ALUMINIUM EXTRUSION AND ANODISING PLANT
[EIRI/EDPR/3773] J.C.: 1867US$
INTRODUCTION
Extrusion
Extrusion is a plastic deformation process in which a block of metal (billet) is forced to flow by compression through the die opening of a smaller cross-sectional area than that of the original billet Extrusion is an indirect-compression process. Indirect-compressive forces are developed by the reaction of the workpiece (billet) with the container and die; these forces reach high values. The reaction of the billet with the container and die results in high compressive stresses that are effective in reducing the cracking of the billet material during primary breakdown from the billet. Extrusion is the best method for breaking down the cast structure of the billet because the billet is subjected to compressive forces only.
Extrusion can be cold or hot, depending on the alloy and the method used. In hot extrusion, the billet is preheated to facilitate plastic deformation
Factors Affecting Extrusion
Shape is a determining factor in the part's cost and ease with which it can be extruded. In extrusion a wide variety of shapes can be extruded, but there are limiting factors to be considered. These include size, shape, alloy, extrusion ratio, tongue ratio, tolerance, finish, factor, and scrap ratio. If a part is beyond the limits of these factors, it cannot be extruded successfully.
The size, shape, alloy, extrusion ratio, tongue ratio, tolerance, finish, and scrap ratio are interrelated in the extrusion process as are extrusion speed, temperature of the billet, extrusion pressure and the alloy being extruded.
In general, extrusion speed varies directly with metal temperature and pressure developed within the container. Temperature and pressure are limited by the alloy used and the shape being extruded. For example, lower extrusion temperatures will usually produce shapes with better quality surfaces and more accurate dimensions. Lower temperatures require higher pressures. Sometimes, because of pressure limitations, a point is reached where it is impossible to extrude a shape through a given press.
COST ESTIMATION
Plant Capacity 10 MT/Day
Land & Building (10,000 sq.mt.) US$ 7.83 Lac
Plant & Machinery US$ 11.30 Lac
Working Capital for 2 Months US$ 12.67 Lac
Total Capital Investment US$ 33.82 Lac
Rate of Return 33%
Break Even Point 55%
CONTENTS
INTRODUCTION
EXTRUSION
FACTORS AFFECTING EXTRUSION
ADVANTAGES OF THE EXTRUSION PROCESS:
TYPES OF EXTRUDED PROFILES
CLASSIFICATION OF ALUMINIUM EXTRUSION
TRADITIONALLY, THE PROCESS HAS BEEN DESCRIBED AS HAVING THREE DISTINCT REGIONS
(B) INDIRECT (BACKWARD) EXTRUSION
(C) HOT EXTRUSION
(D) COLD EXTRUSION AND WARM EXTRUSION
PROPERTIES
PROPERTIES OF ALUMINIUM
WEIGHT
STRENGTH
LINEAR EXPANSION
MACHINING
FORMABILITY
CONDUCTIVITY
JOINING
REFLECTIVITY
SCREENING EMC
CORROSION RESISTANCE
NON-MAGNETIC MATERIAL
ZERO TOXICITY
ANODIZING OF ALUMINUM
WHAT IS ANODISING?
PURPOSE OF ANODIZING
TYPES OF ANODISING
TYPE-I-CHROMIC ACID ANODISING
TYPE-II-SULPHURIC ACID ANODISING
TYPE-III-HARD ANODISING
USES AND APPLICATION
USES
APPLICATION
APPLICATIONS OF EXTRUDED ALUMINUM
B.I.S. SPECIFICATION
PROCESS FLOW CHART
(A) FOR EXTRUSION
(B) FOR ANODISING
MANUFACTURING PROCESS
(A) FOR EXTRUSION
DESCRIPTION OF PROCESS
(1) BILLET PREHEATING
TABLE 1 TYPICAL BILLET TEMPERATURES OF SOFT AND MEDIUM-GRADE ALUMINUM ALLOYS
TABLE 2 TYPICAL BILLET TEMPERATURES OF HARD ALUMINUM ALLOYS
(2) EXTRUSION
(3) QUENCHING
(4) STRETCHING
(5) CUTOFF
(6) ARTIFICIAL AGING
TABLE 3 TYPICAL HEAT TREATMENT PARAMETERS OF SOME 6XXX ALLOYS
(7) INSPECTION AND TESTING
EXTRUSION MATERIALS INSPECTION
ALUMINUM ALLOY CHECK
EXTRUSION DYE CHECK
ADDITIVES CHECK
EXTRUSION VISUAL INSPECTION
VISUAL DEFECTS CHECK
COLOR AND GLOSSINESS CHECK
DIMENSIONAL INSPECTION
COATING AND FINISHING CHECK
WEIGHT AND DENSITY CHECK
EXTRUSION PERFORMANCE INSPECTION
TENSILE TEST
WELDABILITY CHECK
WORKABILITY CHECK
CORROSION RESISTANCE
FLAMMABILITY TESTING
HARDNESS TEST
WEATHERING RESISTANCE TESTING
ABRASION RESISTANCE
CHEMICAL RESISTANCE
DESCRIPTION OF EXTRUSION PRESS
(B) ANODISING
(1) SURFACE PREPARATION
TECHNOLOGIES OF SURFACE PREPARATION
A. MECHANICAL CLEANING
G. ANODIC ELECTROCLEANING (REVERSE ELECTROCLEANING).
H. PERIODIC-REVERSE ELECTROCLEANING.
I. ACID ACTIVATION.
(2) ANODISING PROCESS
(A) CHROMIC ACID ANODIZING, I.E., TYPE 1
A CHROMIC ACID ANODIZING SOLUTION SHOULD NOT BE USED UNLESS:
(B) CONVENTIONAL SULFURIC ACID ANODIZING, I.E., TYPE 2
(D) HARDCOAT ANODIZING, I.E., TYPE 3
ANODIZING EQUIPMENT AND PROCESS CONTROL
(A) FOR CHROMIC ACID ANODIZING.
(B) FOR SULFURIC ACID ANODIZING.
(C) FOR HARD ANODIZING.
POWER REQUIREMENTS FOR THE PRINCIPAL ANODIZING PROCESSES ARE AS FOLLOWS:
(A) FOR CROMIC ACID ANODISING
(B) FOR SULFURIC ACICD ANODISING
(C) FOR HARD COAT ANODISING
(3) RACKING PROCESS
(4) SEALING PROCESS
(5) COLOURING PROCESS
MARKET POSITION
THE GROWING DEMAND OF ALUMINIUM EXTRUSIONS
ALUMINIUM EXTRUSIONS - THE PROS AND CONS
THE PLAYERS
THE FUTURE
SPREADING AWARENESS
FUTURE OUTLOOK
THE SCENARIO OF THE ALUMINUM EXTRUSION INDUSTRY
FUTURE OUTLOOK
CHALLENGES IN THE INDIAN EXTRUSIONS MARKE
RISKS AND AREAS OF CONCERN
PRESENT MANUFACTURERS
ALUMINIUM EXTRUSION SECTIONS
SUPPLIERS OF ALUMINIUM PROFILE
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ALUMINIUM ALLOY BILLET
SUPPLIERS OF DEGREASING CHEMICAL
SUPPLIERS OF PICKLING CHEMICALS
SUPPLIERS OF OIL AND GREASE
SUPPLIERS OF ANODISING MATERIAL
SUPPLIERS OF CAUSTIC SODA
SUPPLIERS OF HYDROCLORIC ACID
SUPPLIERS OF ZINC AMONIUM CLORIDE
SUPPLIERS OF SULFURIC ACID
SUPPLIERS OF CHROME SALT AND CHROMIC ACID
SUPPLIERS OF PLANT AND MACHINERY
CHINA SUPPLIERS FOR ALUMINIUM EXTRUSION AND ANODISING PLANT
INDIAN SUPPLIERS OF ALUMINIUM EXTRUSION PLANT
SUPPLIERS OF EOT CRANE
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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