Aluminum extrusion die molding technology
[China Aluminum Network] The manufacturing of aluminum extrusion dies plays a crucial role in determining their quality and service life. Due to the unique characteristics of aluminum extrusion dies, specific requirements have been imposed on the molding technology used for aluminum profiles:
First, since the working conditions for aluminum alloy extrusion molds are extremely harsh, they must endure high temperatures, high pressure, and significant friction during the extrusion process. This necessitates the use of high-strength, heat-resistant alloy steels. The melting, casting, forging, heat treatment, electrical machining, and surface treatment of these materials involve complex processes, which pose numerous challenges in mold production.
Second, to extend the life of the tool and ensure the surface quality of the product, the roughness of the working area of the mold cavity should be between 0.8 and 0.4 μm, while the roughness of the mold plane should be less than 1.6 μm. This requires special attention during the molding process, particularly in polishing techniques and equipment.
Third, with the development of high-precision and sharp-edged extruded products, some profile wall thicknesses have been reduced to approximately 0.5 mm, and tolerances for extruded products have reached ±0.05 mm. To meet these demands, mold manufacturing precision needs to reach 0.01 mm, making traditional methods insufficient. Therefore, it is essential to update the process and adopt advanced specialized equipment.
Fourth, the complexity of aluminum profiles, especially thin-walled hollow and porous hollow-wall profiles, demands ultra-precise manufacturing. These require special die structures with multiple shaped holes on a single mold. The thickness variation in each section is drastic, and dimensions are complex with many curved corners, creating significant difficulties in processing and heat treatment.
Fifth, due to the wide variety of aluminum extrusion products, small batch sizes, and frequent mold changes, there is a high demand for mold adaptability. This calls for increased production efficiency, shorter cycle times, and quick adjustments to the molding process. It is essential to produce qualified molds accurately based on drawings, minimizing repair work and reducing the need for mold modifications.
Sixth, the range of aluminum extrusion tools is extensive, with specifications varying greatly. From small molds measuring 100mm × 25mm and weighing just a few kilograms to large molds up to 1800mm × 450mm and weighing over 2000kg, the differences in size and weight require completely different manufacturing methods and equipment. Additionally, compact extrusion shafts and massive extrusion cylinders also present unique challenges in production.
Seventh, extrusion tools come in various types with complex structures and high assembly precision. In addition to requiring special processing methods and equipment, specific tooling fixtures, tools, and heat treatment techniques are also necessary.
Eighth, to enhance the quality and lifespan of the tools and dies, besides selecting suitable materials and optimizing design, advanced heat treatment and surface strengthening are required. This helps achieve moderate die hardness and superior surface quality, which is especially critical for difficult-to-extrude materials and molds with intricate designs.
In conclusion, while the processing of extrusion dies shares similarities with general mechanical manufacturing, it is a highly specialized technology that involves numerous challenges and spans multiple fields. To produce high-quality, long-lasting molds, it is not only important to select high-quality materials but also to develop reasonable cold working, electrical, heat treatment, and surface treatment processes.
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