How to reasonably use aluminum extrusion die

So, how can we use these molds more effectively? Here are some key considerations:

1. Strict Adherence to Extrusion Process Guidelines

It’s essential to follow the extrusion process strictly. During the preheating stage, the temperature in the billet furnace should be set between 530°C and 550°C, while the exit section should be maintained at 480°C to 500°C. The holding time must be sufficient to ensure that the entire billet is evenly heated—both the core and surface. If the core isn’t warm enough, it can lead to uneven thermal expansion, causing elastic deformation of the die, which may result in misalignment, length discrepancies, or even permanent deformation and failure of the 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 be perfectly concentric. Any noticeable eccentricity can affect the flow velocity of the extruded material, leading to irregular shapes or inconsistent lengths, ultimately hindering the extrusion process.

3. Proper Selection of Support Pads

Choosing the right size of dual-hole support pads is crucial. They help reduce elastic deformation of the lower die, ensuring better shape stability and minimal dimensional changes in the extruded product. Before placing the die in the furnace, it’s important to have a backup support pad ready. Delaying this step can cause the die to cool too much, resulting in a stuck extrusion or "stuffy car" situation.

4. Strengthen Information Feedback in the Extrusion Process

A. Feedback on Die Plugs

There are many possible reasons for a plugged die, and it’s often difficult for untrained personnel to describe the issue accurately. It’s best to involve experienced technicians who can identify the root cause through proper communication and analysis.

B. Feeding Molding Feedback

In addition to clearly marking the extrusion die number on the die head, it's important to note the overall flow direction, especially when it's hard to see from the material head. Common issues include “cross-feed,” where the outer side flows slower than the inner part; “discharge from the material,” indicating similar flow imbalances; and “left long, right short,” meaning one branch is longer than the other. Noting the exact difference in length is crucial, as the distance from the cutting saw to the discharge port is about 6 meters. Expressing the deviation in the format “A meter/6 meters” helps maintenance staff make accurate judgments and repairs.

C. Feedback on Oversize Errors

If the extrusion looks normal but the dimensions are off, a sample must be taken to accurately identify the problem (including the die number, discharge direction, and specific size defects). Even a small mistake in identification can lead to incorrect die repairs, so attention to detail is vital.

By implementing a comprehensive feedback system, maintenance teams can make better decisions, improve mold maintenance efficiency, and reduce unnecessary trial runs and repairs. This approach not only saves time and resources but also contributes to the longevity and performance of the extrusion dies.