Reduce costs with aluminium prototypes

Using the electrical discharge machining process to produce your prototype in aluminium will help you avoid costly mistakes.

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The ability to make a prototype through three-dimensional printing, computer numerical control – or, CNC – machining and other means has been revolutionary for manufacturing. Being able to test and trial a product or piece before it enters production saves materials, time and money.

Having prototypes in plastic and other materials are helpful, but there is a clear advantage in being able to make a prototype in the same material that you want to use for your product.

Fully functional prototypes

With electrical discharge machining (EDM), fully functioning prototypes can be made in aluminium. These provide an accurate representation of how your final aluminium parts will turn out.

EDM is an industrial process that uses spark erosion to cut conductive metals. For a rough idea of how EDM works, picture a wire cheese slicer that cuts through a block of aluminium rather than a slab of cheese. The electrically charged wire cuts the material and as it sparks, it erodes the metal away.

Hydro has applied this process to making aluminium prototypes for customers. Why?

• Prototypes are cut from aluminium and perform like a production extrusion for precise validation of fit, form and function
• They can be done quickly, within a week
• There is no need to purchase a die or order a minimum of material to validate a part
• Tight dimensional control allows for evaluation of production tolerances
• Aluminium prototypes can be cut, welded, drilled or ground, and will respond within a few percentage points of how the final product will respond
• The precise wire EDM machine can cut delicate or thin parts that are dimensionally accurate
• They offer the ability to produce features on a part and test how they interact with another extrusion, bolts or parts

Additional Cost-Saving Benefits of Aluminium Prototypes

Beyond the immediate advantages mentioned, there are several extended benefits you'll appreciate when adopting aluminium prototypes:

• Material Efficiency: Aluminium allows for recycling and reusing scraps, reducing waste and costs.
• Lower Shipping Costs: Aluminium's lighter weight compared to other metals can lead to significant savings in transportation expenses.
• Enhanced Product Development: By simulating the exact conditions your product will face, you can foresee and correct potential manufacturing issues early, saving on costly overhauls or recalls.

Interchangeability and Consistency

Consistency is a cornerstone of quality production. Aluminium prototypes ensure that every part will closely mirror the amount and behavior of production components. This is especially crucial for complex assemblies where precise fitting is necessary.

Interested in learning more?

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How To Further Know About Aluminum Extrusion Process

Over the years, aluminum extrusion has been a unique aspect of product innovation. Manufacturers use the method in designing various workpieces for workplaces or homes. Most people hardly notice aluminum parts made from extrusion. At Creatingway, we use the procedure in various applications to obtain superb results. Here is an article about the aluminum extrusion process and its importance to your product.

How To Define Aluminum Extrusion Process?

Aluminum Extrusion is melting and pushing aluminum alloy into a die with a given cross-sectional shape. What pushes the alloy is a firm ram that also pulls it along a runout table. By modifying the die’s opening, you can create multiple shapes and sizes according to your liking. The amount of force used in aluminum extrusion is the same as compressing a tube of toothpaste. The opening is a solid circle, and the extrusion always comes out as a long solid.

What Are The Techniques Used in Aluminum Extrusion?

Indirect Extrusion

The method involves heated aluminum and the container moving concurrently as the die sticks to its position. Machinists occasionally use a “stem” during the operation. Whereby the container’s length is shorter than that of the stem. Such a design forces aluminum billet through the stationary die.

The direct extrusion method creates greater friction than the backward extrusion. Therefore machinists use backward extrusion to control the heat much better. A steady temperature allows the creation of better mechanical features and better grain structure. You can achieve greater product quality, making indirect extrusion dependable.

Direct Extrusion

The direct aluminum extrusion process is the most used form of aluminum extrusion method by machinists. The heated walls push the workpiece through the die by placing the heated aluminum in a container. This major step generates a high amount of pressure. Contact prevention between the billet and the ram, place material blocks between them. When the ram and aluminum move forward in the same direction is known as direct/forward extrusion.

The Various Shapes That are Extruded

In terms of shapes, aluminum extrusion possesses unlimited capabilities. However, various sizes and specifications limit the limitless capabilities. Here are the main categories found on extrusion shapes;

• Solid shapes: some include rods and solid bars with varying cross-sections. Examples are circles, squares, and rectangles.
• Semi-solid shapes: examples of such shapes are angles, channels, and partly opened shapes.
• Custom Aluminum Extrusion Shapes: such shapes contain several extrusions. Additionally, they have multiple color profiles with interlocking shapes. All shapes are according to the designers’ specifications.
• Hollow shapes involve shapes like profiles or tubes with varying cross-sections. Some examples include squares, rectangles, and circles.

What Are Steps Followed in Aluminum Extrusion Process?

Ready the Extrusion Die

It is vital to start by making a round-shaped die or using an existing one. Then, preheat the die to 450-5000C before starting the extrusion procedure. Preheating allows metal the o move through evenly, improving the die’s lifespan.

Pre-Heat the Aluminum Billet

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This step requires cutting the cylindrical billet and preheat in an oven. Preheating helps prepare the billet by making it malleable but not molten.

Transfer the Billet to the Extrusion Press

After preheating the billet, transfer it into the press mechanically. Before filling the billet into the press, add a lubricant. Also, ensure there’s a release agent in an extrusion ram. All the additions help prevent the ram and billet from joining together. Once the malleable billet is ready, pass it through an extrusion press. Whereby a hydraulic ram applies 15,000 tons of pressure on the workpiece. The extreme pressure forces the malleable item into the container.

The Extruded Material Presses Against the Die

At the container’s walls, aluminum material fills as it gets pressed against the extrusion die. For this step to prosper, the material needs to be constantly pressed. In turn, the extruded billet emerges through the die opening.

Secure the Extrusion

A puller helps hold the extrusion in place during press exiting. As it leaves the press, the alloy quenches as it moves across the table. A fan or water cools the profile evenly.

Cut the Extrusion to the Table Length

Level the aluminum extrusion process to the table length using a hot saw. Take note of the temperature, as the material hasn’t fully cooled off yet.

Reduce the Extrusion temperature

After the shearing process, cool the extrusion to room temperature. The cooling is achievable by moving the material to a cooling plain. Once you obtain the room temperature, stretching begins.

Move the Extrusions to the Stretcher

In this step, you may notice some twists that need correcting. A stretcher helps repair the deformity by holding the ends of the profile and pulling them till they straighten.

Move the Extrusion to the Finish Saw and Cut Them Evenly

Once the extrusions are straightened and hardened, move them across the saw table. The length they are cut depends on the manufacturers’ liking.

Practice Heat Treatment, Surface Finish, and Fabrication

The properties of the profiles enhance depending on the finish of the extrusion procedure. Heat treatment and fabrication allow the alteration of features improving product quality. As for surface finishing, it improves corrosion resistance and aesthetics.

What Services You Can Get From Creatingway?

Fabricating various products with different shapes requires a reliable process, like the aluminum extrusion process. The procedure helps in making complex or simple shapes with splendid product properties. Additionally, the process allows the use of other after-finish services to improve the aspects of your product. At Creatingway, we use the aluminum extrusion process to obtain the desired shape and outcome. Contact us when dealing with products requiring aluminum extrusion to obtain better services and advice.

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