How to make a correct judgment and repair the aluminum profile die according to the die test situation

The existing problems and solutions of aluminum profile extrusion die are as follows:

1. In order to meet the size requirements, the aluminum profile produced by extrusion die must first ensure the uniformity of metal flow. Extruded profiles often appear concave phenomenon, which leads to the whole surface subsidence and the flatness is not up to standard.

Through a lot of practice, it is concluded that the deep groove profile is caused by insufficient metal supply at the groove.

When manufacturing the aluminum profile extrusion die, the groove of the die should be ensured to be straight enough. If the trial production is unqualified, the groove should be widened appropriately.

For the profile with small groove depth and width, as long as the working area is designed reasonably, the diversion groove is processed according to the die neck angle, and the metal flow rate is controlled well, the sag phenomenon can be avoided.

For the profile with wide groove and deep groove, deepen the two corner guide grooves to ensure the uniform metal flow between the two corners and the middle.

2. When producing angled profiles, if the die is not designed for pre-deformation (pre-opening), after stretching and straightening, the profile angle is often smaller than the product requirements 1-3. In the process of die design and manufacture, the profile hole of die workpiece needs to be deformed 1-3, and the profile deformation changes with the change of external pressure circle.

Once the angle of the profile is pre-deformed, the phenomenon of small angle (closure) still appears, and the following two simple repair methods can be adopted: First, if the angle is small (closure), the flow can be promoted internally.

Secondly, the choke block can be welded on the outside.

The choice of method depends on the surface treatment of profile.

3. The profile with thick wall thickness is produced by conventional thinning, and the metal supply at the end of the profile is insufficient, resulting in shrinkage error. Although the die hole size is consistent, the product size does not meet the requirements.

There are several important factors to control the profile size.

Firstly, when designing the deflector, according to the tonnage of the machine and the diameters of the extrusion cylinder and aluminum rod, the largest optimal circumscribed circle is selected to determine the inlet of the deflector, so as to increase the metal supply above the profiles at both ends;

Secondly, the die enters the first-class welding chamber on the surface of the material, and the two ends avoid the large value, which ensures the stability of metal flow at both ends and the supply of metal above the profile at both ends, which is beneficial to the flatness and surface quality of the profile;

Finally, according to the similar profiles produced in the past, the profile holes are pre-deformed.

When designing a new contour, we can find a similar contour, try to design with a set of its parameters as the initial parameters, and then gradually adjust each parameter until it meets the requirements.

4. When the die meets the use requirements, there are screw holes or grooves on the surface of the extruded profile in the middle and transverse positions, which affects the surface quality of the profile.

Through practice, it is concluded that the transition of the working belt should be smooth when adjusting the outlet position of the working belt of the upper die and the lower die when machining the die.

The working area of the empty cutter under the diversion groove and the empty cutter under the perforation should be shortened (increased) by 0.3- 1.0mm, and the diversion groove should be aligned to ensure proper metal feeding.

Thick profiles even need to be shortened (increased) by 2mm to ensure the surface quality of profiles.