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1、Aluminum Profile ExtrusionShandong University2010.0610ContentsChapter1 Process of Extrusion of Aluminum11.1 Process Overview11.2 Billet21.3 Dies and Tooling21.4 Direct Extrusion Operation51.5 Aging61.6 Packaging7Chapter 2 Metallurgical Principles82.1 Introduction82.2 Structure82.2.1 Lattice Structur
2、e Single Phase92.2.2 Multiphase StructureEquilibrium Diagrams142.2.3 Diffusion, Precipitation, Non-equilibrium182.2.4 Melting and Casting Processes212.3 Development of the Continuous Cast Structure222.3.1 Peripheral Shell and Peripheral Segregation232.3.2 Cast Log Surface242.3.3 Cast Grain and Cell
3、Structure, Intermetallic Phases26Chapter3 Machinery and Equipment for Direct and Indirect Hot Extrusion313.1 Machinery for Direct Extrusion313.1.1 Extrusion Press Design Principles333.1.2 Main Subassemblies of the Direct Extrusion Press403.1.3 Auxiliary Equipment for Direct Extrusion513.1.4 Hydrauli
4、c Drive and Control Systems for Direct Extrusion543.1.5 Electrical Drive, Control, and Regulation for Direct Extrusion593.1.6 Typical Operating Sequence for Direct Extrusion59Chapter 4 Extrusion Tooling594.1 Requirements of Tooling and Tooling Material594.1.1 Requirements of the Extrusion Tooling594
5、.1.2 Requirements of the Tooling Materials594.2 Design of Tool Sets for Direct and Indirect Extrusion594.2.1 Design of the Tool Set for Direct Extrusion594.2.2 Design of the Tool Set for Indirect Extrusion594.2.3 Sealing of the Shape-Producing Tooling with the Container59Chapter5 Extrusion of Semifi
6、nished Products in Aluminum Alloys595.1 General595.2 Extrusion Behavior of Aluminum Alloys595.2.1 Flow Stress595.2.2 Flow Process595.2.3 Thermal Balance and Extrusion Speed595.2.4 Section Surface and Surface Defects595.2.5 Procedures to Control the Thermal Balance595.2.6 Joining by Extrusion59Chapte
7、r 6 Billet Heating Systems596.1 Induction Furnaces596.1.1 General596.1.2 Gas-Fired Billet Preheat Furnace596.1.3 Temperature Measurement and Control596.1.4 Economics596.1.5 Extrusion Billet Transport Mechanisms596.2 Age-Hardening Ovens for Aluminum Alloys596.2.1 Heat Transfer by Convection596.2.2 De
8、sign of the Chamber Furnace596.2.3 Heating596.2.4 Transport Mechanisms59Chapter7 Aluminum Extrusion Glossary59Chapter1 Process of Extrusion of Aluminum1.1 Process OverviewThe aluminum extrusion process really begins with the design process, for it is the design of the product-based on its intended u
9、se-that determines any of the ultimate production parameters. Questions regarding machinability, finishing, and environment of use will lead to the choice of alloy to be extruded. The function of the profile will determine the design of its form and, hence, the design of the die that shapes it.Once
10、the design questions have been answered, the actual extrusion process begins with billet, the aluminum material from which profiles are extruded. The billet must be softened by heat prior to extrusion. The heated billet is placed into the extrusion press, a powerful hydraulic device wherein a ram pu
11、shes a dummy block that forces the softened metal through a precision opening, known as a die, to produce the desired shape.Fig. 1.1 This is a simple diagram of a typical horizontal hydraulic extrusion press; the direction of extrusion here is from left to right.That is a simplified description of t
12、he process known as direct extrusion, which is the most common method in use today. Indirect extrusion is a similar process, but with some important differences. In the direct extrusion process, the die is stationary and the ram forces the alloy through the opening in the die. In the indirect proces
13、s, the die is contained within the hollow ram, which moves into the stationary billet from one end, forcing the metal to flow into the ram, acquiring the shape of the die as it does so.The extrusion process has been likened to squeezing toothpaste out of a tube. When pressure is applied at the close
14、d end, the paste is forced to flow through the open end, accepting the round shape of the opening as it emerges. If the opening is flattened, the paste will emerge as a flat ribbon. Complex shapes can be produced by complex openings. Fig. 1.2 These photos show a new length of extrudate, just emergin
15、g from the press (left) and the production of a profile in progress (right).注释：Main cylinder silind 主液压缸Hydraulic pressure hadr:lk 液压Press column klm 柱式压机Container 挤压筒Dummy block dmi: 挤压垫Ram 挤压杆Billet 坯料Front platen 挤压机前牌坊，前挤压盘Runout table 输出辊道Ribbon ribn 带状物Squeeze skwi:z 榨取, 挤出1.2 BilletBillet is the starting stock for the extrusion operation. Extrusion billet may be a solid or hollow form, commonly cylindrical, and is the length charged into the extrusion press container. It is usual
