How are aluminum extrusion dies designed?
The design of an aluminum extrusion die is a complex and delicate process that requires a number of factors to be considered to ensure that the die is capable of efficiently and accurately producing aluminum profiles.
The main steps and points of aluminum extrusion die design are listed in detail below:
Preliminary Preparation
Familiarize yourself with the dimensions and deviations of the aluminum profile:
The dimensions and deviations of an aluminum profile are determined by the extrusion die, extrusion equipment and other relevant process factors. Therefore, before designing, it is necessary to know in detail the target size of aluminum profiles and the permissible deviation range.
Select the correct tonnage of aluminum extruder:
According to the characteristics of aluminum profiles and production requirements, choose the right tonnage of extruder. The choice of extrusion ratio has an important impact on the mechanical properties and appearance quality of aluminum profiles, which needs to be determined according to the specific product requirements.
2. Mold design
1. Determine the extrusion shape, finished product size, material, embryo diameter, wall thickness, etc.: these parameters are the basis of the design, and need to be accurately set according to product requirements.
2. Drawing design drawings: According to the determined parameters, draw the design drawings of extrusion molding, clear extrusion cross-section size and shape.
3. Make CAD three-dimensional model and two-dimensional drawings: Use CAD software to transform the design drawings into three-dimensional models and two-dimensional drawings for subsequent processing and manufacturing.
Mold processing
1. CNC machining and electrode discharge machining: according to CAD drawings, use high-precision equipment for CNC machining and electrode discharge machining of the mold.
2. Finishing and deburring: after completing CNC and electrode discharge machining, carry out subsequent machining operations such as finishing and deburring to ensure the accuracy and quality of the mold.
Detailed design of the mold
1. Welding chamber height design:
The height of the welding chamber is generally taken as 10-15% of the inner diameter of the extrusion cylinder to ensure that sufficient static pressure can be established to avoid poor welding.
2. Die hole size design:
Considering the mold deformation and other factors, the design of die hole size needs to follow a certain formula, such as A = (1 + K) A0 + T, where Ao is the nominal size of the profile, T is the allowable deviation of the profile, and K is the empirical coefficient, which takes the value of 0.006-0.012.
3. Design of mold hole working belt and empty knife:
According to the differences in wall thickness of each part of the profile section will be divided into a number of segments, according to the principle of equal flow rate of metal mass points in each segment of the profile to determine the length of the working belt. The design of the empty knife is selected according to the thickness and shape of the product to ensure the strength of the mold and reduce resistance.
Finally, other considerations
1. Avoidance of mold flow rate deviation: When designing, we need to pay attention to the aluminum flow rate ratio, chamber size and length, local working belt length and other factors, in order to avoid the flow rate deviation caused by the plugging of the mold and other problems.
2. Selection of the size of the empty knife: the selection of the size of the empty knife needs to be determined according to the size of the die and the tonnage of the extruder, too small may lead to deformation and cracking of the working belt without support, while too large may lead to mold plugging.
Summarize
Aluminum extrusion die design is a comprehensive consideration of a number of factors in the process, the need for accurate calculations and meticulous operation to ensure the accuracy and quality of the die.
Hugh Aluminum is an aluminum extrusion manufacturer based in China. We have aluminum extrusion die design, powder coating, anodizing, CNC and polishing processing capabilities. We are 15 years experienced aluminum extrusion supplier and can offer you factory price and high quality products.
