Metal extrusion process is a manufacturing process that works by forcing a metal through a set of die. This is done to create a required shape or profile of an object.
There are two different types of metal extrusion process. Hot metal extrusion and Cold metal extrusion.
In hot metal extrusion, the material is heated to reduce its strength and improve plasticity. This makes it easy to deform and pass through the die. Hot metal extrusion is usually done in hard materials like steel and titanium.
In cold metal extrusion material is not heated as its force passes through the dies. This process is usually done on softer materials like copper and aluminum.
The process is used for manufacturing different cross sectional profiles like rod and tube.
Metal extrusion tooling is a term used to mention the tools used in the process. This includes dies, molds, and other components used in the metal extrusion process.
In the metal extrusion process it is required to manufacture a set of dies or molds. These dies and molds are designed to shape the extruded material into the desired profile.
This metal extrusion tooling usually consists of a die and a ram. Die is stationary and the ram reciprocates to apply pressure to the metal. This forces the metal through the die opening.
The design of the dies is important in determining the final shape and quality of the product. Their material must be strong to withstand high temperatures and pressures. This enables dies to maintain the desired precision and surface finish needed for the final product.
JCL with its dedicated metal extrusion workshop offer a wide range of materials. Our workshops are already specialized in following material but our working is not limited to these materials.
Aluminum extrusion is the most done process in the world right now with aluminum and its alloys being one of the most commonly extruded metals. This is due to their excellent ductility and low density.
Due to their corrosion resistance various aluminum alloys like 6061 and 6063 are frequently used in corrosion related products.
Copper and its alloys are very good in thermal and electrical conductivity. Copper and its alloys are used in extrusion of products that require specific properties like good electrical conductivity.
Steel Alloys extrusion is not very common in industry. Not all steel alloys can be extruded, only certain steel alloys, like carbon steel and stainless steel, can be extruded.
These are only known for specific applications especially for applications where strength and durability are crucial. The extrusion process for steel often involves higher temperatures compared to non-ferrous metals.
Titanium extrusion process is dedicated to aerospace and medical applications. This is due to titanium's high strength to weight ratio, corrosion resistance and biocompatibility.
Magnesium Alloys
Nickel Alloys
Zinc Alloys
Lead and Tin Alloys
In the metal extrusion process there are several categories of metal extrusion profiles. This is done to make it easy for manufacturers and clients to communicate. Some common categories includes,
Metal extrusion solid profiles have a uniform cross section area. They offer simplicity and structural integrity in the final product.
Rods and bars are examples of solid profiles. Solid profile in metal extrusion is mostly used for cost-effective manufacturing during mass production.
Hollow profile in metal extrusion features enclosed voids. In the manufacturing industry this process is known for its optimized material usage while maintaining strength.
Some common applications of this process are in aerospace and fluid transport systems. As hollow tubes offer a balance between strength and reduced weight. This increases overall efficiency in various applications.
Metal extrusion processes can also process complex profiles. This process not only produces these complex shapes but does it with great control over different design parameters.
Found in automotive and electronics, these profiles provide versatility. This allows the creation of custom components with unique specifications.
One of the most used profiles, the metal extrusion thin wall profiles is famous for its role in crucial applications that prioritizes weight reduction without compromising strength.
Thin wall metal extrusion profiles strike a balance between structural integrity and lightweight design. This makes them integral components in different engineering solutions.
Some of the metal extrusion products that JCL is specialized in manufacturing are
Aluminum Extrusion Products Window Frames Door Frames Heat Sinks | Steel Extrusion Products Structural Components Railings |
Copper Extrusion Products Busbars Electrical Conductors | Titanium Extrusion Products Aircraft Components Medical Implants |
Magnesium Extrusion Products Lightweight Components | Stainless Steel Extrusion Products Medical Instruments Industrial Equipment Components |
Brass and Bronze Extrusion Products Architectural Hardware Musical Instruments | Lead and Tin Extrusion Products Bearings |
Metal extrusion process is recommended for large batch to mass production products. This is because of the fact that there is always a high tooling cost associated with the process. The tooling cost when divided over a greater number does not impact product cost much.
Some other main factors that affect the extrusion process cost are
Material cost
Labor cost
Transportation cost
The metal extrusion costing process involves a detailed analysis of these factors to arrive at a comprehensive understanding of the total production cost.
Reason why JCL is better than other in Metal Extrusion Forming Process
With highly skilled workers JCL ensures that the dies and molds used in their extrusion process are designed, manufactured and maintained with a high level of quality.
High-tech machines at JCL extrusion workshop contribute to efficiency, precision, and the ability to handle complex profiles.
JCL ensures rigorous quality checks at each stage of the metal extrusion process. This ensures that the final products meet industry standards.
JCL makes all essential steps to ensure a balanced speed with quality to ensure that increased production does not compromise the final product's integrity.
Metal extrusion tooling usually takes weeks but JCL makes sure it's done in days. Quick turnaround by JC L is to meet customer demands and respond to market needs promptly.
JCL makes sure that all above steps cost least for each of its clients. JCL makes use of its experience and process optimization to deliver the least possible cost.
We are excited to collaborate with you!
If you have any questions about our products or require custom machining services, please don’t hesitate to reach out to us. We are here to assist you and provide the solutions you need.
