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extrusion die | extrusion dies | Why Extrusion Dies Perform Differently
extrusion die | extrusion dies | Why Extrusion Dies Perform Differently
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Author: Site Editor Publish Time: 2021-12-06 Origin:
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Why Extrusion
Dies Perform Differently
It has long been a mystery as to why some dies turn out to be a major problem for the
Technician and the Production team. These particular dies can be to produce a relatively
simple profile but can be the cause of many discussions and possibly heated exchanges
between Technicians and Production staff.
Let us consider the various scenarios involved.
1.regularly running die that has been hitherto free of problems.
The most likely cause is that the die has worn and thereby gone out of correction. By this I
mean the die has repeatedly used and re-polished and nitride on many occasions and the
bearings have become rounded thus changing it’s extrusion characteristics. The surface
quality may deteriorate and blend lines may appear. The changes in friction may result in
length differences in the case of multi-cavity dies.
The solutions are to study the information and front-ends and check the die thoroughly. The
die can then be brought back into correction providing the tool has sufficient tolerance left
in the die openings. Otherwise a replacement tool should be ordered and the Die
manufacturer advised of any problems. If any improvements to the die design can be made
these should be suggested at this time.
2. A frequently problematic die.
These are the bane of all technicians life. The problem must be approached in a methodical
and scientific way. The solution to such a problem is more often than not in the die design.
This statement is not meant to detract from the die designer as they have done the best they
can at the time. The onus falls now on the die technicians to arrive at an improved design
based on the results obtained. It is all too easy just to dismiss the design as a bad one
and try another die from a different manufacturer. Factors that should be considered are
m any and include die size, bearing lengths, integral recesses, mandrel depth, web
thickness, port openings, flow availability, extrusion breakthrough pressures and extrusion
ratio to name but a few.
The solution is to involve the technicians and the manufacturer and discuss the problems
originating from the die. If the problems are dramatic then a dramatic re-think in design
must follow. If all that can be suggested is a minor change or two of the bearing lengths
then another manufacturer should be consulted and the problems encountered outlined.
3. Surface quality problems.
The quality of the bearing surface has an effect on the overall surface of the extrusion. If
the bearing surface is pitted with spark-erosion marks or has wear from over use then the
solution is obvious. Namely, file and check the bearing for flatness, square-ness and then
re-harden.
If the quality problems are in the form of different colours or banding then the underlying
cause must be detected. The position of any banding in relation to any bearing changes on
the die design should be looked at. If these areas match then the probable cause is at hand.
The solution is to naturally advise the die supplier of the problem and discuss with them
any solution for the next die. The bearing changes can be reduced in many cases without
causing any problems to the die, especially if they are only localised and incorporated in
the design to " hold back a small mass ". The bearing may be removed completely and a
match to the adjacent bearings obtained.
Sharp bearing changes should be present on a modern die and the exit corners of such a
bearing should be smoothly curved with as large a radius as possible.
Bearing changes that extend past the mass area and into the thinner adjacent bearings
should be moved and this will help eliminate the banding on either side of the mass area.
Wherever possible the tapers of the bearing changes should be as long as possible so as to
prevent any sudden localised differences in friction. If the bearing changes are longer then
the likelihood of surface problems will be greatly reduced.
Why Dies Perform Differently
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