一、熱軋工藝1、原料規(guī)格扁錠規(guī)格：（420～460mm）×（1000～2000mm）×（3600～6800mm）。扁錠的合金牌號(hào)：1xxx、3xxx、5xxx、8xxx等。2、設(shè)備構(gòu)成扁錠銑面機(jī)1臺(tái)立推式扁錠加熱爐2套2400mm四輥可逆式雙卷取熱軋生產(chǎn)線1條3、工藝流程及參數(shù)⑴扁錠銑面扁錠銑面是為了去除表面的偏析瘤、夾渣、結(jié)疤和表面裂紋等，減少板片的金屬及非金屬壓入缺陷，提高表面品質(zhì)將規(guī)格為480*1500*6000的扁錠（重量11.66T），推入銑面機(jī)對(duì)扁錠的兩面及兩邊銑面, 銑面機(jī)的運(yùn)行速度0.2m/s, 需要銑掉扁錠最大厚度為6mm,一塊扁錠銑掉鋁屑重量383Kg,扁錠的噸鋁產(chǎn)生的鋁屑32.8kg。⑵扁錠加熱

1、 Hot rolling process 1. Raw material specification: Flat ingot specification: (420-460mm) × (1000-2000mm) × (3600-6800mm). Alloy grades for flat ingots: 1xxx, 3xxx, 5xxx, 8xxx, etc. 2. Equipment composition: Flat ingot milling machine, 1 vertical push flat ingot heating furnace, 2 sets of 2400mm four roll reversible double coil hot rolling production line, 1 line. 3. Process flow and parameters: ⑴ Flat ingot milling surface. Flat ingot milling surface is used to remove surface segregation nodules, slag inclusions, scars, and surface cracks, reduce metal and non-metal pressing defects on the plate, and improve surface quality. A flat ingot with a specification of 480 * 1500 * 6000 (weight 11.66T) is pushed into the milling machine to mill the two sides and two sides of the flat ingot. The operating speed of the milling machine is 0.2m/s, and the maximum thickness of the flat ingot that needs to be milled off is 6mm. The weight of aluminum chips milled off from one flat ingot is 383Kg, and the ton of aluminum from the flat ingot is 383Kg. 32.8kg of aluminum shavings were generated Flat ingot heating

銑面合格的扁錠在立推式加熱爐內(nèi)進(jìn)行加熱，加熱溫度350℃～550℃，加熱時(shí)間5-8小時(shí)。加熱爐設(shè)有5個(gè)區(qū)，每區(qū)安裝一臺(tái)大流量的空氣循環(huán)風(fēng)機(jī)安裝在爐頂，風(fēng)機(jī)運(yùn)行風(fēng)速為10-20m/s，壓縮空氣消耗20m3/min；4個(gè)區(qū)共20個(gè)天然氣燒嘴，分別安裝在爐體上半部分的兩側(cè)，天然氣約消耗1200Nm3/h。⑶熱粗軋

The qualified flat ingots for milling are heated in a vertical push heating furnace at a temperature of 350 ℃ to 550 ℃ for 5-8 hours. The heating furnace has 5 zones, each zone is equipped with a large flow air circulation fan installed on the top of the furnace. The fan operates at a speed of 10-20m/s and consumes 20m3/min of compressed air; There are a total of 20 natural gas burners in 4 zones, installed on both sides of the upper half of the furnace body, with a natural gas consumption of approximately 1200Nm3/h Hot rough rolling

將加熱后規(guī)格為480*1500*6000的扁錠推入四輥可逆熱軋機(jī)熱粗軋，最大軋制速度可達(dá)230m/s,經(jīng)過5～13道次的軋制，最終將扁錠軋制到20～160mm板坯。⑷熱精軋

Push the heated flat ingot with a specification of 480 * 1500 * 6000 into a four roll reversible hot rolling mill for hot roughing, with a maximum rolling speed of 230m/s. After 5-13 passes of rolling, the flat ingot is finally rolled into a 20-160mm slab Hot precision rolling

將熱粗軋后的板坯在熱精軋機(jī)組進(jìn)行精軋操作，最大軋制速度可達(dá)480m/s,經(jīng)過10-18個(gè)道次的軋制，生產(chǎn)出2.5～16mm厚度的板卷。

The hot rough rolled slab is subjected to precision rolling operation in the hot finishing mill, with a maximum rolling speed of 480m/s. After 10-18 passes of rolling, coils with a thickness of 2.5-16mm are produced.

二、冷軋工藝1、入口原料規(guī)格卷材厚度：2.5～15mm卷材寬度：880～2000 mm卷材直徑：φ610～φ2000 mm卷材重量：12.5t2、設(shè)備構(gòu)成2000mm不四輥可逆冷軋機(jī)組2套40t中間、成品退火爐6臺(tái)20m中厚板精密鋸切機(jī)2套MK84180×8000數(shù)控軋輥磨床2臺(tái)3、工藝流程及參數(shù)⑴冷軋2-15mm的鋁熱軋卷在四輥不可逆冷軋機(jī)組經(jīng)過3-6個(gè)道次軋至成品厚度?0.25～0.7mm。采用計(jì)算機(jī)實(shí)行平直度(AFC)、厚度(AGC)、張力(ATC)等綜合自動(dòng)控制進(jìn)行軋制，軋制速度為5～20m／s，連軋時(shí)可達(dá)25～40m／s，壓下率一般在90%～95%。⑵中間退火為消除冷軋后加工硬化現(xiàn)象，部分中間產(chǎn)品需進(jìn)行中間退火作業(yè)，進(jìn)行中間退火時(shí)退火溫度為315～500℃，保溫時(shí)間１～３ｈ。中間退火爐用電加熱，爐子頂部配備了3臺(tái)大風(fēng)量風(fēng)機(jī)，風(fēng)速為10～20m/s，加熱器的總功率1080Kw，壓縮空氣的消耗20Nm3/h。⑶成品退火經(jīng)過冷軋完成后的產(chǎn)品需進(jìn)行退火，退火溫度為260～490℃，保溫時(shí)間1～５ｈ，鋁箔的冷卻速度要小于15℃/h，出料溫度不要高于60℃，其他厚度的軋卷出料溫度不要高于100℃。

2、 Cold rolling process 1. Inlet raw material specifications: coil thickness: 2.5-15mm, coil width: 880-2000mm, coil diameter: φ 610- φ 2000 mm, coil weight: 12.5t2, equipment composition: 2000mm non four roll reversible cold rolling mill, 2 sets of 40t intermediate, 6 sets of 20m medium thick plate precision sawing and cutting machines, 2 sets of MK84180 × 8000 CNC roll grinders, 3. Process flow and parameters: (1) Cold rolling 2-15mm aluminum hot-rolled coils are rolled in 3-6 passes to the final thickness in a four roll non reversible cold rolling mill? 0.25-0.7mm. Using computers to implement comprehensive automatic control of flatness (AFC), thickness (AGC), tension (ATC), etc. for rolling, the rolling speed is 5-20m/s, and can reach 25-40m/s during continuous rolling. The reduction rate is generally between 90% and 95% In order to eliminate the work hardening phenomenon after cold rolling, some intermediate products need to undergo intermediate annealing. The annealing temperature during intermediate annealing is 315-500 ℃, and the holding time is 1-3 hours. The intermediate annealing furnace is heated by electricity, and the top of the furnace is equipped with three high wind turbines with a wind speed of 10-20m/s. The total power of the heater is 1080Kw, and the consumption of compressed air is 20Nm3/h After cold rolling, the finished product needs to be annealed at a temperature of 260-490 ℃ for 1-5 hours. The cooling rate of the aluminum foil should be less than 15 ℃/h, and the discharge temperature should not exceed 60 ℃. The discharge temperature of other thicknesses of rolled coils should not exceed 100 ℃.

三、精整工藝1、成品規(guī)格卷材厚度：0.27～0.7mm卷材寬度：880～1900 mm卷材直徑：φ610～φ1800 mm卷材重量：12.5t2、設(shè)備構(gòu)成2000mm橫切機(jī)組（2～12mm）2套2000mm拉矯機(jī)組（0.1～2.5mm）2套2000mm橫切機(jī)組（0.1～2.5mm）2套2000cm厚板矯直機(jī)組 2套2000mm卷材自動(dòng)包裝機(jī)組2套MK8463×6000數(shù)控軋輥磨床 ??2臺(tái)3、工藝流程及參數(shù)橫切生產(chǎn)線

3、 Finishing process 1. Finished product specifications: coil thickness: 0.27-0.7mm, coil width: 880-1900mm, coil diameter: φ 610~φ 1800mm, coil weight: 12.5t2, equipment composition: 2000mm cross cutting unit (2-12mm), 2 sets of 2000mm straightening units (0.1-2.5mm), 2 sets of 2000mm cross cutting units (0.1-2.5mm), 2 sets of 2000cm thick plate straightening units, 2 sets of 2000mm coil automatic packaging units, 2 sets of MK8463 × 6000 CNC roll grinders?? 2 units 3. Process flow and parameters for cross cutting production line

鋁帶橫剪機(jī)組是用于對(duì)厚為2～12mm鋁及鋁合金卷材進(jìn)行橫向精確裁剪，并按產(chǎn)品要求整齊垛板的設(shè)備。剪切最大長(zhǎng)度可達(dá)到11m。拉矯生產(chǎn)線鋁卷在張力輥組施加的2.0～20 kN的張力作用下，連續(xù)通過上下交替布置的多組小直徑彎曲輥，在拉伸和彎曲的聯(lián)合作用下，沿長(zhǎng)度方向產(chǎn)生了塑性延伸，使帶材各條縱向纖維的長(zhǎng)度趨于一致，改善帶材平直度。機(jī)組運(yùn)行速度可達(dá)到200m/min。厚板矯直生產(chǎn)線輥?zhàn)拥奈恢门c被矯直制品運(yùn)動(dòng)方向成某種角度，兩個(gè)或三個(gè)大的是主動(dòng)壓力輥，由電動(dòng)機(jī)帶動(dòng)作同方向旋轉(zhuǎn)，另一邊的若干個(gè)小輥是從動(dòng)的壓力輥，它們是靠著旋轉(zhuǎn)著的圓棒或管材摩擦力使之旋轉(zhuǎn)的。為了達(dá)到輥?zhàn)訉?duì)制品所要求的壓縮，這些小輥可以同時(shí)或分別向前或向后調(diào)整位置。制品被輥?zhàn)右胫螅粩嗟刈髦本€或旋轉(zhuǎn)運(yùn)動(dòng)，因而使制品承受各方面的壓縮、彎曲、壓扁等變形，最后達(dá)到矯直的目的。該生產(chǎn)線矯直力30MN。

The aluminum strip cross cutting unit is a device used for accurately cutting aluminum and aluminum alloy coils with a thickness of 2-12mm horizontally, and stacking them neatly according to product requirements. The maximum cutting length can reach 11m. Under the tension of 2.0-20 kN applied by the tension roller group, the aluminum coil in the straightening production line continuously passes through multiple sets of small diameter bending rollers arranged alternately up and down. Under the combined action of stretching and bending, plastic extension occurs along the length direction, making the length of each longitudinal fiber of the strip tend to be consistent and improving the flatness of the strip. The operating speed of the unit can reach 200m/min. The position of the rollers in the thick plate straightening production line is at a certain angle to the direction of movement of the straightened product. Two or three of the larger rollers are the active pressure rollers, which are driven by an electric motor to rotate in the same direction, while several small rollers on the other side are the passive pressure rollers, which are rotated by the frictional force of the rotating round rod or pipe material. In order to achieve the compression required by the rollers for the products, these small rollers can be adjusted forward or backward at the same time or respectively. After being bitten by the roller, the product continuously undergoes linear or rotational motion, thus subjecting the product to various forms of compression, bending, flattening, and other deformations, ultimately achieving the purpose of straightening. The straightening force of this production line is 30MN.

四、深加工工藝1、拉絲處理工藝工藝主要流程分為脫酯、沙磨機(jī)、水洗3個(gè)部分。在鋁板拉絲制程中，陽(yáng)極處理之后的特殊的皮膜技術(shù)，一般用直徑0.1毫米的不銹鋼絲刷或百潔布帶刷，也可用尼龍砂帶加工，可以使鋁板表面生成一種含有該金屬成分的皮膜層，清晰顯現(xiàn)每一根細(xì)微絲痕，從而使金屬啞光中泛出細(xì)密的發(fā)絲光澤。近年來(lái)，越來(lái)越多的鋁板產(chǎn)品的金屬外殼都使用了金屬拉絲工藝 ，以起到美觀，抗侵蝕的作用。2、蝕刻處理工藝先用用棗木碳研磨，去掉油膩、劃痕，磨出啞光表面。然后用絲網(wǎng)版印上紋樣，油墨型號(hào)為80-39、80-59、80-49等。印完紋樣后放進(jìn)電爐內(nèi)烘干，然后用即時(shí)貼封住后面，用膠帶封邊，進(jìn)入腐蝕工藝。

4、 Deep processing technology 1. The main process of wire drawing treatment technology is divided into three parts: de esterification, sand mill, and water washing. In the aluminum plate drawing process, the special coating technology after anodizing is generally achieved by using a stainless steel wire brush or scouring pad brush with a diameter of 0.1 millimeters, or by processing with a nylon sand belt. This can create a coating layer containing the metal component on the surface of the aluminum plate, clearly showing every fine wire trace, thus giving the metal matte a fine hair like luster. In recent years, an increasing number of aluminum plate products have adopted metal wire drawing technology for their metal shells, in order to achieve aesthetic and corrosion-resistant effects. 2. The etching process first uses jujube wood carbon to grind, remove grease and scratches, and grind a matte surface. Then use screen printing to print the pattern, with ink models such as 80-39, 80-59, 80-49, etc. After printing the pattern, put it in an electric furnace for drying, then seal the back with instant tape, seal the edges with adhesive tape, and enter the corrosion process.

鋁板的腐蝕液配方如下：三氯化鐵50% ：硫酸銅50%，適量的水，溫度在15～20°之間。鋁板腐蝕時(shí)應(yīng)平放，在腐蝕的過程中紋樣上溢出赭紅色的滓渣，應(yīng)隨時(shí)用毛刷去掉，鋁面上冒出大量泡泡，滓渣隨泡泡浮起。鋁板的腐蝕時(shí)間大約在15～20min左右就可完成。3、電泳涂裝工藝工藝流程：脫脂→熱水洗→水洗→中和→水洗→陽(yáng)極氧化→水洗→電解著色→熱水洗→水洗→電泳→水洗→干燥。

The formula for the corrosion solution of aluminum plate is as follows: 50% ferric chloride, 50% copper sulfate, an appropriate amount of water, and a temperature between 15-20 ° C. When the aluminum plate is corroded, it should be placed flat. During the corrosion process, reddish brown slag overflows from the pattern and should be removed with a brush at any time. A large number of bubbles will appear on the aluminum surface, and the slag will float up with the bubbles. The corrosion time of aluminum plate can be completed in about 15-20 minutes. 3. Electrophoretic coating process flow: degreasing → hot water washing → water washing → neutralization → water washing → anodizing → water washing → electrolytic coloring → hot water washing → water washing → electrophoresis → water washing → drying.

在陽(yáng)極氧化的基礎(chǔ)上，通過電泳的作用，在氧化膜上均勻覆蓋上一層水溶性丙烯酸漆膜，使型材表面形成陽(yáng)極氧化膜和丙烯酸漆膜復(fù)合膜。鋁板帶進(jìn)入固體份7%～9%、溫度20～25℃、pH8.0～8.8、電阻率(20℃)1500～2500Ωcm、電壓(DC)80～25OV、電流密度15～50 A/m2的電泳池經(jīng)過1～3 min的時(shí)間電泳可涂膜7～12μm厚度。

On the basis of anodic oxidation, a water-soluble acrylic paint film is uniformly covered on the oxide film through electrophoresis, forming a composite film of anodic oxide film and acrylic paint film on the surface of the profile. Aluminum strip can be coated with a film thickness of 7-12 μ m after 1-3 minutes of electrophoresis in an electrophoresis cell with a solid content of 7% -9%, temperature of 20-25 ℃, pH of 8.0-8.8, resistivity of 1500-2500 Ω cm (20 ℃), voltage of 80-25OV (DC), and current density of 15-50 A/m2.

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