How to choose appropriate billet size when extrusion aluminum profile

The choice of billet size directly impacts factors such as extrusion speed, die life, surface finish, and mechanical properties of the final extruded profile. Here are several key considerations to help guide the decision-making process:

Profile Design: Begin by assessing the design requirements of the desired aluminum profile. Consider its dimensions, complexity, and section thickness. These factors determine the total volume of aluminum needed and subsequently influence the billet size selection.

Extrusion Ratio: The extrusion ratio, defined as the ratio of the cross-sectional area of the original billet to that of the final extruded product, has an impact on the extrusion process. Higher extrusion ratios require larger billets to ensure proper material flow and prevent defects such as surface cracks or excessive strain on the equipment.

Die and Press Size: The capacity of the extrusion press and the available die sizes are pivotal factors to consider. The billet size should match the press tonnage and not exceed the die's capabilities to prevent overloading and ensure a successful extrusion process.

Material Utilization: Maximizing material utilization is essential for cost-effectiveness. By choosing the right billet size, you can minimize scrap and waste. Analyze the dimensions of the billet that provides the best yield given the profile's dimensions and reduce material loss.

Extrusion Speed and Cycle Time: Billet size affects the extrusion speed and cycle time. Larger billets generally allow for faster extrusion speeds, leading to improved productivity. However, excessively large billets may cause poor metal flow or increased back pressure, negatively impacting the surface finish and overall quality of the extruded product.

Heat Transfer and Cooling: Heat transfer during the extrusion process is influenced by the billet size. Thicker billets tend to have slower heat transfer rates, potentially leading to non-uniform temperature distributions or difficulties in cooling the extruded profile adequately. Balancing billet dimensions with efficient heating and cooling systems is crucial to ensure consistent product quality.

Mechanical Properties: Billet size can affect the mechanical properties of the extruded profiles. Larger billets often result in profiles with better mechanical strength due to refined grain structure during extrusion. However, excessively large billets can lead to increased internal stresses and potential distortion. It is essential to strike a balance between favorable mechanical properties and manageable stress levels.