With the increasing adoption of aluminum profiles across various industries, the complexity of profile cross-sections and dimensions continues to grow. Aluminum extrusion press machine, as key equipment in aluminum product manufacturing, significantly impact the surface quality and dimensional precision of aluminum profiles. A high-quality extrusion press can bring substantial economic benefits to enterprises. As the industry trends toward larger-scale and automated presses, selecting the right equipment has become a crucial challenge for manufacturers. Below are some practical guidelines to assist in choosing the most suitable Extrusion press, using Huanan Heavy Industry Technology Co., Ltd. as an example.

1. Choose Based on Machine Type

Extrusion presses can be categorized by their structure, transmission method, and functional purpose. Common types include hydraulic, oil-hydraulic, vertical, horizontal, forward extrusion, and backward extrusion presses. When selecting the appropriate type, consider the specific aluminum alloy and its intended application. For instance, a forward single-action horizontal press is ideal for extruding 6063-T5 industrial aluminum profiles, while a forward double-action horizontal press suits soft alloy tubing. Enterprises should choose based on their production needs and budget. In industrial production, forward single-action horizontal hydraulic extrusion press machine are the most widely used.

2. Choose Based on Extrusion Capacity

After deciding on the type, the next step is to determine the press's extrusion capacity. Extrusion presses are classified as heavy-duty, large, medium, or small based on their force capacity. For example, a 7500-ton hydraulic press is heavy-duty, a 4000-ton press is large, a 2500-ton press is medium, and presses under 1000 tons are small. The required extrusion capacity is calculated based on production conditions, technical capabilities, and market demands. Parameters such as annual production hours and hourly output must be considered.
The size and complexity of the profile cross-section, as well as the alloy composition, dictate the required extrusion force. For example, standard aluminum profiles typically require 250-400 MPa, hollow profiles need 450-1000 MPa, while pure aluminum requires a lower force of 150-250 MPa. Additionally, the extrusion method impacts the force required—forward extrusion generally demands 1/3 more force than backward extrusion.

3. Choose Based on Equipment Grade

Once the type and capacity are decided, the next step is to select the appropriate grade of extrusion press. This choice should align with the manufacturer’s product positioning and budget. For mid-range aluminum profiles, domestic extrusion presses are a cost-effective option. However, for high-end products, investing in imported equipment may be necessary.
Regardless of the grade, the decision should be practical and economically sound. For instance, if your production focuses on mid-range profiles, there’s no need to opt for high-cost imported presses from Germany. Not only is the initial investment significantly higher, but maintenance and operational costs also increase, potentially impacting production schedules. It’s essential to evaluate all aspects comprehensively and choose Aluminum extrusion equipment that fits your operational needs and financial capacity.

By following these principles, aluminum profile manufacturers can make informed decisions, ensuring efficiency and quality while optimizing costs.

An aluminum extrusion machine is a commonly used industrial device for shaping aluminum alloys into various profiles through the extrusion process. Understanding its working principle and structure is crucial for optimizing extrusion and profile production.

Working Principle of the Aluminum Extrusion Machine

The aluminum extrusion machine typically consists of several key components

1 Heating System
The heating system heats the aluminum alloy to the appropriate extrusion temperature before it is fed into the extrusion chamber. This system commonly uses electric or gas heating to achieve the desired temperature for efficient processing.

 2 Extrusion Chamber
The extrusion chamber contains a mold cavity, or die, with the desired cross-sectional shape of the aluminum profile. Inside the chamber, aluminum alloy is fed and pressed through the die, forming the required profile.

3 Feeding and Pressing System
Aluminum alloy is introduced into the extrusion chamber through a feeding system. A piston or screw mechanism applies pressure to force the aluminum through the die, shaping it into the desired profile.

4 Cooling System
A cooling system rapidly cools the extruded aluminum profile to maintain its shape and ensure its performance. This step prepares the profile for subsequent processing and treatment.

 

Key Considerations in the Extrusion Process

1 Temperature Control
Maintaining the correct heating temperature is essential for ensuring the aluminum alloy has the right plasticity, making it easier to extrude.

2 Chamber and Die Design
The design of the extrusion chamber and die plays a critical role in achieving the desired profile shape. Proper design ensures uniform filling of the aluminum alloy in the die and maintains the stability of the profile's geometry during the process.

3 Cooling Efficiency
The cooling system significantly affects the quality and properties of the extruded profile. Proper cooling speed prevents deformation, cracks, or other defects, ensuring the final product's durability and performance.

In summary, understanding the aluminum extruder structure and working principle allows manufacturers to optimize the extrusion process and produce high-quality aluminum profiles efficiently.

 

                               What materials can be extruded using an aluminum extrusion machine?

Extrusion casting, also known as liquid die forging, involves completing the filling, solidification, and shrinkage compensation processes under pressure, which refines the grain size, improves the microstructure, and controls casting defects.

The most significant feature of extrusion casting compared to other solid-liquid forming methods is high-pressure solidification and crystallization. The process is highly adaptable and suitable for producing multi-alloy systems, including both cast and forged aluminum alloys. It is also effective for creating complex-shaped, thick-walled, and large-cast parts. The process is simple and can be easily automated. Extrusion castings have excellent microstructural quality, with fine grains, compact microstructures, low porosity, and superior mechanical properties. The castings can undergo solid solution and aging treatments, offering high surface quality and dimensional accuracy. Due to these advantages, extrusion casting has largely replaced other forming methods in the production of precision, high-quality castings and parts that meet special performance requirements, such as high strength, toughness, wear resistance, and gas-tightness, in industries like automotive, telecommunications, high-speed rail, and power generation.

Alloy materials play a crucial role in determining process parameters and directly influencing the service life of molds. Currently, aluminum alloys and aluminum-based composites are the focus of extrusion casting materials. Among them, Al-Si, Al-Cu, and Al-Zn series aluminum alloys are the most widely used, with the research on Al-Si alloys being the most developed due to their excellent casting properties. Key factors such as filling ability, hot crack sensitivity, and shrinkage compensation ability are critical indicators of alloy performance in casting processes. It has been found that extrusion casting exhibits strong adaptability to aluminum alloys, with relatively low requirements for the alloy’s processability—emphasizing instead the alloy’s end-use performance. To meet specific performance requirements like high strength, toughness, wear resistance, corrosion resistance, fatigue resistance, and creep resistance, the development of dedicated extrusion casting alloys is essential.

Expanding the application range of aluminum alloy extrusion casting technology and improving casting quality remain enduring themes in the development of this field. Huanan Heavy Industry Technology Co., Ltd, Our company has made significant progress in Aluminum extrusion machine, tooling, process control, and numerical simulation technologies. The direction of extrusion casting products is moving towards larger, more complex designs, with greater emphasis on controlling temperature and stress fields to reduce casting defects. We have made breakthroughs in both equipment and process areas to support this development.

 

                                           Aluminum Extrusion press for prestressed composite frames

A solid extruder structure is a prerequisite for ensuring the performance of the extruder. After being used for a period of time, many Aluminum extrusion machine become loose, the interfaces age, and the cylinders bend, resulting in deformation and unstable quality during the aluminum extrusion production process. In fact, the main reason is that the extruder as a whole is not strong enough.

The stress during the operation of the extruder is very large, and our extruders mostly adopt a prestressed composite frame structure, which is composed of a high-thickness integral front beam, a high-thickness rear beam, and a square prestressed sleeve to form a closed The prestressed composite frame uses a special hydraulic preloading tool to apply an overpressure tensile load to the entire length of the tie rod, and at the same time applies compressive stress to the pressure sleeve, so that the entire frame is in a stress pretightened state, and the tension column prestress is 115% of the maximum load. above. For example, our 7500-ton hydraulic extrusion press has a front beam thickness of 1950mm made of ZG35Mn, a rear beam thickness of 1800mm (material ZG35Mn), and a square pre-applied sleeve (material ZG35). It can make it bear force better, which is also an important reason for the long service life of the extrusion machine.

 

Other advantages of prestressed composite frames

1. The center distance of the four stressed tie rods of the frame is symmetrical to the center of the press, so that the entire frame is stressed evenly. The main reason why the quality of aluminum materials produced is stable or unstable is whether the force is uniform. Only by maintaining uniform force can the overall density of the aluminum material be uniform, thereby improving the accuracy of extruded products.

 

2. The prestressed composite frame frame has a larger bending section, which makes the frame elongation and bending deformation smaller under the action of extrusion force. Therefore, the extrusion beam and the lower part of the extrusion tube can be fixed on the lower frame. The horizontal and vertical guide rails are very convenient for centering adjustment between the extrusion beam, extrusion barrel and mold. The upper frame can be used as an X-shaped moving guide rail for the extrusion barrel. On the premise of ensuring the stability of the machinery, the available space is used to reduce the space occupancy of the machinery.

 

3. There are two sets of elastic anchoring devices and foundation anchors on the lower part of the rear beam to make the rear beam fixed reliably.

 

After many years of production experience and continuous improvement based on customer feedback, our extrusion press is currently one of the most stable extruders on the Chinese market and one of the longest-lasting Aluminum extrusion machine.

 

 

Extrusion oil and cutting fluids are essential components in the aluminum extrusion machine and deep processing of aluminum profiles. With the increasing demand for high-precision metal processing in the manufacturing industry, metalworking fluids are evolving towards being more environmentally friendly, of higher quality, and technologically advanced. For aluminum extrusion machines, which are large-scale equipment, the comprehensive performance requirements of hydraulic oil are very stringent. Poor-quality hydraulic oil can disrupt normal equipment operation, leading to production line stoppages and significantly impacting the economic benefits of the entire workshop.

 

Just as engine oil is crucial to the functioning of a car, hydraulic oil is vital to the machinery. It is imperative to further reduce the friction coefficient of hydraulic oil, which will enhance the efficiency and stability of the extrusion press.

 

Our aluminum extrusion machines have very stringent requirements regarding hydraulic oil and hydraulic systems. We use the most advanced hydraulic oil and systems in the industry. The pump station of the extrusion machine features an integrated design, centrally located at the rear bottom of the machine's oil tank. The system uses imported German Rexroth (Bosch Rexroth) electro-hydraulic proportional control axial piston variable pumps and a domestic stainless steel plate-type circulating filtration cooling system. The pipeline system is designed with necessary buffering and anti-vibration measures, such as buffer pads, flexible hoses, or vibration absorbers, and employs flexible rubber joints to absorb vibrations.

 

Isolation control valves are designed between the oil pump groups to ensure that when two mechanisms need to operate simultaneously according to the program, they do not interfere with each other. The system can achieve pump isolation, no-load start, pressure regulation, and overload protection functions. The pump head electro-hydraulic proportional valve and electronic control device are imported with the main pump and connected to the main control computer of the aluminum extruder, allowing for integrated control.

 

As one of the most critical components of the Aluminum extrusion machine, Huananmachine ensure the highest quality standards for our hydraulic oil system. This rigorous quality assurance is a key reason we confidently guarantee the quality to our customers.

You may be curious about how aluminum is made. From aluminum bars to the aluminum we commonly see, it has to go through a variety of processes and is made by a variety of equipment. Below we will introduce several of the most common aluminum production machinery and equipment.

1, Automatic Multi- Billet Hot Shears Furnace. The original aluminum billet is several meters long, which requires the aluminum billet to be cut and heated before the heated aluminum billett can be extruded. Automatic multi aluminum billet hot shears furnace is the newest production equipment which combine heating engineering ,mechanism ,automatic control system , hydraulic , photoelectric and thermometry in one .It is consist of aluminum bar feeding drive transport rack ,furnace ,hot shears, electricity control system and so on .

 

 

2, Aluminum extrusion machine. This is a machine that makes aluminum billet into basic aluminum Profile materials. The heated aluminum bar (the length of the aluminum bar is less than half a meter) is squeezed by strong hydraulic pressure. When the aluminum billet is squeezed by the extrusion pressure and passes through the small hole of the mold, the basic aluminum material can be formed.

 

3, Infrared Die Heating Furnace. Before placing the die into the aluminum extruder, the die needs to be heated. Infrared die heating furnace use iron aluminum alloy wire ,features: high efficiency and energy saving. There installed infrared radiation plate behind of the iron aluminium alloy wire which can reflect heat back to the furnace effectively , radiation plate, iron aluminum alloy wire composed of a set of infrared heater, the heating way is first radiate the heating energy in form of electromagnetic energy to the furnace hearth,then the mold absorb the electromagnetic energy and converted into heat energy.

 

 

4, Automatic Double Puller (Three Heads).This machine is used to extrusion profile traction and cutting operation. The aluminum coming out of the aluminum extruder needs to be pulled and cut to length and placed.The profile is led out of the mold cavity straightly and cooled under tension, preventing the profile from being uneven in length, hanging, or twisting, thereby improving the quality of the aluminum material.

 

 

5,Handling Table Production Line. The main function is to place and cool the aluminum. The temperature of the aluminum coming out of the extruder is relatively high and needs to be cooled naturally before the next step of processing.

 

 

6, Aluminium Profile Double Doors Ageing Furnace. Aluminum profile ageing furnace is the equipment in the process of aluminum profile heat treatment. The extruded aluminum profile needs aging heat treatment before it undering electrophoretic polishing and oxidation surface treatment technology. Aging of aluminum profile is one of the key processes of heat treatment. The heating rate and the uniformity of furnace temperature are strictly required in this process, and the aging temperature of the process is mostly (210 ±5) ℃.

 

 

In addition to the above important aluminum production equipment, there are some frequently used equipment, such as: Nitriding Furnace, Film Laminating Machine, Wrapping Machine, Hot top Casting table. 

What to Consider When Purchasing an Extrusion Machine

Many customers are purchasing an Aluminum Extrusion Machine for the first time and may not know what type of machine they should buy or what preparations need to be made.

Before purchasing an aluminum extrusion machine, it is important to know the size of the aluminum profiles you intend to produce. Different sizes require different types of extrusion machines. For example, if you are planning to produce standard window and door profiles, an extrusion machine with a capacity of 1100 to 1500 tons should suffice.

It's assumed that you have already prepared a floor plan for your factory before purchasing the extrusion machine. If you are setting up a new factory, it's even better. Our engineers can assist in planning the layout of the factory, including where to place the extrusion machine, the cutting machine, and other related equipment. It's advisable to follow the engineers' recommendations, as they have years of experience in planning and can help you make the most efficient use of your factory space.

The time from placing an order to the completion of the product usually ranges from 3 to 8 months, depending on the size of the extrusion machine. The larger the machine, the more time it will take to produce. Shipping from the factory to the customer’s location typically takes about a month, and the number of containers required for transportation, which ranges from 1 to 3, depends on the size of the machine.

Some customers may worry about the installation and after-sales service of the product. There is no need to worry about this. Our factory will send two workers to the customer’s location to install the machine, even for overseas customers. The installation process usually takes about a month, during which the customer’s factory staff will need to cooperate with our workers to complete the installation. We will ensure that the machine operates smoothly.

Therefore, the time required from placing the order to the machine’s normal operation typically ranges from 5 to 10 months. Customers can use this timeline as a reference to plan their schedules, prepare for the purchase of aluminum production machinery, and minimize any potential time wastage. Huananmachine is a professional aluminum extrusion machine manufacturer,get more details from us quickly!

The 75MN horizontal short-stroke front-loading single-action aluminum alloy profile extrusion machine adopts a horizontal three-beam and four-column prestressed composite frame structure, a forward extrusion method, direct drive by an oil pump, and is equipped with advanced foreign electromechanical and hydraulic control components and systems, and The complete set of mechanized auxiliary equipment adopts PLC and computer two-level control to accurately control the speed, position and pressure of the press. The technology used embodies the development trend and advanced technology level of contemporary extrusion presses, and is suitable for production. Manufacturing, operation and maintenance are conducive to improving production efficiency and reducing usage costs.

Prestressed composite frame

The stress-bearing frame of the Aluminum extrusion machine body consists of an integral front beam ZG35Mn (thickness 1950mm) and a rear beam thickness 1800mm (materialZG35Mn), square prestressed sleeve (material ZG35) is a closed prestressed composite frame. Special hydraulic preloading tools are used to pull the An over-pressure tensile load is applied to the entire length of the rod, and compressive stress is applied to the pressure sleeve at the same time, so that the entire frame is in a stress pre-tightened state.The column prestress is above 115% of the maximum load.

(1) The center distance of the four stressed tie rods of the frame is symmetrical to the center of the press, so that the entire frame is stressed evenly. This can increase the squeeze

Accuracy of pressed products.

(2) Since the frame has a large bending resistance section, under the action of extrusion force, the frame elongation and bending deformation are small, so it is the frame can be fixed with horizontal and vertical guide rails at the bottom of the extrusion beam and extrusion barrel.

The centering adjustment is very convenient, and the upper frame can be used as an X-shaped moving guide rail for the extrusion barrel.

(3) There are two sets of elastic anchoring devices and foundation anchors at the lower part of the rear beam to make the rear beam fixed reliably.

Main working cylinder/side cylinder

1. The main working cylinder of aluminum extrusion press is a plunger cylinder, which is fixed to the center of the rear beam through four pressing blocks. The plunger diameter is Φ1740mm, and the medium pressure is 28Mpa. Under the action, it can produce 66.55MN extrusion force. The cylinder body is made of 20MnMo forged steel. After forging and tempering treatment in three sections, it is buried Arc narrow gap welding, processed according to GB\T6402\2008 II level flaw detection. The main plunger is made of forged steel. The outer surface Stainless steel cladding is welded to 2Cr13 with medium frequency treatment, surface hardness is HRC46~48, and polishing degree is 0.2um. V-ring used for master cylinder seal Combined seal, using copper sleeve inner guide

2. The two main side cylinders are horizontally fixed on both sides of the rear beam main working cylinder. The diameter of the side cylinder is Φ450/Φ320mm, which generates an extrusion force of 8.9MN and a return force of 4.4MN, which can realize the rapid forward, backward and extrusion of the main plunger. The cylinder block and piston rod are made of 45 forged steel quenched and tempered. The two-way seal and piston rod seal of the combined piston head adopt V-ring combined seals, and are guided by copper sleeves.

Hydraulic transmission and control system pump station

The pump station of the Aluminum extrusion press adopts an integrated design and is centrally arranged under the rear part of the oil tank of the press. It is composed of an imported German Rexroth electro-hydraulic proportional control axial piston variable pump and a Chinese-made stainless steel plate circulation filtration and cooling system. The piping system design adopts necessary buffering and anti-shock measures, such as cushioning pads, hoses or shock-absorbing hoses, and flexible rubber pipe joints that can absorb vibration. The main system consists of 10 355L/min plunger pumps and 10 320L/min vane pumps from the German REXROTH company. They are designed to be arranged and matched in a certain combination. They can generate a pressure of 28Mpa and a flow rate of 3350L/min to meet the needs of main and side work. According to the cylinder operating speed requirements, closed-loop adjustment of the extrusion speed of 0~21mm/s is achieved, and the extrusion barrel locking cylinder is matched with a dedicated oil pump. Isolation control valves are designed between each oil pump group. If the two mechanisms need to operate at the same time according to the program, they can not interfere with each other. It can realize functions such as isolation between pumps, no-load starting, pressure regulation and overload protection. The pump head electro-hydraulic proportional valve and electronic control device are imported with the main pump and connected with the press main control computer to achieve online control. The main oil cylinder, auxiliary oil cylinder, spindle cylinder, and scissor oil cylinder are integratedly controlled by logic valves. The sliding mold and supporting frame are integratedly controlled by three-position four-way electro-hydraulic reversing valves. Main hydraulic components: master cylinder reversing surface valve, overflow surface valves etc. The main control system oil pump station has a total flow rate of 3350L/min, and its oil pumps are individually controlled.

The design of each aluminum extrusion machine is to maximize the use of resources under the premise of ensuring quality, and has been in a leading position in the industry.