How to reasonably use aluminum extrusion die

So, how can we use these molds more efficiently? Here are some practical steps to consider:

(1) Strictly Follow Extrusion Process Guidelines

It is essential to follow the prescribed extrusion process for aluminum profiles. During the initial heating phase, the temperature of the aluminum billet in the furnace should be set between 530°C and 550°C, while the outlet section should be maintained at 480°C to 500°C. The holding time must be sufficient to ensure that the entire billet is uniformly heated—both the core and the surface. If the core isn't properly heated, it can lead to uneven thermal expansion, causing elastic deformation of the die, which may result in issues like misalignment or uneven lengths. In severe cases, this could even cause plastic deformation and damage to the extrusion die.

(2) Ensure the "Three Centers" Are Aligned

The center of the extrusion sleeve, the center of the extrusion rod, and the center of the die holder must all be perfectly aligned. Any noticeable eccentricity can affect the flow velocity of the extruded product, leading to irregular shapes or differences in length, which can halt production entirely.

(3) Choose the Right Support Pads

Selecting the appropriate size of two-hole special support pads is crucial to minimize elastic deformation of the lower die, ensuring better shape stability and minimal size changes in the extruded product. Before placing the mold in the furnace, it's important to have a suitable double-hole support pad ready. Otherwise, if you wait too long to find the right pad, the die may cool down excessively, leading to issues like "stuffy car" problems during extrusion.

(4) Improve Information Feedback in the Extrusion Process

A. Feedback on Die Plug Issues

There are many possible reasons for die plug problems, and it's often difficult for untrained personnel to describe them clearly. It’s better to involve experienced supervisors or technicians to identify the root cause before taking action.

B. Feed Molding Feedback

In addition to having a clear die head with an extrusion die number, it's important to note the flow direction on the material head, especially when it's hard to see. For example: “cross-feed” indicates that the outer side is slower; “discharge from the material” suggests similar issues; and “left long, right short” means the left branch is longer than the right. Pay attention to the difference in length, as the distance from the cut-off saw to the discharge port is about 6 meters. Expressing the issue as “A meter per 6 meters” helps in accurately identifying the problem, which is vital for proper maintenance and repair.

C. Feedback on Oversize Errors

If the molding looks normal but the dimensions are off, it's essential to take a sample to correctly identify the issue (including the extrusion die number, discharge direction, and specific size defects). Any mistake in identification could lead to fixing the wrong die, so this step must be taken very seriously.

By implementing a complete and accurate information feedback system, maintenance teams can make better judgments, improve efficiency, reduce the number of repairs, and avoid unnecessary trial runs. This not only saves time and resources but also enhances the overall performance of the extrusion process.