China Aluminum has conducted extensive research by consulting industry-related books, engaging with technical experts in the aluminum processing field, and analyzing the key factors that influence flatness issues. Based on this comprehensive study, a practical solution to address the flatness problem was developed.
1. The use of effective repair molds to improve product flatness is a widely adopted method both domestically and internationally. This approach involves repairing molds to ensure better flatness during extrusion. The main advantage of this technique is its broad applicability, as it can be used for most extruded materials. However, there are several drawbacks. It requires halting production, which leads to downtime. Once the mold is repaired, retesting and reinstallation are time-consuming and labor-intensive. Additionally, this method is not very energy-efficient and may increase material consumption. Poor flatness often results from uneven metal flow within the mold. By adjusting the size or angle of the guide pit, or modifying the length of the working belt, the flow rate of the metal can be balanced, resulting in more uniform flow and eliminating plane gaps. This method is typically applied during the early stages of production. Some molds can resolve the flatness issue after a single repair, while others may require multiple adjustments—three or more times—to fully correct the problem. The success of this process depends not only on the mold's design but also on the skill level of the operators.
2. Using offline finishing to correct the flatness of the product involves configuring the rollers of the offline finisher according to the specific flatness characteristics of the plate. The product is then continuously adjusted using a highly flat reference plate to fine-tune the height and position of the roller. Once the flatness meets the required standards, the roller settings are fixed, and the entire batch of products is processed offline. While this method is effective, it is generally time-consuming and labor-intensive. It can also affect the surface quality of the product. Figure 3 shows an example of offline finishing for a sheet with poor flatness, exhibiting noticeable convex and concave deformations. During the process, the middle and edge parts of the product are subjected to pressure from the roller, helping to correct the flatness issue.
3. To enhance efficiency and reduce labor costs, China Aluminum explored the possibility of online finishing. Given the large order volumes, relying solely on offline methods would significantly reduce production efficiency and waste resources. After thorough discussions and analysis, the company combined the principles of offline finishing with the concept of online processing, leading to the development of a small-scale online finishing equipment. If successful, this system would allow for continuous production without interruptions, saving both time and labor. Figure 4 presents a schematic of the online finishing device designed for plates. It is based on the same principle as offline finishing, with the addition of a bearing seat and roller installed at the outlet of the extruder. By adjusting the height and position of the roller, the pressure applied to the product can be controlled, causing a slight deformation that brings the flatness within acceptable limits. This enables real-time correction of flatness issues during the production process.
Corbels and Brackets
PU Corbels and Brackets is a very attractive piece,used for Curtain Rod, beam shelves and wall shelves.
Various design and size to be choosed,decorate Corbels and Brackets with other elements, bring your new decoration vision.
You also may paint or draw color for PU Corbels and Brackets (Decorative Brackets For Shelves, Corbel and Brackets, Pu Corbel Moulding, Pu Decorative Corbels, Decorative Polyurethane Corbels)as you are interested.
Advantages:
1.Can support up to 10kg with proper installation.
2.Can be cut, drilled, glued or screwed.
3.Primed in white and ready to paint or faux finish.
4.Can be used on the interior or exterior
5.High density polyurethane for maximum durability and detail.
6.Modeled after original historical patterns and designs.
Our Service:
1. Best quality
2. Short production time
3. Best price
4. Excellent aftersales service
Decorative Brackets For Shelves, Corbel and Brackets, Pu Corbel Moulding,Pu Decorative Corbels, Decorative Corbels,Polyurethane Corbels
Suntronic New Materials Technology Co., Ltd. , https://www.dsmdecor.com