Simmal Aluminum Extrusion Designing To The Limits Nov 09

1. Aluminum Extrusions designing to the limits of your imagination! Brought to you by: Simmal Ltd www.simmal.co.uk

2. Introduction Frank Power Director

3. Presentation Agenda Simmal Ltd – company history The extrusion process Ideas taking shape Advantages of aluminium Advantages of aluminium extrusions Design solutions Case studies Why focus on innovation? Questions and answers How to contact us?

4. Simmal Ltd – Company History Founded in 1986 The early years How did we get here?

5. In the begining Founded in 1986 with the current Chairman’s redundancy money. Today we are a second generation family business with significant cash reserves, trading positively cash generative turning in excess of £10 million per year

6. Simmal Ltd – Company History Why are we here tonight? Two reasons. One we eat sleep and breath all things aluminium. Secondly we don’t have a product, so need people far more intelligent than us to design and specify the next generation of aluminium products

7. The extrusion process Requires three basic elements: 1 - An Extrusion Press/Ram 2 - Aluminium Billets 3 - An Extrusion Die

8. The extrusion process The Extrusion Press comes in many different sizes, such as: 4” 1000 tonne press 7” 2400 tonne press 24” 5000 tonne press 36” 12000 tonne press

9. The extrusion process The size of the press determines the size of the extrusion that can be made

10. The extrusion process Billets or logs come in a variation of diameters and lengths to suite the press. So for example a 9 press will use 9” diameter billet. Aluminium by nature is a soft and weak metal, which therefore needs to be alloyed in order to produce a usable extrusion. We focus mainly on the 6000 series of alloys here in the UK which includes as it’s main alloying elements, Mg ( Magnesium) Si (Silicon) Cu (Copper) Ti (Titanium) Mn (Manganese) All of the 6000 series alloys have their unique properties. The 2 main alloys here in the UK are 6082, which is the hardest of all of the 6000 series alloys and is used for engineering products, and 6063 which is the high surface quality alloy good for painting and anodising and is used for architectural and building products. Aluminium extrusions can come in different tempers. T6 Fully age hardened T5 Semi age hardened T4 Un aged F Very soft O Annealed age hardened and then softened. ( Not common in extrusions)

11. The extrusion process NOTE: A common mistake is selecting the wrong alloy

12. The extrusion process There are two main types of dies. Solid or flat face die used to produce shapes such as angles, channels, flat bars etc etc, or basically any extrusion which does not require a hole any where in the shape. A porthole die is used to produce hollow sections - for tubes or any extrusion with a hole in the profile.

13. The extrusion process Single or multi cavity dies

14. The extrusion process

15. The extrusion process Other parts of the process: Quenching. Stretching Cutting Ageing Packing

16. Ideas taking shape An idea takes shape in the designer’s mind and then takes shape as a final product All thanks to the amazing versatility of aluminum extrusion

19. It can be formed to:

20. Facilitate manufacturing and assembly

21. Reduce costs for materials and production

22. Increase product reliability and durability

23. Simplify maintenance and repairs for the final user of the product

25. Design Flexibility

26. Performance

27. Efficiency

28. Reliability

31. Strong

32. High Strength-to-Weight Ratio

33. Resilient

34. Corrosion-Resistant

35. Heat Conductive

36. Reflective

37. Electrically Conductive

38. Non-Magnetic

39. Non-Sparking

40. Non-Combustible

42. Only about one-third as heavy as iron, steel, copper or brass. Thus, in applications where volume remains the same regardless of metal used, aluminum goes about three times as far as the other metals.

43. Strong

45. Resilient

47. Heat Conductive

48. Reflective

49. Electrically Conducive

50. Non-Magnetic

51. Non-Sparking

52. Non-Combustible

55. Strong

57. High strength plus low weight permits substantial reductions in the weight of both parts and final products

58. Resilient

60. Heat Conductive

61. Reflective

63. Non-Magnetic

64. Non-Sparking

65. Non-Combustible

67. Strong

69. Resilient

70. Aluminum products can deflect under loads and shocks and spring right back

72. Heat Conductive

73. Reflective

75. Non-Magnetic

76. Non-Sparking

77. Non-Combustible

79. Strong

81. Resilient

83. Excellent corrosion resistance in a wide variety of environments and contact with a myriad of substances. It develops its own inert aluminum oxide film, which is self-protective, blocking further oxidation

84. Heat Conductive

85. Reflective

87. Non-Magnetic

88. Non-Sparking

89. Non-Combustible

91. Strong

93. Resilient

95. Heat Conductive

96. Conducts heat better than any other common metal on both a weight and cost basis.

97. Reflective

99. Non-Magnetic

100. Non-Sparking

101. Non-Combustible

103. Strong

105. Resilient

107. Heat Conductive

108. Reflective

109. Highly reflective (more than 80 percent) of both visible light and the invisible radiation beyond both ends of the visible spectrum

111. Non-Magnetic

112. Non-Sparking

115. Strong

117. Resilient

120. Reflective

122. Volume for volume, aluminum carries electricity about 62% as well as copper. On an equal weight basis, aluminum can be twice as conductive as copper, and aluminum is often the most economical choice.

123. Non-Magnetic

124. Non-Sparking

127. Strong

129. Resilient

132. Reflective

134. Non-Magnetic

135. The non-magnetic character of aluminum makes it particularly useful for a variety of electrical and electronic applications

136. Non-Sparking

139. Strong

141. Resilient

144. Reflective

146. Non-Magnetic

147. Non-Sparking

148. Even though it is an excellent electrical conductor, aluminum does not produce sparks. This is an essential property for products used with highly flammable or explosive materials and atmospheres

151. Strong

153. Resilient

156. Reflective

158. Non-Magnetic

159. Non-Sparking

161. Solid aluminum does not burn or generate hazardous emissions, making it safer in applications where fire is a potential hazard

163. Strong

165. Resilient

168. Reflective

170. Non-Magnetic

171. Non-Sparking

173. Cold Strength

175. Advantages of Aluminum Extrusions Attractive Suitable for a wide range of finishes Virtually seamless Easy to fabricate Joinable by various method Suitable for easy-assembly designs Suitable for complex, integral shapes Produced to close tolerances Produced with uniform quality Cost-effective

177. Aluminum’s natural metallic surface is aesthetically pleasing. The natural protective oxide coating can be thickened by anodizing for extra protection, with additional appearance benefits.

178. Suitable for a wide range of finishes

179. Virtually seamless

180. Easy to fabricate

181. Joinable by various method

182. Suitable for easy-assembly designs

183. Suitable for complex, integral shapes

184. Produced to close tolerances

185. Produced with uniform quality

188. Aluminum accepts a great variety of finishes, colors and textures

199. Aluminum extrusions, even tubes and other hollow shapes, have no mechanically joined seams which could loosen, leak, mar appearance or reduce strength. They are one-piece products, both visually and functionally

210. Aluminum extrusions can be made with almost any cross-sectional shape. Parts can be easily cut, machines, finished, fabricated and assembled.

220. Joinable by various methods

221. Aluminum extrusions can be joined to other aluminum products or to different materials by all major methods, including welding, soldering, brazing, bolts, rivets, chips, adhesives, clinching and slide-on, snap-together or interlocking joints.

232. Aluminum extrusions can be designed for easy assembly with other parts including mating surfaces or shapes that match up for easy joining.

243. Shapes can combine functions that would otherwise require the production and joining of several different parts.

254. Tight tolerances are routine and the ability of aluminum extruders to meet even more critical dimensions is keeping pace with advances in technology.

265. This reliability reduces customer costs by minimizing rejections rate, corrective fabrication and production slowdown – particularly important to the manufacturer who depends upon just-in-time (JIT) delivery.

275. Cost-effective

277. Painting (wet and powder)

278. Polish, bright dip & anodize

279. Mechanical Finishes

280. Silk screening

281. Fabrication

282. Sawing

283. Punching/piercing/drilling

284. Machining

285. Bending

286. Welding

287. Milling

289. How can YOU use this flexibility to:

290. Spark your imagination?

291. Create new product concepts?

294. Case Studies Skirting Medical Ladder safety Trunking Cricket Ground

295. Skirting heating system – By Simmal

296. Super car parts – By Simmal

297. Blood Analysis machine part – By Simmal

298. Ladder safety/transport parts – By Simmal

299. Developed/supplied – By Simmal

300. Perimeter Cable Trunking – By Simmal

301. Headingley Cricket Ground The building structure – By Simmal

302. Why focus on innovation? Help educate the UK designers and engineers of today and tomorrow about the versatility of aluminium extrusion for their business Coordinate technical support to help them develop new products in aluminium for UK PLC These activities should encourage the increasing specification of aluminium extrusion By supporting the use of extrusion in good product design today, we intend that the business of supplying aluminium extrusions will grow in the future Inform designers and engineers about the huge environmental / recycling benefits of aluminium and the advantages for their products

303. Questions/answers/ and thank-yous Simmal Ltd would like to thank Sapa for their technical help and providing us with some of the photos use in this presentation

304. How to contact us? FREEPHONE 0800 731 8238 Ask for Frank Power Or visit our web site at www.simmal.co.uk

Simmal Aluminum Extrusion Designing To The Limits Nov 09

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