Twisting during the extrusion of aluminum profiles is a common problem, which is usually related to multiple factors such as the unevenness of metal flow, die design, extrusion process parameters, and equipment status. The following is a detailed analysis and solution for the twisting caused by aluminum profile extrusion:
Cause analysis
Mold design issues
Unreasonable cavity design of the mold, such as inconsistent lengths of the working band and asymmetrical cavity shapes, will cause uneven force on the metal during the extrusion process, thereby resulting in twisting.
Improper design or installation of the mold's guiding system (such as the guide path) cannot effectively guide the flow of metal and will also increase the risk of twisting.
Extrusion process parameters
If the extrusion speed is too fast, the flow rate of the metal is difficult to control, which can easily lead to twisting.
If the extrusion temperature is too high or too low, it will affect the fluidity and plasticity of the metal, and then cause twisting.
Improper selection of the extrusion ratio (i.e., the ratio of the volume of metal in the extrusion cylinder to the volume of the profile after extrusion) may also lead to twisting.
Uneven metal flow
During the extrusion process of metals, due to the influence of factors such as temperature, speed and pressure, uneven flow may occur, resulting in uneven force distribution on different parts of the profile and causing twisting.
Equipment status
Insufficient precision and stability of the extruder, such as wear or improper installation of components like the extrusion shaft and extrusion cylinder, will affect the stability of the extrusion process and increase the risk of twisting.
Inappropriate guide or no guide installed:
The function of the guide path is to guide the metal to flow in the predetermined direction during the extrusion process. If the guide path is inappropriate or not installed, it will cause the metal to flow out of control and result in twisting.
Improper lubrication
Insufficient lubrication or improper lubrication methods will increase the frictional resistance of the metal during the extrusion process, causing the metal to flow poorly and resulting in twisting.
Solution
Optimize mold design
Ensure that the cavity design of the mold is reasonable, the length of the working band is consistent, and the cavity shape is symmetrical.
Regularly inspect and maintain the guiding system of the mold to ensure that it can effectively guide the flow of metal.
Adjust the extrusion process parameters
Select the appropriate extrusion speed and temperature based on the material and specification of the aluminum profile.
The optimal extrusion ratio is determined through experiments to reduce the occurrence of twisting.
Improve the uniformity of metal flow
Before extrusion, the metal should be fully preheated and homogenized to enhance its fluidity and plasticity.
Appropriate lubrication measures should be adopted during the extrusion process to reduce the frictional resistance between the metal and the die, making the metal flow more smoothly.
Improve the accuracy and stability of equipment
Regularly maintain and inspect the extruder to ensure that all its components are in good working condition.
Adopt advanced control technologies and equipment to enhance the degree of automation and stability of the extrusion process.
Adopt auxiliary equipment
During the extrusion process, auxiliary equipment such as traction machines or straightening machines are used to pull and straighten the extruded aluminum profiles to reduce the occurrence of twisting.
Strengthen quality control
During the extrusion process, strengthen the monitoring and inspection of the quality of the profiles, and promptly identify and handle quality issues such as twisting.
Record and analyze the production data to continuously optimize the extrusion process and die design.
Through the implementation of the above measures, the risk of twisting during the aluminum profile extrusion process can be significantly reduced, and the quality and pass rate of the products can be improved.
