[China Aluminum Industry Network] Executive summary:
There are many varieties of green aluminum alloy aluminum alloy formwork profiles, a wide range of specifications, complex shapes, high technical content of mold design and manufacturing, production technology is difficult. This article only selects two typical difficult sections as an example, analyzes and discusses the design scheme, manufacturing process and innovation points of the mold. The comparison of the extrusion effect and service life of the mold shows that the high-quality mold is in the green building aluminum. Alloy template profiles play an important role in industrial mass production.
Keywords: green building, aluminum alloy formwork profiles, width-to-thickness ratio 100, flat wide profiles, special widening, shunting, combined modules, high tongue ratio, semi-hollow profiles, shielded protective molds, green building aluminum profiles, profiles, mold characteristics and technical difficulties, analysis, 1.1 Overview, aluminum alloys There are dozens of varieties of building formwork profiles, and a wide range of specifications. Some profiles are made up of several small and medium-sized profiles with different shapes. The circumcircle diameter is more than 600mm. Hollow profiles, solid profiles and semi-hollow profiles, forming a difficult, high dimensional and geometric requirements, requires high mechanical properties, b330MPa), excellent weldability, wear resistance, corrosion resistance and other comprehensive performance. And it requires industrial mass production. Therefore, different forms of special structural molds are required, such as special diverter molds, shield profile molds, and special width molds, etc., to ensure the formation and dimensional accuracy of different profiles, and to require high service life (required service life requirements are higher than The increase of 2-3 times) to ensure its mass production. In the following, only two typical and more difficult profile molds are selected from dozens of profiles to discuss the design and manufacturing technology of green building aluminum alloy profile profile molds. One of them is a width of 400mm and a width to thickness ratio of more than 100. With reinforced siding profiles WYY1237 (see Figure 1), the other is a semi-hollow section WYY1125 (see Figure 2) with a tongue ratio greater than 5 and a size and shape with superior precision.
1.2 Characteristics and Technical Difficulties of Die Profiles for Aluminum Alloy Formwork Profiles (1) There are many types of profile profiles, complex shapes, and large dimensional changes. Therefore, it is required to design and manufacture high quality molds of different specifications, different structures, and different forms to ensure the forming, size and shape. Accuracy requires a lot of test work.
(2) The template requires industrial mass production, the first key is to improve the service life of the mold. The development subject requires that the service life of the extrusion mold is 2-3 times higher than the original one. The difficulty is very great.
(3) The width-to-thickness ratio of flat wide formwork profiles is more than 100. It is difficult to ensure wide and thin wall part dimensional accuracy and plane clearance, and a special structure of wide spread and split flow die is required to reasonably distribute metal flow. In order to ensure the formation of the profile and high-precision size requirements, in particular to ensure ultra-high precision shape and position tolerance, the technical difficulty is even greater.
(4) Most of the semi-hollow profiles in the formwork profile have a tongue ratio greater than 5, and the precision of the dimension and shape requires ultra-high precision. It requires a special structure of the mold to ensure that its profile is formed, and high precision is achieved, and the mold must be guaranteed With sufficient strength, no deformation, no cracking, no collapse, and high service life, the difficulty is very great.
(5) Template profiles require smooth surfaces, high dimensional accuracy and shape accuracy. Therefore, it is necessary to use high-quality die steels and strict die heat treatment processes and machining to implement all CNC process specifications in order to obtain high strength, high toughness, and high precision. High quality molds with low surface roughness.
WYY1237 and WYY1125 template profile mold design basis and technical requirements 2.1 WYY1237 template profile mold design basis and technical points (1) WYY1237 profile alloy state is 6061ET6, extrusion material by precision water \ fog, gas quenching + artificial aging after delivery The goods require the size and shape accuracy of the profile to reach ultra-high-precision level, and have reasonable mechanical properties, wear resistance, corrosion resistance, weldability and other comprehensive performance of the reasonable match.
(2) Profiles of WYY1237 are flat-width thin-walled profiles (see Figure 1). They are characterized by serious wall thickness differences and plane gaps. Both sides of the profile are not sufficiently thick due to insufficient filling material. WYY1237 profiles are wide and thick. If the ratio is as high as possible, and the ordinary flat die cannot meet the technical requirements for extruded profiles, a special combination die must be designed to ensure the formation and accuracy requirements.
(3) WYY1237 profile has large dimensions and must be produced in a large extruder with a capacity of 7,000 tons or more. The diameter of the barrel is 418mm. The width of the profile is almost equal to the diameter of the barrel. This requires designing a special multi-stage. Extensive extrusion die can ensure the profile forming and the width accuracy and plane clearance.
(4) WYY1237 profiles of the two support legs and the wall angle, the geometric tolerance value has exceeded the GB5237 high-precision level requirements, the need to repeatedly calculate and balance the distribution of metal flow in order to ensure the accuracy of the angle. The requirement of the user to ensure that the accuracy of the two angles of the profile is to ensure the smooth loading and unloading of the template and the overall flatness, and the design and manufacture of the mold is extremely difficult.
(5) It is required to select excellent mold materials, advanced heat treatment and surface treatment processes to ensure that the service life of the mold is increased by 2-3 times.
2.2 WYY1125 formwork die design basis and technical requirements (1) WYY1125 template profile alloy state is 6061ET6, extrusion material by precision water, fog, gas quenching + artificial aging after delivery, requires the profile size and shape accuracy to achieve super Advanced level, and has good mechanical properties, wear resistance, corrosion resistance, weldable and other comprehensive matching of reasonable performance.
(2) WYY1125 formwork profile is a typical high-tongue semi-hollow profile (see Figure 2). The shape of the profile is surrounded by three and a half aspects. On the one hand, there is a part of the opening, and the enclosed part is the space area. This area is a cantilever beam in terms of the mold. The cantilever beam is thin and deep, and the cantilever beam can easily collapse. The mold is also very easy to damage, it is difficult to squeeze qualified profiles, it is difficult to guarantee the dimensional accuracy and shape accuracy of the profile.
(3) The profile has three 90-degree corners, of which two angles are, and one angle is, the tolerance values of these three angles have exceeded any of the national standard. The user's requirement to ensure that the three-angle accuracy of the profile is to ensure the overall flatness of the template assembly, which brings great difficulties to the design and manufacture of the mold.
(4) It is required to select excellent mold materials, advanced heat treatment and surface treatment processes to ensure that the service life of the mold is increased by 2-3 times.
3. Design and manufacture of template profile molds, technical solutions and measures to improve service life and innovation point analysis 3.1 WYY1237 profile molds (1) WYY1237 profile mold design basis and design parameters are shown in Table 1 and Table 2.
Table 1 mold design parameters of WY1237 profile
alloy
status
Profile section area Cm2
Circumcircle
diameter
Mm
Implementation standards and
Accuracy level
Extruder tonnage t
Extrusion barrel diameter mm
Specific pressure
MPa
Extrusion ratio
l
Deformation rate%
6061ET6
24.717
F410
GB5237 - Ultra High Precision
7000
F418
459
55
98
Table 2 mold design program parameter table
Mould
model
mold
specification
Mm
mold
Types of
Mold steel
Grade
Mold heat treatment hardness HRc
Metal shrinkage factor
Die hole production accuracy, mm
Die surface roughness
Split ratio
Extensive, mm
Wide angle b
Profile wall die hole, mm
Profile profile die hole,
WYY1237
F620x350
Special wide spread shunt modular
4Cr5MoSiV1 (Premium)
47-49
0.01-0.012
0/-0.02
0/-0.1
Ra0.04mm
13
80
25°, 5°
(2) Schematic diagram of the WYY1237 mold design, see Figure 3.
Fig. 3 Schematic diagram of the special wide-split and split-flow assembly model for building aluminum profile profile WYY1237
