Türkçe
English
Français
Deutch
Русский
Español
Value Engineering in Aluminum Profiles: Reducing Costs by Lightening the Design
- Doing "More" with "Less"
In the aluminum extrusion industry, cost is largely indexed to the profile's weight (kg/meter). Therefore, reducing profile weight directly lowers costs. However, unconscious "wall thinning" can lead to loss of strength, increased scrap rates during production, and functional failure. True Value Engineering (VE) is the process of optimizing design geometry and material properties to ensure the most efficient production without compromising the profile's function.
- Design Optimization Strategies
2.1. Uniform Wall Thickness
In the extrusion press, aluminum flows through the die like water; it prefers the path of least resistance (the widest opening). If a profile has one thick side and one very thin side, the metal flows faster through the thick section, struggling to fill the thin section. This causes twisting or bowing defects.
- Optimization: Keeping wall thicknesses as uniform as possible increases production speed and reduces scrap. The thickness ratio between adjacent walls should not exceed 2:1. Uniform distribution ensures straighter profiles even with thinner walls.
2.2. Alloy Selection: 6063 or 6061?
Correct alloy selection directly impacts cost.
- 6063 Alloy: Used in 90% of architectural applications. It offers high extrudability (faster press speeds), excellent surface quality, and cost-effectiveness.
- 6061 Alloy: Required for higher structural strength (truck chassis, structural columns). However, 6061 is harder, forcing slower press speeds compared to 6063. If your project doesn't genuinely need the extra strength of 6061 (over-engineering), switching to 6063 can increase production speed and reduce costs by 10-15%.
2.3. Integration of Functions (Function Analysis)
The greatest strength of aluminum extrusion is the ability to create complex shapes in a single piece. Parts that would be joined by welding, rivets, or screws in other materials (e.g., steel sheet) can be designed as a single aluminum cross-section.
- Example: Integrating details like screw ports, hinge bosses, or clip snaps into the profile may slightly increase the per-kg cost, but it dramatically reduces subsequent assembly and labor costs. This results in significant total cost savings.
- Mertcan Metal Design Support and Critical Limits
Clients often arrive with a finished technical drawing. As the Mertcan Metal engineering team, we intervene by asking: "Where will this profile be used, and what loads will it bear?"
- Thin Wall Limits: In standard industrial production, 0.8mm - 1.2mm wall thicknesses are safe limits. However, with special die designs and precise press control, it is possible to go down to 0.6mm. Reducing the wall thickness of a 1.00-inch diameter tube from 1.2mm to 1.0mm reduces weight by 20% without affecting function.
- Non-Visible Surfaces: By defining wider cosmetic tolerances for the unseen inner parts of a profile, die life can be extended, and costs reduced.
- Conclusion
Value engineering in aluminum profiles is not about stealing from the material, but using it wisely. With the right alloy selection, geometry designed for fluid dynamics, and assembly-friendly details, a 15-20% cost advantage can be achieved. Mertcan Metal increases its clients' competitiveness through design consultancy offered before the die order.