Aluminum extrusion workshop operation flow and work instruction

Squeeze

I. Operation procedure.

1. Adopt the form of step temperature of heating 100℃/1 hour to heat up the ingot barrel to 380℃---420℃.

2. According to the operation plan, select the appropriate amount of suitable aluminum rods into the rod furnace to heat up to 480℃---520℃, and special industrial profiles will be executed according to the specified process temperature.

3、Select the die according to the work schedule, heat up to 460℃--500℃, keep warm for 2--4 hours.

4. Start the extruder cooling motor - oil pressure motor.

5、According to the order of the schedule, select the special pad for the die to be installed in the die holder, and lock the die holder in the extrusion position.

6．Close the Sheng Ding cylinder and raise the heated aluminum bar to the material gall alignment position using the feeding frame.

7、Main cylinder advance extrusion

8．The extrusion speed should be slow at the beginning, and the extrusion speed should be adjusted according to the surface quality of the profile at the material outlet.

9. Put the die number, aluminum bar number, main cylinder pressure and discharge speed into the original record in detail.

II. Process requirements

1. The heating temperature of aluminum bar is: A. Flat die: 500℃---520℃ B. Shunt die: 480℃--500℃ C. Special industrial materials are executed according to the special process requirements.

2. Mould heating process.

A. Flat mold: 460℃---480℃ B. Shunt mold: 460℃---500℃

3、Shengding cylinder temperature: 380℃---420℃ The temperature of the end surface of the ingot cylinder is 280℃---360℃

4. The extruded material must have smooth surface, longitudinal indentation without hand feeling, detailed and uniform extrusion pattern, no bright band, black line, plane gap between yin and yang, angle deviation, cut slope according to the national standard high precision grade.

5. Extrusion pressure: ≤200㎏/cm2

6、Blocking pressure of material gall 120kg/cm2-150kg/cm2.

7、Hydraulic oil temperature≤45℃

8、The speed of profile outflow is generally controlled as follows: 5m/min ---30m/min

9. Mould time in the furnace: ≤8 hours

10. Every 80 bars-100 bars are extruded, the material gall must be cleaned once with special cylinder cleaning pad.

III. Caution

1. When extruding, if the die is plugged, the bogging time should not exceed 5 seconds.

2、When loading the die, pay attention to safety, prevent the screw from slipping off and hitting the foot.

3、When discharging the material, it is strictly forbidden to peer into the outlet in a straight line.

4 Before loading the die on the machine, must check the center position, whether the extrusion rod is centered, no-load test run once before starting the machine, to confirm that there is no error officially start the machine.

5、Measure whether the bar temperature, die temperature and ingot barrel temperature meet the requirements.

6、Check the quality of 3-5 rods once.

7、Check the oil temperature frequently.

8、Whether each aluminum bar has furnace number and alloy grade label.

Interruption

I. Operating procedures

1、When the main machine is discharged, hold the material head with pliers, guide the profile to the slide out platform and turn on the cooling fan, and open the water cooling system for the profile requiring water cooling.

2、Saw off the material head about 50cm with interrupting saw, write down the mold number and put it away centrally for the reference of mold repairer.

3、The material is normal, and the profile of about 50cm is cut off with the interrupted saw and handed over to the quality inspector for quality inspection.

4、Cooperate with the machinist to interrupt the profile at 13m, 19m or 25m according to the length of the outgoing material in order to straighten it. If the total length is less than 26 meters. Then interrupt at the material joint.

5、After the profile is interrupted, immediately push it to the cold bed by gently holding it with asbestos gloves.

6、Check the quality. Especially the first and second bars, and then every 3 - 5 bars should check the surface quality.

II. Process requirements.

1、Air-cooling speed of the material outlet is not less than 110℃/min

2、When sawing the material, pay attention to light pressure and synchronize the saw with the material to prevent the profile from being bent.

3、When pushing the material, take it lightly and put it down gently to avoid artificial abrasion and material table rubbing.

4、When sawing the material, make sure to grab the profile with your hand to prevent the profile from swinging and rubbing.

III. Caution:

1, traction is strictly forbidden to reach the head and operating hand is facing the mouth of the material, to prevent danger.

2、When opening the interrupted saw, the operator should not face the interrupted saw. Within 30cm of the saw blade, it is forbidden to approach the person to ensure safety.

3、Pay attention to the discharge road to prevent the material bed from topping the profile.

4、Pay attention to safety, be careful of burns.

5、Pay attention to the twisting and turning when the profile is discharged.

Stretching

I. Operation procedures.

1、Check whether the oil pressure system is leaking and the air pressure is normal.

2、Check whether the conveyor belt, cold bed and material storage table are damaged and scuffed.

3、Before stretching, confirm the length of the profile, and then book the stretching rate to determine the stretching length, i.e. the main chuck moving position, usually the stretching rate of 6063T5 is 0.5% - 1%, and the stretching rate of 6061 T6 is 0.8% - 1.5%.

4、Confirm the clamping method according to the shape of the profile. For large section hollow profile, the stretching pad can be stuffed, but try to ensure enough clamping area.

5、When the profile is cooled down to below 50℃, open can stretch the profile.

6、When the profile is bent and twisted at the same time, the twisting and twisting should be corrected first and then the bending should be pulled.

7、The first and second ones are test-drawn to confirm whether the predetermined stretching rate and clamping method are appropriate. Visually bend, twist and twist, check the plane gap, flare and parallel mouth of the profile, and if it is not suitable, adjust the stretching rate appropriately.

8. If the normal stretching rate still cannot eliminate bending and twisting, or cannot make the geometry qualified, the operator should be notified to stop extrusion.

9. The profiles on the cooling table should not be rubbed against each other, collided, overlapped and stacked to prevent rubbing.

Second, process requirements.

1. Cooling temperature of the profile: ≤50℃

2、There should be a certain distance between two rows of materials to prevent mutual rubbing.

3. When stretching, the clamping direction of both ends should be the same. The main chuck can be stretched only after the tail chuck is clamped.

4、After the main chuck unloads the pressure, the jaws open before, the main chuck do not return.

Caution.

1、When the jaws are clamping the profile, do not hold your hand on the clamped part.

2、When the oil level is lower than the lower limit, the filter is blocked or the oil temperature is too high, stop the oil pump operation.

3、When there is an abnormal sound, judge the reason and report to the head of the big shift in time.

4、Oil is strictly prohibited on the surface of the profile.

Sawing

I. Operation procedure.

1、Open the sawing machine, check whether the feed and retreat are normal and whether the saw blade needs to be repaired and replaced.

2、Move the straightened profile to the plastic roller roller bed.

3、Set the ruler stopper at the required place and make it firm.

4、Saw off the head of the profile about 40cm, and then hold the ruler stopper, press the profile by hand and step forward switch to saw off the profile.

5、Step back the saw blade and check the quality of each profile.

6、Load the qualified profile in the special frame.

7、The material mouth is trimmed and the tracking card is filled out, and the delivery is made to the statistical overweight after the signature of quality inspection.

II. Process requirements.

1、Sawing head material should be not less than 30㎝ and tail material not less than 40㎝ to ensure the quality.

2、Sawing large material can not exceed 6 branches each time.

3、Sawing mouth should be neat, no serious deformation and burr.

4、The margin of sawing mouth is generally left 20mm if the customer has no special requirement, and no sub-tolerance is allowed.

5、Lightly lift and place the profiles when moving them to prevent rubbing and scratching them.

6、Place more than 5 pads on each layer of the frame, pay attention to the device of different materials to prevent deformation.

7、The material mouth is repaired evenly and smoothly.

Caution.

1、When the saw blade advances, people should not stand in the front of the saw blade to prevent injury.

2、Control the amount of oil spray and dry the oil on top of the profile.

3、Control the expansion and contraction of the saw blade between 10-15 seconds.

4、If the saw mouth is rolled or deformed, it should be corrected and cleaned or replaced.

Timing

I. Operating procedures.

1、Check whether the temperature gauge is normal, the material mouth and profile quality are qualified, and whether the profile name, quantity, frame number and tracking card match before opening the furnace.

2、Load the furnace, open all the aging switches (such as gas device, electric circuit, etc.), and then check whether each part of the equipment is normal.

3、Fill in the time of entering the furnace, holding time and time of leaving the furnace.

4、After aging, the profile is discharged from the furnace and forced to cool.

5、Tracking card is registered according to the aging situation, check the hardness, and insert the card into the profile frame when qualified.

II. Process requirements.

1、Temperature: 200±5℃

2、Time 2-2.5 hours, temperature difference in the furnace cannot exceed 10℃. The profiles with special requirements are executed according to the specified process requirements.

3、The material is cooled down to 50℃ or less to measure the hardness, and the Wechsler hardness is ≥8HW. Special hardness requirements are implemented according to special requirements.

Caution.

1、No one is allowed to stand under the overhead crane  

2. The lifting frame shall not touch or damage the profile, and shall not trample on the profile artificially.

3. The profile out of the furnace should not be exposed to corrosive gas, dust, etc., and it is required to cover with colorful cloth before and after the furnace.

4、The material frame should not be stacked on high shelves, generally not more than 3 shelves.

Precautions

1、Note to the machine manager

The production plan directly affects the normal situation of production, in addition to the production order with the mold and aluminum bar, the key is to let the staff understand the shift leader's plan, what material to produce first, then what to produce, and then what to produce, so that the production has a clue. To use the plane die, shunt die, production must be prepared before the special pad, can not wait for the upper set of die unloading the next set of up mold from the mold furnace, and can not find the special pad, resulting in mold temperature drop, can not be pressed or crushed mold, affecting the planned completion time, increasing production costs. Mold on the machine to check whether the mold number and scheduling the same, the wall thickness, length, color, order number of mastery is conducive to improving production and control the quality.

2、Cautions for the host hand

A qualified host hand must have tacit cooperation with the shift supervisor, can communicate with the shift supervisor, clear production plan of the shift supervisor, the shift supervisor can direct the production when he is not on site, will not cause downtime.

A machinist can only know the skills to start the machine if he is familiar with the production plan, and control the extrusion speed according to different surface treatment, section and wall thickness to improve the output and reduce the production of scrap.

In strict accordance with the process, equipment operating procedures is the sacred duty of the machine hand, the main cylinder into the time to pay close attention to the hand can not leave the operating table pause control switch, to prevent no on the extrusion cake or mechanical hand failure caused by the extrusion rod punch off the accident.

3, interrupter operating procedures

The interrupter should firstly check whether the saw blade fixation, rotation device, safety device and buttons are normal at the time of shift change.

Pay close attention to the smoothness of the walking of the profile at the outlet, and start sawing when the required length of the profile is reached.

Press the handle switch or foot pad switch to press the saw blade toward the outfeed profile, and keep moving in the same direction as the outfeed speed to interrupt the saw during the sawing process, and the saw blade should move away from the profile quickly when the profile is cut off.

Then the sawed profile will be slid into the material frame for cooling, and the surface quality must be checked by sawing a sample board every 3-5 materials, and the saw blade should be properly coated with lubricant.

4 Operating procedures of straightening workers

The straightening worker checks whether the mechanical fasteners and hydraulic transmission system, operating handle and buttons are normal at the time of shift change. Start the hydraulic pump and motor to see if they are normal.

According to the length of the profile, adjust the distance of the rear chuck appropriately, and fix the rear chuck, test run with no load, operate the jaws "open-close", the car "stretch-return" several times, check whether it is normal, determine the profile temperature is lower than 50 ℃ before straightening, feeding operation jaws release clamping, the car return in the limit position, the rear chuck is in the straightening state when clamping at the same time.

In the process of straightening, the profile is straightened by breaking the profile by hand, or the profile is straightened by pressing the rotation of the chuck, and the stretching starts by pressing the stretching handle, and the stretching rate should be no more than 1.5%, and the change of the shape and size of the profile is noted to avoid stretching too much, and after the stretching is finished, the car returns, the front and rear chuck is released, and the profile is sent to the storage table.

The profile should be straightened in time to prevent the blanks from accumulating on the cold bed, causing bruises, scratches and abrasions, and the decorative surface of the profile should face upward to avoid abrasions on the decorative surface, and the conveyor belt that transmits the straightened blanks and the over-bridge belt should keep synchronous operation.

5 Sawing and framing operation procedure

Firstly, check whether the saw blade fixing, transmission, safety devices and buttons are normal, and then load the cabinet according to the length, color and direction of the profile on the Extrusion Scheduling List, which cannot be mixed. Feed the material to the sawing table until it touches the blocking scale, and set the profile straight. Spray the appropriate amount of cooling and lubricating oil to the saw blade, and then start sawing. When sawing, control the number of sawing branches at a time to prevent rubbing, and use clean cloth to space between each branch when sawing finished blanks and glossy fabrics.

The sawed profile will be loaded into the designated frame, and the material with quality problems cannot enter the frame, and the heavy profile will be loaded below and the light profile will be loaded above during the loading process. At the same time, it should be handled lightly to prevent crushing, denting and damage. In principle, profiles of different lengths are not mixed, but when they need to be mixed, the frame should be installed in the way of long under and short on top, and after the frame is installed and covered with colorful cloth, it should be transferred to the transit warehouse for furnace aging in time.