cantilevered walls and closed cross-sections, insert the pad in the closed cavity during straightening and place the support frame in the suspended wall section. This reduces the amount of deformation in the length direction. Fixtures must be specially designed, staffed, and instructed to use.
At the same time, in order to prevent workers from being unwilling to use quilts due to nuisance, it is necessary to establish reward and punishment mechanisms linked to the rate of production and wages.
It is very important to strengthen aluminum extrusion dies and production of original record management die cards and production of raw records. The die card must be able to truly show the nitridation of the dies, the maintenance situation, and the outsourced condition. The original records must be able to be truly displayed. The weight, cast length and quantity provide a reliable basis for the next production.
Many companies now implement computerized data management, but there is still a long way to go in practical use.
The use of non-compression excess extrusion to reduce the geometric waste fixed pad without pressure extrusion, is the extrusion pad fixed on the extrusion bar, and make a certain transformation between the two. When the extruding barrel is not returned, the pressure pad is also easily separated from the ingot. Then directly push the next ingot into the extrusion cylinder. Squeeze with the remainder of the last ingot, thus avoiding one shear per shear for the ingot. According to the quality requirements and the order quantity, it can be decided how many times the cast shear will be pressed once. Usually 40-50 cuts once.
Optimizing the extrusion process of aluminum extrusions, reducing the impact of technical waste on the extrusion process of technical waste There are many aspects that cover the entire extrusion process. Mainly include: ingot quality, process temperature, extrusion speed, extrusion tools, mold, transfer loading and unloading, aging heat treatment. In addition to formulating advanced and scientific production processes, we must also correctly and strictly enforce operating procedures and improve the proficiency and responsibility of workers.
Minimize the production of each class, it is better to arrange only 3-5 varieties of each class, increase the production of a single set of machine on the machine. The more die on the machine, the more mold aluminum that is carried away, and the lower the yield.
The impact of mold on the yield is mainly in two aspects: The more mold test molds and production molds are used, the more aluminum molds are removed and the lower the yield is. Therefore, we must improve the design and production level of the mold.
The production of molds must be carefully maintained, reasonably nitrided, and maintained in time. Ensure that each time the machine pass rate is high. Good molding, high durability. If each class is unqualified due to mold maintenance, 3-4 types of machine production failures will result in a decrease of at least one percentage point in the yield.
Aluminum extrusion tools include: squeeze tube, squeeze rod, extrusion pad, mold pad and so on. The main guarantee is that the extrusion tube, rod and mold are concentric at three points. Followed by a reasonable maintenance squeeze tube, the correct heating to ensure that the end of the tube flat. Eliminate the phenomenon of poor fit of various extrusion barrels and molds. Regularly clean the residual aluminum on the inner wall of the squeeze tube, check whether there is any damage on the inner hole wall, properly use the mold pad, and increase the mold support strength.
Extrusion temperature, extrusion speed, and cooling have a great influence on the product structure, mechanical properties, and surface quality, as well as the yield. In addition, the three will affect the length of the product. When the temperature of the casting rod is high, the extrusion speed is high, and the cooling rate is low, the length of the product after extrusion will increase. The growth rate can reach 0.5%-1%, which also affects the profile. Line density, so a stable process can increase the yield.
Improve the follow-up process to avoid causing technical waste. After the extrusion of the extrusion process, the main attention was given to the scratching of the profile.
A porous extrusion can improve the yield.
When some products are suitable for multi-space extrusion, porous extrusion is used as far as possible, which can not only reduce the extrusion coefficient, decrease the pressure, but also improve the yield. In the case where the technical scrap is zero, the rate of double-hole extrusion can be increased by 3% to 4% compared with single-hole extrusion.
Extrusion speed is an important process parameter in the extrusion process. It relates to the quality of the product and the level of production efficiency. Extrusion speeds are not as easy to grasp as the process temperature. An alloy heat treatment process can basically select an easy temperature, and the extrusion speed is an empirically strong process parameter. Different profiles of different profiles of different alloys, choose different extrusion speed, the same product in the extrusion process affected by temperature changes, before and after the extrusion speed is not the same. To properly control the extrusion speed should do:
Skilled and flexible to grasp the various alloys, various sections (including wall thickness) of the extrusion speed range, and observe the impact of the extrusion speed on the aluminum profile, such as surface quality, molding and so on.
Familiar with the ability of extrusion equipment to control extrusion speed. Some extruders have constant speed extrusion control and PLC control, some have only PLC control, and some have neither. When given a squeezing speed, some extruders can start squeezing at this speed. As the billet in the squeezing cylinder gradually decreases, the squeezing force decreases, and the outflow speed of the product becomes faster and faster. It will cause cracks in the back of the product. Therefore, it is necessary to adjust the extrusion speed. Only by understanding the state of the equipment can the speed of extrusion be properly adjusted and controlled.
Understand the impact of different molds on the extrusion speed. In general, the extrusion speed of a flat die (solid profile) is higher than that of a flow die (hollow profile). However, the same type of molds and products with the same cross-sectional shape have different extrusion speeds due to different design and manufacturing levels. In particular, semi-hollow sections with poor wall thickness or open sections have a large relationship with the mold. Only a certain extrusion speed using the mold design is better, and if the speed is too fast or too slow, it is easy to produce twist. Open mouth phenomenon.
Reduce the production of waste by strengthening the first inspection and process inspection. External dimension of aluminum scraps such as wall thickness tolerance, twisting, plane clearance, opening or closing, etc., mainly rely on the test of the former support rod by the host hand during discharge inspection And quality inspectors check the gate after stretching to prevent the production of such waste products. The general wall thickness tolerance must be controlled from the negative tolerance, because with the continuous production of products, due to the gradual wear of the mold, the product wall thickness will gradually become thicker. For large-walled profiles, carefully check the drawing when straightening and straightening to control a reasonable amount of stretching.
Surface waste products such as scratches, orange peels, organizational texts, dark spots, bubbles, etc. often do not appear on every product. It is necessary to inspect each other and supervise the removal of scraps from the surface through the master hand, quality inspectors, and the sawing process of the stretched products.
If quality inspectors have not found any scratches on the material discharge table, and the products are found to be scratched when the product is sawed, it is necessary to check from the conversion process of the cooling bed, whether it is to transport belts, feeders, etc. The parts are hardened and scratched.
Quality management is the management of the entire staff and the whole process. Each process must integrate good quality, self-inspection, mutual inspection, and special inspection to effectively eliminate technical waste products in the bud. Artificial control and improve the yield.
Through the above measures, the geometric waste can be reduced. It can be seen that the reduction of geometric waste products is an important technical management measure of the company and has great significance for high economic efficiency.
To improve the yield of aluminum extrusion billets is to have a comprehensive and meticulous work process in extrusion production. Not only must the technical process be in place, management must also be solid and in place. There is still a lot of room for China's aluminum extrusion companies to increase their finished product rate. The improvement of the finished product rate will be a continuous process. Increasing the yield and improving the product quality and output are closely linked. It is a comprehensive manifestation of enterprise technology and management level.
Improved Oxidation and Coloring Aluminium Product Finished Rate Oxidation finished product rate is a one-time production yield, that is, a finished product that is not reworked. According to the production practice, the cost of the reworked profile is three times that of the non-reworked profile, and the surface quality of the profile cannot be guaranteed. . Of course, the quality of the oxidized product starts from the smelting shop. Due to the space limitations, the following will discuss some of the details of the oxidizing process.
The fixing rod and the conductive beam should be fastened with the screws. Before each tie, it is necessary to check whether the hanging rod is loose. If it is loose, it should be fastened in time. Another corrosion, the rod will become smaller, need to be replaced in time, because the conductive area becomes smaller, and easily lead to heat, at the same time to tie tight to prevent the profile dropped into the slot caused by the touch pole, short circuit damage to the power supply.
At the same time, the profiles dropped into the tank need to be cleared out in time. If a section is dropped into a caustic tank, it will corrode quickly. Experiments have shown that the alkali consumption is equivalent to alkali consumption of caustic washing 50-100 profiles. Falling into the coloring tank or sealing groove, due to corrosion, a large amount of aluminum ions will accumulate in the tank, affecting the service life of the tank fluid.
Two types of aluminum wire used for binding materials are better. The coarse aluminum wire is used as an agglomerate, and the finer aluminum wire is used for medium and small materials. Two kinds of specifications, 2mm and 3mm, or 2.2mm and 3.2mm, can be used for annealing. Hardness is 1/2~3/4. At present, many companies have switched to fixtures.
Carefully fasten each profile before lifting it into the oxidation tank. When the material is oxidized before the rework material is tightly squeezed, it must be tapped with the vise to displace the end of the profile before it is tightly displaced, so that there is no film at the contact area to ensure good conductivity.
When the type material is hung into the oxidation groove and the coloring groove conductive seat, it is necessary to pay attention to the centering, otherwise it is easy to have the yin and yang face color difference.
After the end of oxidation and power off in a timely manner, staying in the oxidation tank for a few minutes will affect the sealing hole, and will also make the coloring speed faster; After the oxidation hangs in the air to stay too long, the end of the dripping acid solution due to the expansion of the oxide film Make the coloring deeper, easy to appear two color.
The four tanks before and after the coloring tank should keep the pH of each tank relatively stable. The pH of the normal four tanks is controlled as follows:
Oxidation before the washing tank pH value: 0.8~1.5
The second washing tank after oxidation pH value: 2.5~3.5
After coloring by the front of the washing tank pH: 1.5 ~ 2.5
Second wash tank after coloring pH: 3.5~5.0
Under normal circumstances, a certain amount of overflow water is opened during production. When the production is stopped, the water inlet valve is closed in a timely manner. The whole tank should not be drained and water added. After oxidation, the coloring speed is accelerated by staying for a few minutes in the previous washing tank. Staying in the second wash tank will slow the coloring.
For the production of light-colored imitation steel, it is generally used to color, back to the standard color plate method for coloring. Because the imitation steel color difference of the coloring time control range is very small (only 2 to 3 seconds), and the use of fading law can have 10 to 15 seconds of color control time, and the uniform fading is also conducive to the same color, imitation steel material fade and Complementary colors tend to bluish, while one-time coloring tends to be red.
After hanging from the coloring tank and coloring, the type material does not need to be stopped for too long after being lifted in the front rinsing tank. Otherwise, color, uneven color, and white water on the surface of the lining will appear on the surface of the profile. Wash the next time in a timely manner, accurate color should be carried out after the second wash. In general, for imitation steel materials, if the color of the comparison sample is reddish, it indicates that the coloring time is not enough, then it should be complementary; if the color is yellowish, it has already been colored, and the color depth can be selected according to the degree of color depth. Fade correction.
Coloring tank drug addition method: stannous sulfate and nickel sulfate must be dissolved with the bath solution, while the color additive dissolved with pure water (pure water soluble), we must pay attention to the complete dissolution of solid additives before pouring, concentrated sulfuric acid directly down Into the coloring slot.
The temperature, time, and water quality of the hot water washing before electrophoresis must be ensured. If the residual SO42- in the pores of the oxide film is not washed, the yellowing and opaqueness of the paint film are likely to occur after electrophoresis and baking. Under normal circumstances hot water temperature control 60 ~ 70 °C, hot water wash time 5 ~ 10 minutes.
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