Aluminium Extrusion Manufacturing Process

GAL Aluminium Manufacturing Process

"From concept to completion: Advanced manufacturing for superior aluminium profiles"

GAL Group boasts an ultra-modern tool room capable of producing premium and complex dies. Our tool shop is supported by an international quality billet casting facility. With the help of our abundant dies, we can recommend more than 5500 product outlines to our clients and thus can meet their demands.

State-Of-The-Art Manufacturing Facilities

Our modern plant is equipped with automatically controlled, compact hydraulic extrusion presses, offering the flexibility to extrude 6”, 7”, 8”, and 9” diameter billets. All presses feature precise speed controls and a high degree of stability, ensuring consistent and high-quality output.

Die Components for Die Toolsets

Understanding the intricate components of our die toolsets is crucial to appreciating the precision and quality embedded in every aluminium profile we produce.

• Die Block: This is the main part that all the other parts are attached to.
• Punch Plate: This part holds and supports the different punches in place.
• Blank Punch: This part along with the Blank Die produces the blanked part.
• Pierce Punch: This part along with the Pierce Die removes parts from the blanked finished part.
• Stripper Plate: This is used to hold the material down on the Blank/Pierce Die and strip the material off the punches.
• Pilot: This is used to keep the material being worked on in position.
• Guide / Back gage / Finger stop: These parts are all used to make sure that the material being worked on always goes in the same position, within the die, as the last one.
• Setting (Stop) Block: This part is used to control the depth that the punch goes into the die.
• Blanking Dies: Complement the Blanking Punch in the blanking operation.
• Pierce Die: Works with the Pierce Punch for piercing operations.
• Shank: Used to hold in the presses. It should be aligned and situated at the center of gravity of the plate.

Die Forming

Progressive die with scrap strip and stamping forming dies are typically made by tool and die makers and put into production after mounting into a press. The die is a metal block that is used for forming materials like sheet metal and plastic.

Vacuum Forming Technology

Precision Forming for Automobile Body Parts

For automobile body parts, which demand precise formation of sheet metals, a two-part system is often employed. One part, called the punch, performs stretching, bending, and/or blanking operations. The other part, called the die block, securely clamps the workpiece and provides similar stretching, bending, and/or blanking operations.

• The workpiece may pass through several stages using different tools or operations to obtain the final form.
• In automotive components, there will usually be a shearing operation after the main forming is done and then additional crimping or rolling operations to ensure that all sharp edges are hidden and to add rigidity to the panel.

In-House Powder Coating Capabilities

GAL Group has an in-house powder coating line with the following production capacity and film thickness:

Capability	Specification
Horizontal Powder Coating Line	Annual Capacity: 2400 MT
Minimum Film Thickness	60 Microns

Available Powder Types:

• Epoxy Powder: Excellent hardness and chemical resistance.
• Epoxy Polyester Powder: Good balance of mechanical properties and weather resistance.
• Polyester TGIC Powder: Superior outdoor durability and color retention.

We follow all procedures as per the norms of QUALICOAT with a guarantee period of 5 to 10 Years.

Our Contribution to the Industry