【佛山铝管厂家】运营铝型材挤压厂时如何降低废料进步效益
Understanding the Extrusion Press as the Conversion Point,
Part 3: Case Study – Billet Taper Quench
怎样看待挤压成型后的废弃物造成高些的成本费（III）
经典案例：柱锭梯度方向水冷散热
David Jenista, Granco Clark, Inc
David Jenista
INTRODUCTION 前言
In our 2010 paper to the Guangdong Extruder Conference, we discussed the extrusion press as the conversion point of the extrusion process. The value added is converting billet to profile at the press. In 2012 we used the Hot Log Saw as a case study. In this paper we use the Billet Taper Quench as a case study of this concept, showing the benefit of longer billets and how to optimize production with long billets.
在2010年广东省挤压成型技术性讨论会上，大家发布了一篇毕业论文探讨了连续挤压机是挤压成型步骤的大转折。连续挤压机把废铝转化成铝型材便是给铝型材授予了使用价值。2012年大家用热锯做研究对象。文中中，大家将以“柱锭梯度方向水冷散热”做为例，科学研究在挤压成型中短锭将能产生哪些经济效益，怎么使用短锭提升生产制造。
REVIEW回望
In 2010 paper, we provided the following summary of the financial considerations associated with the extrusion plant:
1.There is a large cost associated with owning a press line. This cost falls on the PROFILE because the profile has the added value.
2.There is an operating cost for the extrusion department that also falls on the profile, because the profile is the only source of revenue. So the profile yield is very important to maximize the economic result.
3.The cost of the other departments and the company profit is also covered by the profile selling price. This cost may be more than the entire cost of the extrusion department (#1 and #2 above).
4.Decisions must be focused on the maximum shippable Kg/Hr to spread all of the cost over the most products.
在2010间的毕业论文中，大家明确提出了经营铝合金型材挤压成型厂所需考虑到的一些经济发展要素，小结以下：
1.有着一条挤压成型生产流水线要资金投入极大的成本费，资金投入成本费必须靠铝型材的售出去均衡，由于铝型材本身具备了使用价值。
2.挤压成型单位的经营成本也必须靠铝型材的售出去均衡，由于铝型材是收益的唯一来源于。因此 ，铝型材的盈利针对经济收益的利润最大化尤为重要。
3.企业别的单位的经营成本和企业的盈利一样取决于铝型材的市场价，此项支出很有可能超过全部挤压成型单位的需要成本费（以上1、2两点）。
4.做管理决策时务必以单位时间可供送货商品量Kg/Hr利润最大化做为关键总体目标，尽量地保证数最多的商品的成本费比。
CASE STUDY 经典案例
For direct extrusion presses, temperature tapering of the billet can provide significant increase in press speed without reducing profile quality and in some cases improving profile quality.
针对顺向连续挤压机而言，短锭溫度下降却能使挤压成型速率明显增强，不容易危害铝型材的品质，一些情况下还会继续提升铝型材品质。
Taper heating of the billet with an electric induction billet heater is a common practice, but the equipment is not easily and accurately adjustable for different profiles and billet lengths. import suppliers of electric induction heaters can provide a precision gradient but these units are very expensive to purchase.
用直流炉对短锭梯度方向加温是普遍的作法，但是针对应用他们并不是一件非常容易的事，尤其是要对于不一样的铝型材和针对不一样的长短的短锭必须做细致的调节。虽然進口直流炉的经销商可出示一个精准的温度场，可是要选购这种机器设备十分价格昂贵。
Electric cost causes many extruders to choose gas heating. The benefits of gas heating can be combined with the Billet Taper Quench to provide billets with a precise temperature taper.
能耗成本增加也引起许多连续挤压机挑选应用燃气加温。燃气加温的益处即融合应用柱锭梯度方向水冷散热设备可以向短锭出示精准的温度场。
The Granco Clark Billet Taper Quench provides accurate temperature tapering with adjustment from the operator console.
格兰克沃尔特斯梯度方向水冷散热设备可根据机器设备工作台出示精准的调节温度场。
Figure 1.Taper Quench processing a billet
图1 梯度方向水冷暴力短锭
TECHNICAL CONSIDERATIONS技术性考虑要素
The direct extrusion press design is the most popular design because it is simple to produce, operate and maintain. The continuous extrusion model with welding dies functions well with puller systems and other automated handling equipment.
顺向连续挤压机是广泛选用的设计方案，因为它便于生产制造、操纵应用和维修保养。它可有着一个持续挤压成型的方式，由于有柱锭焊接工艺，也有牵引带系统软件和其他自动化技术的挤压成型配套设施机器设备。
But the direct extrusion press has a thermodynamic problem. At the beginning of the cycle, the aluminum in the press container is too cold and at the end of the cycle the aluminum is too hot. The temperature change is caused by the friction in the container and the flow stress of the aluminum. The result is the aluminum is difficult to push through the die at the beginning of the cycle and the extrusion speed must be reduced at the back of the billet to prevent defects.
可是顺向连续挤压机也存有一个热学的难题。在挤压成型循环系统逐渐时废铝在压主缸太凉，在循环系统结尾时废铝又变成太热了。在压主缸的滑动摩擦力和废铝的流变性地应力造成溫度转变。其結果是，在挤压成型周期时间逐渐时废铝无法被挤压成型根据模貝，废铝后侧的挤压成型速率务必被减少，以避免挤压成型出废料。
Extruders are always seeking ways to improve production capacity. One method that extrusion press suppliers can offer is a press with a longer container. The longer container increases the ratio of live-cycle-time to dead-cycle-time, increasing the production capacity of the press. Twenty years ago the standard for maximum billet length from most extrusion press manufacturers was 400% of the billet diameter. For example, a press designed to process a 178毫米 billet would have a container that was 710Mm long. Now imported extrusion presses will have containerswith billet lengths that are 500% or greater. It is common to see a specification for a 950–100mm long container for 178毫米 billet.
连续挤压机一直在寻找方式来提升生产能力。连续挤压机经销商出示的一种方式便是出示一种长压缸连续挤压机。长压缸扩大了挤压成型時间和非挤压成型時间的比例，提升了连续挤压机的生产能力。二十年前绝大部分铝挤压成型生产商的规范是较大 的短锭长短是短锭直徑的400％，比如，设计方案一连续挤压机挤压成型178mm的短锭必须一个710mm的压缸，如今進口的连续挤压机的压缸长是短锭长短的500%或更长一些，针对178mm的短锭一般选用的是950－1000mm规格型号的压缸，已广泛由此可见。
This change is good for increasing the productive time of the press but it increases the natural thermodynamic problem with the direct extrusion press. The longer billet results in more container friction and increased heating of the back of the billet. So the benefit of tapered billets is even greater with a modern imported extrusion press.
提升了挤压成型的生产制造時间这一转变是好的，但也提升了顺向挤压成型的热学难题。短锭越长造成压缸造成更高的磨擦，促使短锭后侧的关注度提高，应用当代的進口连续挤压机可获得更强的短锭梯度方向减温的益处。
With an imported extrusion press, the extrusion speed increase will be 20% to 30% for many profiles. In our testing we found that the most difficult profiles will give the largest increase in speed.Many profiles with thin walls using industrial alloys will have speed increases much greater than 30%.
针对许多铝型材应用進口的连续挤压机可提升挤压成型速率20－30%。在大家的检测中，大家发觉绝大部分无法挤压成型的铝型材在挤压成型速率上都是有巨大的提升。许多选用工业生产铝合金型材厚壁的铝合金型材的挤压成型速率已提升了30%。
When combined with a Granco Clark “Hot Jet” gas furnace, this taper quench solution is less expensive to purchase and lower cost to operate than an imported electric induction heater with precision taper heating.
当与格兰克沃尔特斯热喷涌天然气热处理炉一起应用时，其梯度方向水冷散热解决方法要比具备精准梯度方向加温的進口直流炉的选购价格低，经营成本更低。
The Granco Clark Taper Quench has the following features and specifications:
The Taper Quench is located after the billet furnace and before the press loader.
The unit provides temperature gradients of up to 140C0.
The variation of the taper is less than 10C0.
The operator can select which portion of the billet will be tapered.
Quench does not limit the throughput of the system.
格兰克沃尔特斯梯度方向水冷散热具备特性规格型号以下：
梯度方向水冷散热设备安裝在柱锭热处理炉以后和短锭运输台以前。
梯度方向水冷散热可出示了达到140 C0的温度场。
梯度方向转变范畴在10 C0以内。
操作工可挑选对某一部分的短锭开展温度场下降。
热处理沒有系统对的生产量有一切限定。
FINANCIAL CONSIDERATIONS经济发展考虑要素
The most important economic issue is the higher production rate. The added benefits of reduced profile defects and protecting the extrusion die from overheating are not calculated in this financial analysis.
最重要经济发展的难题便是高些的生产效率。降低铝型材残品和维护超温的冲压模具的经济效益并沒有测算在本财务报表分析中。
This is an example of the calculation for the costs of profile production:
Profile cost per ton:
The cost of profile productionis from the 2010 Conference paper. The profile cost is dependent on production rate, so our assumptionwill be 1.2 ton/hr and 6000 hr/yr production time.In the 2010 conference paper, our sample showed the cost of ownership was RMB 1200/hr, the cost of overhead was RMB 660/hr, the cost of operation was RMB 1000/hr.
1.Cost of ownership: RMB 1200/hr÷ 1.2 ton/hr = RMB 1000/ton
2.Cost of overhead: RMB 660/hr÷ 1.2 ton/hr= RMB 550/ton
3.Cost of operation: RMB 1000hr÷1.2 ton/hr = RMB 833/ton
Total Cost:RMB 2383/ton
下边是相关铝型材成本费的测算：
一吨铝型材成本费：
大家2010年讨论会的毕业论文中有提及铝型材的成本费难题。铝型材成本费是依据生产效率而定，生产效率大家假定为1.2吨/钟头和6000钟头/年生产制造時间。2010年讨论会的毕业论文中大家练习题表明的是生产流水线项目投资成本费1200元/钟头，直接成本是660元/钟头，经营成本是一千元/钟头。
1.生产流水线项目投资成本费： 1200 元/ 钟头÷1.2吨/钟头 = 一千元/吨
2.直接成本： 660元/ 钟头÷1.2吨/钟头= 550元/吨
3.经营成本： 一千元/ 钟头 ÷ 1.2吨/钟头= 833元/吨
累计：2383元/ 吨
Please note that this cost is the cost if the factory has excess capacity. If the factory production is full then the cost must also include the cost of lost sales. Studies have shown that this cost will be 2 to 3times greater because the entire gross margin of the value added in all departments is lost when the order is lost.
必须留意的是，大家这儿提及的成本费资金投入前提条件是加工厂有超量生产量。假如加工厂生产量是超负荷的，那成本费资金投入还务必包含市场销售机遇缺失的成本费。研究表明该成本费会扩大2到3倍，由于全部企业的利润率可能由于订单信息的遗失而损害。
In this example, if the Taper Quenchimprovesthe net press throughput by 15% then the resulting cost per ton would be:
1.Cost of ownership: RMB 1200/hr ÷ 1.38ton/hr = RMB 870/ton
2.Cost of overhead: RMB 660/hr ÷ 1.38 ton/hr= RMB 478/ton
3.Cost of operation: RMB 1000/hr ÷ 1.38ton/hr = RMB 725/ton
Total Cost:RMB 2073/ton
此类中，假如梯度方向水冷散热将提升纯挤压成型生产量15%，那麼一吨成本费結果将是：
1.生产流水线项目投资成本费：1200 元/ 钟头 ÷ 1.38吨/钟头 = 870 元/吨
2.直接成本：660 元/ 钟头 ÷ 1.38吨/钟头 = 478元/吨
3.经营成本： 1000 元/ 钟头 ÷ 1.38吨/钟头 = 725元/吨
累计：2073 元/ 吨
The example result is a RMB 310/ton (RMB 2383/ton – RMB 2073/ton) cost reduction. If the three year production is 24,840 tons (6000hr/yr╳1.38 ton/hr╳ 3yr) then the payback for the taper quench is RMB 7,700,000.
练习题的結果是一吨铝型材可控制成本310元（2383元/ 吨－2073元/ 吨）。假如三年的生产制造是24,840吨（6000钟头/年╳1.38吨/钟头╳三年），那麼梯度方向水冷散热的项目投资收购 将是770万余元。
The calculation for each company and each factory will be different, but the example above can be used as the template to make the calculation for the individual situation.
每一个企业和加工厂的测算方法很有可能会不一样，可是以上例子能够做为一个模版，融合个人详细情况来多方面测算。
SUMMARY 总结
The extrusion press is a valuable resource and highshippable kg/hr is required to achieve financial success. This must be considered in all equipment and process decisions.
连续挤压机是珍贵的資源，高交货量KG/钟头是完成会计上的取得成功所必不可少的。在做相关机器设备和加工工艺的管理决策时，它是务必都需要考虑到以内的。
