Extrusion die design is a critical task for enhancing production efficiency, as it directly impacts product quality, production time, and costs. The design influences the uniformity of metal flow, and improper design can lead to defects in the finished product.
Dies for extruded aluminum profiles fall into two main categories: solid dies and hollow dies. Solid dies are used for extruding solid profiles and can be designed with a thin profile. Hollow dies can be further classified into flat porthole dies, spider dies, and bridge (tongue) dies; among these, the flat porthole die is the most widely used. Flat porthole dies enable the production of high-precision, complex, thin-walled hollow profiles, though die correction and scrap removal are relatively difficult. Spider dies require lower extrusion force, offer higher yields, and facilitate easier scrap removal, but they are more difficult to manufacture. Bridge dies offer low extrusion resistance, easy scrap removal, and convenient die correction, making them suitable for thin-walled hollow profiles that require higher extrusion forces.
Die design involves several core elements. The layout of die apertures on the die face must account for extrusion stability, the protection of decorative surfaces, metal flow characteristics, and structural strength; thin-walled sections should be positioned as close to the center of the extrusion container as possible. The shape, number, size, and arrangement of the portholes significantly influence metal flow and must be determined based on the size of the extrusion container and the shape of the product.
