“For most engineers, injection molding and stamping are the most common processes, and little is known about aluminum or aluminum extrusion. However we see a trend that aluminum or aluminum extrusion is increasingly used in various industries, and the use of aluminum extrusion can play an unexpected role in cost reduction and weight reduction.”
In our last blog (Aluminum Extrusion Explained, Pros and Cons) we briefly covered the fundamentals of aluminum extrusion, extrusion methods, material selection, and the advantages and disadvantages of aluminum extrusion. Only when we fully understand the process, tooling, characteristics, and application of aluminum extrusion molding and other related knowledge, we can be able to design aluminum extrusions to ensure high quality and low cost of aluminum extrusions, which is the most critical point for good DFM.
To bring you a more comprehensive understanding of aluminum extrusion molding. This chapter will elaborate on the aluminum extrusion process from three aspects: extrusion aluminum touch tool, process characteristics, and application scenarios.
Aluminum Extrusion Dies
Although product design engineers do not design aluminum extrusion dies, understanding the basic extrusion die structure and the mechanism of how it forms different extrusion profiles can help to reduce die costs and improve extrusion productivity through optimized design when designing extrusions.
What are Aluminum Extrusion Dies
Extrusion dies are essentially thick, circular steel discs containing one or more openings to form the desired profile. They are typically made of H-13 die steel and are heat-treated to withstand the pressure and heat of hot aluminum as it passes through the die.
Aluminum Extrusion Dies
Although aluminum appears to be a very soft metal, it takes a lot of pressure to push a solid aluminum ingot (billet) through a thin, porous aluminum extrusion die to form the desired shape.
Types of Extrusion Dies
According to the cross-sectional shape of aluminum extrusions, their corresponding dies are divided into three categories: solid dies, semi-hollow dies, and hollow dies. Among them, the hollow die has the most complicated structure, easy to wear and break, and has the highest cost.
Solid Aluminum Extrusion Die
Hollow Aluminum Extrusion Die
Semi-hollow Aluminum Extrusion Die
Extrusion Die Life
Heat buildup and uneven pressures (e.g., thin walls, uneven wall thicknesses, and protruding features) resulting from aluminum extrusion design are the biggest killers of extrusion die life.
Heat and uneven pressures can be controlled by proper die design and extrusion speeds can be reduced to extend die life, but eventually dies must be replaced.
Before designing an aluminum extrusion, the product structural design engineer should understand which design features will most significantly affect tooling costs. Changing the design of the aluminum extrusion cross-section, setting proper tolerances, and selecting the right aluminum alloy material can save the machining cost of the aluminum extrusion die according to the requirements.
If you have any questions on Aluminum Extrusion Service, Custom Parts Manufacturing. We will give the professional answers to your questions.