The factors affecting the flatness problem were summarized, and based on this, a solution to the flatness problem was formulated.
1. Use effective mold repair to improve the flatness of the product
Mold repair is the most commonly used solution to poor flatness of extruded materials at home and abroad. The advantage of this method is that it has a wide range of applications. Basically all extruded materials can be treated with this method. The disadvantage is that production needs to be terminated. After the mold is processed, the machine is tested again, which is time-consuming and labor-intensive, and is not conducive to energy saving and consumption reduction. The poor plane gap of the plate is mainly related to the uneven flow rate of the mold. By changing the size or angle of the diversion pit, or changing the length of the working belt, the metal flow rate can be effectively adjusted so that the flow rate is uniform and the defect of poor plane gap is eliminated. This type of plate generally uses this method in the early stages of production. Some molds can be repaired once to solve the flatness problem, while some molds need three or more times to completely solve the flatness problem. This is not only related to the mold itself, but also has a lot to do with the technical level of the mold repair workers.
2. Use offline finishing to correct product flatness
First, according to the specific flatness characteristics of the plate, the rollers of the offline finishing machine are reasonably configured, and then a product with excessive flatness is used to fix the roller. By continuously adjusting the height and position of the roller, after the flatness of the product is qualified, the height and position of the roller are fixed, and then the batch of products is finished offline. Offline finishing is generally time-consuming and labor-intensive, and it is also easy to have a certain impact on the appearance of the product. An example of offline finishing of plates. The flatness of the plate is convex and concave, and the flatness is out of tolerance. A matching roller is used. When the product passes through the roller, the middle and edge of the product will be subject to a certain amount of pressure from the roller, thereby correcting the plane gap of the product.
3. Use online finishing to correct product flatness
Considering that the order quantity is relatively large, if offline finishing is used, the production efficiency will be greatly reduced and a lot of manpower will be wasted. After a certain period of discussion and combined with the principles of offline finishing, the concept of online finishing was proposed and decided to make a small online finishing equipment. If successful, it will not affect production efficiency but also save a lot of manpower. The simplified diagram of the online finishing equipment designed for this plate is based on the principle of offline finishing. It installs bearing seats and rollers on the basis of the original extruder exit guide device. By adjusting the height and position of the rollers, the pressure on the product is changed to cause a certain amount of deformation of the product, so that the flatness of the product is controlled within a reasonable range, thereby achieving the purpose of online finishing.
