Mold opening for ultra large section aluminum profiles

Ultra-large cross-section aluminum profiles are a technological high ground in the field of industrial aluminum profiles. Unlike conventional profiles, ultra-large cross-section profiles typically have a circumscribed circle diameter of ≥600mm and a meter weight of ≥30kg/m. Their requirements for extrusion equipment tonnage, die design, and metal flow rate control are much higher than those of conventional profiles. With the rapid development of industries such as large equipment, rail transit, and new energy, the market demand for ultra-large cross-section, high-precision, and lightweight aluminum profiles continues to grow.

Shanghai Chuansi Aluminum focuses on the core requirements of "ultra-large cross-section, high strength, high precision, and one-time molding" for ultra-large cross-section aluminum profiles, providing one-stop services for the entire process, from cross-sectional structure design, mold development, and 12,000-ton large-tonnage extrusion molding (cooperative production line) to CNC precision machining, welding, and assembly.

01 Quality starts with raw materials

It is produced using A00 virgin aluminum ingots, containing no waste aluminum, with pure materials, dense structure, and stable mechanical properties. The metal flow of ultra-large cross-section is extremely sensitive to the quality of raw materials, and virgin aluminum ingots are the foundation for ensuring the quality of extrusion forming of ultra-large cross-section profiles. Various materials such as 6061-T6 (high-strength heavy-load structure), 6063-T5 (large-section decorative/heat dissipation structure), 6005-T6 (rail transit, fatigue resistance scenarios), and 6082-T6 (large load-bearing structure) can be selected according to the stress conditions of the structural components.

02 12000T large-tonnage cooperative extrusion capacity and ultra-large cross-section forming

Relying on the cooperative production line's 12000T large-tonnage extrusion capacity, it can form 750mm-level ultra-wide cross-sections in one go without the need for segmented welding. It can produce super-large materials with a circumscribed circle diameter of 600-700mm and a meter weight of ≤80kg. Special-shaped parts with ultra-large cross-sections, multiple cavities, thin walls, large cross-sections, and significant wall thickness differences can be extruded and molded in one go, increasing the overall strength by more than 300%. The closed-loop extrusion process controls the temperature and extrusion speed, and the supporting artificial aging process fully releases internal stress.

03 High-precision CNC machining

Equipped with precision equipment such as a five-axis CNC machining center, multiple imported machine tools and an ultra-long aluminum profile machining center with a stroke of up to 6.5 meters. The machining accuracy can reach ±0.01-0.005mm, and the dimensional tolerance is stably controlled between ±0.02mm and ±0.04mm. It can complete deep processing processes such as precision cutting, end face milling, precision drilling and tapping, and large mounting surface machining of ultra-large section profiles.

04 Full-process quality control

Multiple quality control nodes are set up in the production process, from raw material spectroscopy inspection and full process inspection to finished product three-coordinate inspection, to ensure that the dimensional accuracy and mechanical properties of each batch of ultra-large cross-section profiles meet the standards. Material inspection report and dimension inspection report are provided for each batch.

Processing capacity parameters:

Typical application scenarios for ultra-large cross-section aluminum profiles:

Typical application scenarios:

• large-scale heavy-duty

• rail transit vehicle body structure

• large bridge structural member

• Heavy machinery load-bearing beam

• main beam of large conveyor line

• New energy battery tray

• large-scale energy storage equipment frame

• ship cabin structural components

• large-scale building curtain wall

• heavy-duty shelving column

• aerospace large structural components

• large mechanical equipment base

FAQ (Frequently Asked Questions)

Q1: What is the difference between ultra-large cross-section aluminum profiles and conventional aluminum profiles?

A: There are four core differences between ultra-large cross-section aluminum profiles and conventional aluminum profiles: First, the cross-sectional dimensions are different—the diameter of the circumscribed circle of ultra-large cross-section profiles is usually ≥600mm, and the meter weight is ≥30kg/m, while the circumscribed circle of conventional profiles is usually less than 200mm. Secondly, the equipment requirements are different—ultra-large cross-section profiles require a 12,000-ton large-tonnage cooperative production line extruder, while conventional profiles require 3,000-6,000 tons. Third, the difficulty of mold design varies—ultra-large section profiles have long metal flow paths and extremely uneven flow velocity distribution, requiring CAE simulation and optimization for mold design, while conventional profile mold design is relatively simple. Fourth, the application scenarios are different—ultra-large cross-section profiles are used for large heavy-duty equipment frames, rail transit vehicle bodies, etc., while conventional profiles are used for general industrial structural components. Ultra-large cross-section profiles can be formed in one go without the need for segmented welding, and the overall strength is increased by more than 300%.

Q2: How accurate can ultra-large cross-section aluminum profiles be?

A: The dimensional tolerance is stably controlled within ±0.02mm to ±0.04mm, the CNC machining accuracy is ±0.01-0.005mm, the maximum cross-sectional width is 750mm, the maximum circumscribed circle is 600-700mm, the maximum meter weight is ≤80kg, the tensile strength is ≥260MPa, and the maximum machining length is 6500mm. The specific accuracy depends on the cross-section complexity, material selection, and extrusion equipment capabilities. Large-tonnage cooperative production line extruders can ensure the density and dimensional stability of ultra-large cross-section profiles.

Q3: What are the advantages of large-tonnage cooperative production line extruders compared to conventional extruders?

A: The large-tonnage cooperative production line extruder (12000T) has three major advantages compared to conventional extruders (3000T-6000T): First, the ultra-large cross-section forming capacity - it can produce ultra-large materials with an ultra-wide cross-section of 750mm and a circumscribed circle of 700mm; Secondly, the structure is denser – the extrusion force is greater, the internal structure of the profile is denser, and the mechanical properties are more stable; Third, one-time molding without splicing – ultra-large cross-sections with multiple cavities and thin walls and large cross-sections can be extruded in one go, without the need for segmented welding, and the overall strength is increased by more than 300%.

Q4: What is the mold opening cycle and minimum order quantity for ultra-large cross-section aluminum profiles?

A: The conventional structural mold opening cycle is 10-15 days for sample production, and 15-20 days after sample confirmation for batch delivery. Supports small-batch customization. Simple large cross-section (single cavity, symmetrical structure) sampling takes 10-12 days; Multi-cavity large cross-section sampling takes 12-14 days; Thin-walled large cross-section (wall thickness ≤2mm) samples will be taken out in 14-16 days. The mold opening fee is based on H13 hot-worked mold steel. The mold life is ≥50,000 cycles. If the agreed mass production quantity is reached, the mold opening fee will be fully refunded.