Extrusion is a process used to create objects of a fixed cross-sectional profile.

A material is pushed or drawn through a die of the desired cross-section.

Commonly extruded materials include metals,

polymer, ceramics, concrete and foodstuffs.

 Diagrammatic

Representation

The process begins by heating the stock material (for hot

or warm extrusion).

It is then loaded into the container in the press.

the ram then presses on the material to push it out of the die.

Afterward the extrusion is stretched in order to straighten it.

 The

die assumes the shape of a block with

depth, beginning first with a shape profile that supports the center section.

The die shape then internally changes along

its length into the final shape, with the

suspended center pieces supported from the back of the die.

 Direct

extrusion, also known as forward extrusion

It works by placing the billet in a heavy walled container. force required is at the beginning of process and slowly decreases as the billet is used up At the end of the billet the force greatly increases

Highest

 This

is backwards extrusion as the billet and container move together while the die is stationary.
die is held in place by a "stem" which has to be longer than the container length.

The

This

process requires more energy & hence fuel and energy consumption is MORE.

 Surface

cracking - happens the surface of an extrusion splits. Pipe is a flow pattern that draws the surface oxides and impurities to the center of the product. Internal cracking - when the center of the extrusion develops cracks or voids.) Surface lines - when there are lines visible on the surface of the extruded profile as some residues of the material extruded can stick to the die surface and produce the embossed lines.

Aluminum extrusion construction versus steel construction comparison table

Aluminum Weight Steps: 20 pounds Design time bill of materials purchase materials assemble frame

Steel 33 pounds Design time bill of materials purchase materials cut to length

Set up fixture weld grind welds, clean spatter drill & tap holes degrease, mask, prime & paint

Materials: 4 - 18 inch extrusions 4 - 21 inch extrusions 8 - saw cuts 8 - inside corner brackets 32 - nuts & bolts 30 - minutes of labor @ $25/hour

$30.24 $35.28 $14.80 $32.40 $18.24 $12.50

4 - 18 inch extrusions $7.96 4 - 21 inch extrusions $9.28 welding supplies, sandpaper, cleaning supplies, tape, paint $15.00 5 - hours of labor @ $125.00 $25/hour

Total cost:

$143.46

$157.24

 Aluminum

extrusions are ideal for a wide range of uses the extrusion process is both economical and versatile. Compared with machining, extruding is economical Unlike machining, where the cost of producing each piece is additive, extrusion can reproduce a shape indefinitely with no additional preparation costs.

Parts made with sand and permanent-mold casting often require extensive finishing.
Also, as parts get more complex, casting mold costs rise far more rapidly than extrusion dies. Generally, extrusion dies are rather inexpensive. extrusion dies can be finished with less lead time than forming dies and casting molds. Extrusion dies cost much less than roll-forming dies Extruding is almost always less expensive than fabricating shapes by welding

More than a third of all the aluminum currently produced globally originates from old, traded and new scrap.
Compared with the production of primary aluminum, recycling of aluminum products needs as little as 5% of the energy and emits only 5% of the greenhouse gas Aluminum can be recycled over and over and over again without loss of properties. The high value of aluminum scrap is a key incentive for recycling Refiners and remelters play integral roles in aluminum recycling but they, in turn, have crucial links with collectors, dismantlers, metal merchants and scrap processors who deal with the collection and treatment of scrap

Aluminum recycling rates are high, up to 90% for transport and construction applications and about 70% for beverage cans
A major barrier to the recycling of aluminum is the increase of inclusions and impurity elements in re-melted post consumer scrap. The aluminum soda / beverage can is by far the most recycled consumer beverage package globally by units, pounds and percentage recycled. It amounts to more than twice the recycling rate and recycled content percentages for beverage packages of other materials.

 Dwarkadhish

metals pvt. Ltd is a private limited company functioning as scrap suppliers, aluminum scrap recovery, scrap recycling, recycling of soda can, metal scrap importers.U.S andMiddle East countries.
It is a family run business located in the industrial estate of OdhavAhmedabad.

Purchase

Import Transportation

Processing

Sorting & Cutting Melting & Skimming

Finishing

Cooling & Shaping Cleansing

Sale

Final Sale OR Further In-house Extrusion

The cost of purchase of scrap and import duties etc varies from supplier to supplier and depends on existing market conditions.
The cost of bringing the material from the port to ahmedabad comes to around Rs. 3 per km. The cost of melting the material, cutting it, unloading the container and preparing the finished product costs in all rs 6 per kg The market price of each kg of purified aluminum is varying upon market & contract conditions .

Particulars
Raw Material
Transportation cost Labor

Price Per Kg
108 3
3 114

Prime Cost

Factory Expense :
Coal & Power 2 116

Factory Cost Administration Expense Cost Of Production Profit Selling Price

1 117 5 122

Company
Low profit margins No scope for expansion Unstable demand & market condition Being international trading unit, fluctuation of exchange rates affects severely
No control over the cost of production.

Cost System
Difficult to derive exact cost & develop the uniform costing method as, variation is found in the prices and sources of raw materials as 70% of raw materials are imported. Fluctuation in demand for labor Complex process of manufacturing makes it difficult to derive exact processing cost

Project
Time constraints Company is a private unlisted company, so its not possible to get financial reports Figures and information given are not totally reliable as most of the companies are hesitant in providing cost information to the outsiders

Develop processing in such a manner to maintain uniformity in processing cost

Professionalized management.

Professionalized management.