Die mold manufacturing, one of the key factors to determine its quality and service life on aluminum extrusion processing profile. As there are a series of characteristics on aluminum extrusion die mold, it needs much highly requirements on making aluminum die mold.
1. There are a series of difficulties on making aluminum die mold process because of the bad working conditions. Due to withstand high temperature high pressure and the effect of high friction in the extrusion process, high-strength alloy steel are needed for which the processing on smelting, casting, forging, heat treatment, machining, mechanical processing and surface treatment are complex.
2. In order to improve the service life of aluminum extrusion processing die mold and ensure the surface quality of the product, the roughness of the mold cavity working belt is required to reach 0.8-0.4μm, and the roughness of the mold plane is below 1.6μm, therefore, special polishing process and polishing equipment are needed while making the aluminum die mold.
3. Due to the development of extrusion products in the direction of high, fine and sharp, the wall thickness of some profiles and pipes is required to be reduced to about 0.5mm, and the tolerance of the extruded aluminum products is required to reach ±0.05mm. In order to extrude ultra-high precision products, the manufacturing accuracy of the aluminum die mold is required to reach 0.01mm that the traditional process can not be manufactured at all. Therefore, It is required to update the process and adopt new special equipment. For example: CNC lathe, CNC machining center and slow wire processing and other advanced high precision processing equipment.
4. The section of aluminum profile is very complex, especially the ultra-high precision of the thin-wall hollow extrusions and porous hollow wall aluminum extrusions, which required to use special structure of extrusion die mold that have more than one profile hole cavity in a die mould at the same time with the thickness of each section change sharply, the related dimension complex, arc corner lot, as a result, this has brought a lot of trouble to die mold processing and heat treatment.
5. Aluminum extrusion processing products of various varieties, small batch, frequent die change, the requirements of strong adaptability of the die mold. Therefore, it is required to improve the production efficiency of mold making, shorten the mold making cycle as far as possible so as to change the die mold making procedure quickly, process the qualified die mold according to the drawing accurately, and reduce the workload of mold repairing to the lowest degree.
6. Since the application of aluminum extrusion processing products are becoming more and more widely with the broad range of specifications, therefore, there are not only the light to several kilograms with the size of 100mm×25mm small die mold, but also more than 2000kg with the size of 1800mm×450mm large die mold. There are light to a few kilograms with the size of 65mmx800mm small extrusion shaft, but also the weight of more than 100T with the size of 2500mmx2600mm large extrusion cylinder. The huge differences in the specifications and quality of die molds which require completely different manufacturing methods, procedures and processing equipment.
7. With various types, complex structure and highly assembly accuracy requirements of extrusion aluminum die mold, it is necessary to use special tooling, clamping tools and special heat treatment methods except requiring special processing methods and special equipment.
8. In order to improve the quality and service life of die mold, it is necessary to use * better heat treatment and surface strengthening treatment technology so that to obtain the mold hardness of moderate and high surface quality except choosing reasonable materials and optimization design, which is particular important for the extrusion products with extremely complex shape and die mold with special structure.
To sum up, in fact, it is different from the general mechanical manufacturing technology, the processing technology of aluminum extrusion die mold is a special technology with lot of difficulties and involves a wide range of areas. In order to produce high quality and high life of the mold, it is not only the selection and preparation of high quality mold materials, but also to make up a reasonable cold processing technology, electrical processing technology, heat treatment technology and surface treatment.
