"Porous" is widely recognized in the industry as "porous mold." The extrusion process using "one-mode porous" technology represents an advanced manufacturing technique that enhances yield, production efficiency, and profile quality. It significantly contributes to energy conservation, labor reduction, land saving, and cost control, aligning with national policies on energy efficiency and emissions reduction. This technology plays a crucial role in promoting sustainable development.
1. **Mold Design and Manufacturing**
In designing a "one-mode porous" mold, optimization is key. When placing the pores, it's essential to consider the strength of the steel material to prevent spacing issues—either too close or too far apart. A symmetrical layout is recommended, with holes ideally placed horizontally. If a top-and-bottom arrangement is necessary, the holes should be staggered. During mold manufacturing, high-precision tools are vital for achieving accurate results. For example, splitting holes and welding chambers should be machined using CNC centers, while cavities can be cut via slow wire EDM to ensure verticality, parallelism, and smoothness of the working surface.
2. **Extrusion Process Control**
2.1 **Process Parameters**
2.1.1 **Bar Temperature Control**
For porous dies, the bar temperature is typically maintained between 390°C and 480°C. A step-cooling method is used, starting from the upper limit and gradually decreasing by 10°C until reaching the lower limit.
For split-mode porous dies, the bar temperature range is generally 430°C–500°C, following similar cooling procedures.
2.1.2 **Mold Temperature**
The mold temperature should be kept within 430°C–480°C to maintain optimal performance.
2.1.3 **Ingot Cylinder Temperature**
The cylinder temperature is usually controlled between 410°C and 440°C, with the upper limit being acceptable under certain conditions.
2.1.4 **Outlet Port Temperature**
The outlet temperature should be between 520°C and 580°C. Too low or too high temperatures can affect the hardness and overall quality of the profile.
2.2 **Operational Requirements**
2.2.1 **Aluminum Rod Heating**
Heating is done through a rod furnace, typically using zone-controlled heating methods. For porous molds, the temperature decreases from the furnace area to the tapping area.
2.2.2 **Mold Heating**
Mold heating time is generally limited to 6 hours. The mold should be heated together with the pad and sleeve but not overheat, as this can impact surface quality. Molds should be placed in the center of the furnace, at least 5 cm away from walls and fans. The furnace must remain clean to avoid dust contamination.
2.3 **Extrusion Process Control**
2.3.1 The time between mold removal and extrusion should not exceed 3 minutes.
2.3.2 The first rod produced should be short (200–300 mm) and extruded without pressure.
2.3.3 The initial extrusion should be done with the “0†section, gradually increasing speed after material flow begins.
2.3.4 Use high-temperature pads and graphite plates to prevent surface damage during handling.
2.3.5 Adjust the tractor’s pulling force intermittently to maintain dimensional accuracy.
2.3.6 Normal extrusion speed is around 30–40 m/min.
2.3.7 Follow proper quenching or air-cooling procedures based on alloy requirements.
2.3.8 Avoid random shutdowns. If the machine stops for more than 3 minutes, the mold must be reheated to 500°C before reinstallation.
2.4 **Profile Temperature and Speed Control**
2.4.1 Adjust the aluminum rod temperature based on the profile discharge temperature.
2.4.2 Maintain the discharge profile temperature between 520°C and 580°C.
2.4.3 If the profile turns black, immediately reduce temperature and extrusion speed.
2.4.4 Operators must continuously monitor rod and profile temperatures, as well as equipment performance. Any abnormality must be addressed immediately to avoid mold damage.
3. **Extrusion Equipment**
To achieve the goals of improved yield and efficiency, advanced equipment such as twin-tractor machines with flying saws, mold systems, aluminum rod furnaces, and long-spindle hot-shear technology are essential. These components work together to ensure stable and consistent output.
4. **Conclusion**
With continuous improvements in the extrusion process, the efficiency and yield of "one-mode porous" technology have been steadily increasing. However, due to variations in equipment, mold materials, and extrusion techniques across different companies, the development of this technology may vary.
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