Factors Affecting Aluminum Extrusion Shape is a determining factor in the part's cost and ease with which it can be extruded. The characteristics of profile consist of: solid profile with rectangular shape, general wall thickness 2.3 mm, width 24 mm, height 15.3 mm, CCD 28.5 mm, section area 1.7 cm 2 , perimeter 20.32 mm . This along with the ability to run more complex profiles without issues, from .020" wall thickness to high tongue ratio semi-hollow profiles. CNC Breaking, CNC Punching, Aluminum Extrusion, Extrusion Fabrication A glimpse of a few of our products: Entrance Doors, Steel . wide. Generally this tongue ratio is greater . Maybe you've heard of this manufacturing procedure and are curious about what it is and the way it works. The solution below shows a narrow, deep channel and an extrusionfriendly profile. See the above image with maximum tongue ratios recommended for the three types of dies. With us, you can choose your alloy, the texture, heat sinks, tongue ratio, tight aluminum extrusion and many other specifications that need customization. The higher the ratio, the more difficult the part will be to extrude. First, aluminum offers many unique properties, such as its high strength-to-weight ratio, corrosion resistance, and electric conductivity, to Tongue Ratio - Width of the gap vs. its depth. View or Download an Aluminum Extrusion Manual from AEC. One of the biggest mistakes designers make in alloy specification, however, stems from concerns over strength. Below are some things to keep in mind when designing your profile. Shape. In most alloys, for example, a .062-in. Why has the auto industries not thought about using Aluminum sooner? It is the most abundant metallic element, comprising about 1/12th of the earth's crust. Generally, the extrusion ratio is applicable between 10 and 150. wall is possible in a 3-in.-wide shape but not possible for one 10-in. Aluminum Extrusion Design: 6 Mistakes Designers Make and How to Avoid Them PAGE 2 Today, more and more designers across a number of industries are using aluminum extrusions in their products for two reasons. A correct extrusion press machine to be used depends on the cross-sectional dimensions of the aluminum profile. Step 6: Stretching and Cutting, A gripper is used on both ends of the extruded pieces. These include size, shape, alloy, extrusion ratio, tongue ratio . In short, the size, shape, alloy, extrusion ratio, tongue ratio, tolerance, finish, and scrap ratio are important interconnected components, all to obtain a proper extrusion process, determining the speed, temperature, extrusion pressure, and alloy needed for the request needed for a project. The alloy's properties are usually different from those of the components. We have known these qualities of Aluminum alloys for quite some time. Good Aluminum Extrusion Design Practices Balanced walls Avoid/minimize hollows The tongue ratio of an extrusion is determined as follows: square the smallest opening to the void, calculate the total area of the shape, and then divide the opening squared by the area.. The tongue ratio of an extrusion is determined as follows: square the smallest opening to the void, calculate the total area of the shape, and then divide the opening squared by the area.. Design The extrusion ratio is a numerical value indicating the difficulty of the die to achieve extrusion. Temperature Of The Billet In fact, extrusion is just one of them, we supply varied services from designing, packaging and other related requirements. If the extrusion ratio is less than 10, the mechanical properties of the product are low; If the calculated value of the tongue ratio for any gap width exceeds . Aluminum - A silver-white soft metal, noted for its lightness, high reflectivity, high thermal conductivity, nontoxicity, and corrosion resistance. This is especially true on almost the first ten feet of the extruded aluminum. . Fabrication - Expanded to include the myriad ways in which aluminum extrusions can be processed after extruding to facilitate cost savings, part-count reduction, increased product functionality, and more Microstructure - Discover how alloy grain structure is critical to achieving the needed extrusion performance for demanding applications. In fact, it takes 100,000-125,000 psi of force to push a billet through an 8" inch press. Extrusion ratio (ER) and tongue ratio (TR) are influenced by die which is a critical criterion to the extrusion processing. Tolerance - Limits of variation in which a part or product can be produced to. Extrusion Ratio - Area of the billet/area of the shape. Aging a change in properties of an aluminum alloy that generally occurs slowly at atmospheric temperatures and more rapidly at higher temperatures. The higher the ratio, the more difficult the part will be to extrude. . By using this site, you consent to the placement of these cookies. The higher the ratio, the more difficult the part will be to extrude. The higher the tongue ratio, the more complex it is going to be during the component extrusion process. Technavio reported that the worldwide aluminum extrusion demand would have a growth rate of about 4% between 2019 and 2023. Uniform wall thicknesses are less costly to extrude Rounded Fillets & Corners Rounded corners & fillets are easier to extrude than sharp ones. This also reduces the tongue ratio and it will take a second process to close the shape up which usually calls for a brake press. Narrow . Die Ring: A cylindrical sleeve that holds the die and backer in axial relationship to each other. The tongue ratio is important because the higher the tongue ratio, the more difficult a shape becomes to extrude. This stretches the piece until completely straight, then the stretched pieces are cut to normal length (approx. 1.1.1 Selection of tonnage of aluminum extrusion machine. Die lines are present to some degree in all extrusions and are caused by a roughening of the die bearing. Joining Methods Tongue Ratio Symmetry Symmetrical parts are easier to extrude Tooling Costs Lead Times Typical Lead Time for Mill Finish Extrusions: 3 weeks To put that force into context, a power washer to clean a car pushes out water at around 2,500 psi. Die, Semi-hollow: A circular steel extrusion tool which forms an open profile with a high tongue ratio. In one of the slides, light weighting from Al extrusions was shown to contribute only 15% towards meeting the 54.4 mpg, while transmission (I think) contributed 50%. The cooling process As the extruded metal leaves through the die, it's passed to a cooling table. This website uses cookies to store information on your computer. What are the problems/concerns? The tongue ratio also plays an important role in determining a part's extrusion performance. Its metallurgical construction is mechanically infirm and shapes that have an extrusion ratio below 10:1 may not have all the mechanical properties. Alloy material that has metallic properties and which is composed of two or more chemical elements, one always being metal. Multiple profile solutions It has a 35,000 psi yield strength compared to 23,000 psi for 5052 H32. Some of these features can be seen in our Inspire tool. Variety within the solution for your application. Some of these cookies are used for visitor analysis, others are essential to making our site function properly and improve the user experience. I've typically been given Area / (opening width) as the guiding equation, and that it must be 3 or less, otherwise there's a chance that the steel "finger" on the die will snap off due to the forces exerted on it during the extrusion process. Both extrusion ratio and tongue ratio cause the difficulty of extrusion processing. Alloy - Chemical composition of other elements added to pure aluminium to enhance its properties such as strength, etc. The pressure produced in an extrusion press is 20 times that amount. Thereafter, area of the entire shape is calculated then divided with the initial squared value of the tiniest opening to the void. Aluminum extrusion has been increasingly popular in product innovation and manufacturing in recent years. To accurately determine the tongue ratio, the smallest opening to the void is squared. Where possible, reduce deep narrow "tongues" by redesigning the profile. Aluminum extrusion ratio calculation formula is used for expressing aluminum alloy deformation size parameters in the production of aluminum extrusion profile, namely extrusion coefficient. Shape Constraints Avoid high tongue ratios (width of fin vs. height). Extrusion Ratio Extrusion Ratio = Area of billet / area of shape A clear indication of the amount of mechanical working that will occur as the shape is extruded Low extrusion ratios have little mechanical work hardening performed on it High extrusion ratios have more mechanical work hardening The tongue ratio of extrusion is determined as follows: square the smallest opening to the void, calculate the total area of the shape, and then divide the opening squared by the area. Aluminum extrusion must cool at a specified rate, Temperatures should be measured many times in order to ensure alloy properties met. - The "tongue ratio", shown here, shown toward the bottom of the page. Our 3" indirect extrusion presses allow us to achieve tighter tolerances, with higher consistency then traditional direct extrusion presses. (Click to enlarge) Remember that high levels of force are being applied to the die. Complex elements in aluminum extrusion design can include multiple hollows, specific geometry (such as asymmetrical profiles and high tongue ratio), transition in wall thickness, permanent and reusable snap/hinge features, as well as precision surfaces. Tongue area is the proportional area between width of the gap and its width. AEC divided all aluminum extrusions into two material groups (alloy groups A and B) and divided gap widths into certain bands. The minimum wall thickness goes up as the extrusion shape gets larger. That is products' total cross sectional area before extrusion (unit mm2) divides products' total cross sectional area after extrusion (unit mm2). As expected, the circumstance is contradictory to what happens when the ratio of extrusion is high. It is the comparison of billet area and profile area. It is never found in nature as an elemental metal, but only in combination with oxygen and other elements. Also, keep somewhat balanced wall thicknesses. It is considerably stronger than common aluminum-sheet alloys such as 5052 H32. Increasing that pressure to 5,000 psi can destroy the brick on a building. The common tonnage of aluminum extrusion press machine is 800T, 1000T, 1200T, 1800T, 2300T, 2800T, 3600T, 4000T, 5000T, and so on. 6.0-9.0 meters).