Aluminum extrusion die molding technology

[China Aluminum Network] The production of aluminum extrusion dies is a critical factor that influences their quality and durability. Due to the unique characteristics of aluminum extrusion dies, specific requirements have been imposed on the molding technology used in the manufacturing process:

First, aluminum extrusion molds operate under extremely harsh conditions, facing high temperatures, intense pressure, and significant friction during the extrusion process. As a result, high-strength and heat-resistant alloy steels are essential. The melting, casting, forging, heat treatment, electrical machining, and surface finishing processes involved are all highly complex, presenting numerous challenges in mold production.

Second, to enhance the lifespan of the tools and ensure the surface quality of the final product, the roughness of the working areas of the die cavity should be maintained between 0.8 and 0.4 μm, while the flat surfaces should have a roughness below 1.6 μm. This requires careful attention to polishing techniques and specialized equipment during the molding process.

Third, with the development of high-precision and sharp-ended extruded products, some profiles and tubes now require wall thicknesses as low as 0.5 mm, and dimensional tolerances can reach ±0.05 mm. The required mold precision must be as tight as 0.01 mm, which traditional methods cannot achieve. Therefore, it is necessary to update the process and adopt advanced, specialized equipment.

Fourth, the complexity of aluminum profiles, especially thin-walled hollow sections and porous structures, demands extremely high precision. These types of molds often feature multiple custom-shaped holes and sharp variations in thickness. The dimensions are intricate, with many curved corners, making processing and heat treatment particularly challenging.

Fifth, given the wide variety of aluminum extrusion products, small batch sizes, frequent mold changes, and the need for high adaptability, it is crucial to improve the efficiency of mold production, shorten the manufacturing cycle, and quickly adjust the molding process. The goal is to produce qualified molds accurately based on the drawings, while minimizing repair work and reducing downtime.

Sixth, the range of extrusion tools is vast, from small molds measuring 100mm×25mm (weighing just a few kilograms) to large molds as big as 1800mm×450mm (with weights exceeding 2000 kg). Compact extrusion shafts can be as small as 65mm×800mm, while large extrusion cylinders may weigh over 100 tons and measure 2500mm×2600mm. These huge differences in size and weight necessitate entirely different manufacturing approaches and specialized equipment.

Seventh, extrusion tools come in various types and have complex structures, requiring high assembly precision. In addition to special processing methods and equipment, custom tooling fixtures, specific heat treatment techniques, and tailored manufacturing procedures are also needed.

Lastly, to improve the quality and longevity of the tools and dies, besides selecting suitable materials and optimizing the design, advanced heat treatment and surface strengthening techniques are essential. These help achieve an ideal balance of hardness and surface finish, which is especially crucial for difficult-to-extrude materials and complex-shaped molds.

In summary, while the manufacturing of extrusion dies shares similarities with general mechanical processes, it is a highly specialized field filled with challenges and covering a broad range of disciplines. To produce high-quality, long-lasting molds, it's not only about choosing premium materials but also about developing appropriate cold working, electrical, heat treatment, and surface finishing processes.

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