1. Difficulties in the extrusion molding process of aluminum product processing
Aluminum product processing extrusion molding faces many difficulties. First, the fluidity of aluminum alloy materials varies greatly, and aluminum alloys of different compositions have completely different requirements for process parameters such as temperature and pressure during the extrusion process. For example, aluminum alloys with high silicon content have good fluidity at high temperatures, but are prone to thermal cracking; while some alloys with high magnesium content may have mold sticking during extrusion. Secondly, the design and manufacture of molds are key challenges. The mold needs to withstand high temperature, high pressure and strong friction of aluminum metal, and is prone to wear, deformation and even cracking. Aluminum product processing with complex shapes requires the mold to have a high-precision cavity and good demolding performance, otherwise it is difficult to ensure the dimensional accuracy and surface quality of the product. Furthermore, the temperature control during the extrusion process is difficult. Too high temperature will cause coarse aluminum alloy grains and reduce the mechanical properties of the product; too low temperature will increase the extrusion resistance, which may cause overload or even damage to the extrusion equipment.
2. Material solutions
For the fluidity problem of aluminum alloy materials, it can be improved by optimizing the alloy composition. For example, adding an appropriate amount of trace elements such as titanium and boron to refine the grains, improve the uniformity and fluidity of the material, and reduce the risk of hot cracking and sticking. At the same time, the aluminum rod is homogenized before extrusion to eliminate internal stress and component segregation, so that the material can show more stable performance during the extrusion process. In addition, according to the characteristics of different aluminum alloys, the extrusion temperature range is accurately formulated, and advanced heating equipment and temperature control systems are used to ensure the uniformity and stability of the temperature of the aluminum rod throughout the extrusion process.
3. Countermeasures for molds
In mold design, advanced CAD/CAM technology is used for optimization, and the structure of the mold is reasonably designed, such as increasing the demoulding slope, optimizing the flow channel shape, etc., to improve the demoulding performance and metal fluidity of the mold. Select high-quality mold materials, such as hot working die steel, and perform appropriate heat treatment to improve the hardness, wear resistance and heat resistance of the mold. In the mold manufacturing process, strictly control the processing accuracy, use high-precision processing equipment and detection methods to ensure the dimensional accuracy and surface finish of the mold cavity. At the same time, develop mold surface treatment technologies, such as nitriding and coating, to reduce the friction coefficient between aluminum metal and the mold surface and extend the service life of the mold.
4. Process control and equipment improvement
In terms of extrusion process control, establish a complete process parameter monitoring and feedback system, adjust extrusion speed, pressure and other parameters in real time, and optimize according to the shape, size and material properties of aluminum product processing. For example, for products with complex shapes, use segmented extrusion process to control extrusion parameters at different stages. In terms of equipment improvement, develop high-performance extruders, improve the pressure stability and control accuracy of the equipment, use advanced cooling systems to timely remove the heat generated during the extrusion process, and ensure that the temperature of the mold and aluminum product processing is within a reasonable range. Through these comprehensive measures, the difficulties in the extrusion molding process of aluminum product processing can be effectively overcome, and product quality and production efficiency can be improved.
