General Extrusions - Aluminum Extrusions

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Design Guide for Aluminum Extrusions

We're here to help - General Extrusions offers Engineering Support

Aluminum extrusions can reduce assembly time and improve component appearance and performance. Use these basic design considerations to convert from other processes or create a new aluminum component.

The push to combine higher quality with lower costs has never been stronger than today. But nowhere do those goals compete more aggressively than on the design engineer's desk.

At General Extrusions, we offer the engineering support you need to meet your performance and cost goals without sacrificing quality.

Aluminum extrusions can reduce assembly time and improve component appearance and performance.

Many of the component parts now machined, cast, stamped, formed and welded can be converted to extrusions, resulting in greater strength, dimensional stability, fewer assembly operations and the most efficient use of material.

Once your component is designed, General Extrusions can provide the extrusion, the fabrication and finishing operations as well--for single-source convenience and quality assurance.

A complete design guide kit is available upon request or view design guide here.

Samples

Instead of this... ...examine this  
General Extrusions welding example General Extrusions extrusion example Convert forging into a low-cost extrusion.

Machining from Bar
Stock

Sand Castings


Stampings
Forming


Weldments
Hobbing
General Extrusions extrusion example Convert powdered metal gear into an extrusion.
General Extrusions extrusion example Convert a die cast housing into an extrusion.
General Extrusions extrusion example Convert a stamping into an extrusion.
General Extrusions die cast example General Extrusions extrusion example Convert a die sand casting into an extrusion.


 

Instead of this... ...do this  
General Extrusions indexing mark General Extrusions indexing mark Built-in indexing mark.

An index can also be used to help identify pieces that are similar in appearance, or to distinguish an inside vs. an outside surface.

General Extrusions knife edge General Extrusions avoid knife edge Avoid knife edges.

A knife edge is difficult to fill, and when extruded will appear wavy. Change the profile to blunt or rounded part.

General Extrusions semi hollow area * Symmetry preferred in semi-hollow areas.

When designing, visualize the die that will be necessary to produce the shape. In this case, by keeping the void symmetrical about the throat opening, the pressure on the die "tongue" is balanced and die breakage is minimized.

* General Extrusions semi hollow area Rounded corner strengthens tongue.

The preceding cross section has been further improved. The die tongue is now less likely to snap off.

General Extrusions void area General Extrusions reduce void areas Reduce areas of void.

Further improvement results if outline can be changed to reduce area enclosed. Reduced area means less pressure on the tongue; easier extrusion.

      A. Original void area
      B. Void area reduced


 

THREAD
SIZE:
PERCENT THREAD - CUT TAP PERCENT THREAD - ROLL FORM
60% 65% 70% 75% 80% 60% 65% 70% 75%
3-48 0.0828 0.0814 0.0801 0.0787 0.0774 0.0905 0.0898 0.0890 0.0884
4-40 0.0925 0.0909 0.0893 0.0876 0.0860 0.1018 0.1010 0.1000 0.0993
5-40 0.1055 0.1039 0.1023 0.1006 0.0900 0.1148 0.1140 0.1130 0.1123
6-32 0.1136 0.1116 0.1096 0.1076 0.1055 0.1252 0.1243 0.1230 0.1221
8-32 0.1396 0.1376 0.1356 0.1336 0.1315 0.1512 0.1503 0.1490 0.1481
10-24 0.1575 0.1548 0.1521 0.1494 0.1467 0.1729 0.1717 0.1700 0.1688
10-32 0.1656 0.1636 0.1616 0.1596 0.1575 0.1772 0.1763 0.1750 0.1741
12-24 0.1835 0.1808 0.1781 0.1754 0.1727 0.1989 0.1977 0.1960 0.1948
1/4-28 0.2110 0.2078 0.2045 0.2013 0.1980 0.2295 0.2280 0.2260 0.2245
1/4-28 0.2222 0.2198 0.2175 0.2152 0.2129 0.2354 0.2343 0.2329 0.2318
5/16-18 0.2692 0.2656 0.2620 0.2584 0.2548 0.2898 0.2879 0.2861 0.2842
5/16-24 0.2800 0.2773 0.2746 0.2719 0.2692 0.2955 0.2941 0.2927 0.2912
3/8-16 0.3263 0.3222 0.3182 0.3141 0.3101 0.3495 0.3474 0.3452 0.3431
3/8-24 0.3425 0.3398 0.3371 0.3344 0.3317 0.3580 0.3566 0.3552 0.3537