Review of planning and production control in aluminum industry

History of Aluminum Rolling Company

1-Introduction

Arak Aluminum Rolling Company was established in 1351, 2 km from Arak-Aqran road, on a land with an area of ??22 hectares, approximately 1.2 hectares of which is under the factory building and administrative role, and 2 hectares of it is green and open space, which is the development and expansion and renovation of Iran's industries. After the installation of the machines and the start-up of Almefa, the first production of the factory was realized in 1364. The subject of the company is the establishment of manufacturing and industrial factories for the purpose of manufacturing aluminum sheets and any other aluminum products.

Consumable raw materials

The raw materials used by the group are aluminum slabs or ingots in different alloy groups, mainly group 1 and 3, which are in the shape of a rectangular cube with dimensions of 25 x 51 x 3 cm and It weighs approximately 2.3 tons, which is supplied from within the country (mostly from Iralco) or abroad, depending on the type of alloy. Slabs with alloy 11 and 33 are the most used.

Description of the production line

The company's lines are divided into two categories: heavy lines and light lines, each of which includes other lines, which are:

1- Heavy lines: including hot rolling and cold rolling lines.

2- Light lines: including transverse cutting line, forming line, pipe making line, strapping line or slitter is In general, the operations that are carried out in the production line are as follows:

Given that the surfaces of the ingots in the casting stage have uneven surfaces and in the hot rolling stage they face technological problems such as creating waves on the edge or in the middle of the sheet, which is better to remove their surfaces by (SCALPER ingot lathe) in the amount of four to six millimeters. After this stage (the ingot enters the Shams HEALING FARNACE furnace), the ingots are heated in this furnace to 450-550 degrees Celsius depending on the alloy type. After the ingot is ready to be delivered to the hot rolling line, it is placed on the hot rolling rail by a overhead crane and pushed to the hot rolling by a carriage. Roll the 270 mm thick billet into a coil or sheet with a thickness of 4.6 mm with a maximum of 17 passes in the HOT MILL hot rolling machine. The quality control unit controls the product produced by Nordem Garm both during the production stages (various passes) and at the end. If the order is about a sheet with a thickness of 30 to 4.6 mm, it will be cut by scissors installed at the end of the hot rolling rail and sent to the product warehouse after packaging. In order to reduce the thickness to less than 4.6 mm, the coils are kept in the warehouse for 24 hours during hot rolling to reach the ambient temperature. Then it enters the COLD MILL line and is reduced to a thickness of 3 mm in three passes. The quality control unit supervises the production of the coils of this machine and controls their quality. After this stage, the coils enter the ANNEALING FUNNACE and, depending on the type of alloy, they are heated between 410-350 degrees for fifteen hours, then they are left to reach the ambient temperature (24 hours) Cold rolled to reach a thickness of less than 3 mm. After the approval of the quality control unit, it enters the longitudinal cutting line and is sent to a width of 1000 mm for light lines (forming and transverse cutting) and belts for pipeline construction. All coil, belt, tube, simple and shaped sheet products are prepared and all products are taken off the line with the approval of the quality control unit and delivered to the product warehouse.

Casting

Aluminum alloys can be produced by most casting methods, sand casting, permanent mold casting and pressure casting are among the methods that are often used. Most aluminum alloys have silicon and magnesium, and copper, iron and zinc are other elements that make up aluminum alloys.

Aluminum alloys

are melted in furnaces that are heated directly or indirectly with fuel. Melting of aluminum alloys is also done in electric furnaces. The casting ability of aluminum alloys changes with the combination of elements. Aluminum alloys that contain silicon are easier to cast and create the most fluidity for casting deep and narrow parts. In general, the higher the percentage of silicon is than the autotechnic composition (12.Melting of aluminum alloys is also done in electric furnaces. The casting ability of aluminum alloys changes with the combination of elements. Aluminum alloys that contain silicon are easier to cast and create the most fluidity for casting deep and narrow parts. In general, the higher the percentage of silicon is than the autotechnic composition (12.5% ??silicon), the easier it is to cast the aluminum alloy. The most difficult aluminum alloy to cast is the alloy that has significant amounts of magnesium.

Types Aluminum alloy castings are:- Sand casting

- Plaster mold casting shell casting (loose sand)

- Carbon oxide casting

- Precision precision casting

- Permanent mold casting

Pressure casting

Suitable casting based on the size, weight, shape, number of pieces to be produced, mechanical properties, precision dimensions The necessary and the cost of making cast parts are selected in different ways based on the conditions. Emphasized conditions such as mechanical characteristics or dimensional accuracy may limit the choice of methods to two methods, for example, ultra casting can be produced either with a plaster mold or a precision method. The choice between the two methods depends on the size and shape of the casting part and its cost. If the casting part is small, for example, the precision method is used for a large casting part. The plaster mold method is more suitable when a casting part can be successfully made in three or more ways. In this case, the required production quantity is generally the determining factor. A 5 kg casting piece with medium complexity and unusual condition table in terms of mechanical properties with dimensional accuracy can be cast in four different ways from one sample to a high production rate. In the initial stage of increasing production, sand casting is used. With the increase of production amount and choosing the appropriate molding method, the cost of each casting piece increases, reducing the equipment.