Aluminum profile extrusion die correction involves several key aspects aimed at ensuring uniform metal flow and producing high-quality extruded products. The primary methods include adjusting the metal flow distribution ratio, such as modifying the size of die flow diversion holes or channels, adjusting the depth of electric erosion drainage grooves, and optimizing the contact friction coefficient between the metal and the die. Additionally, techniques like using blocking barriers or adjusting the length of die holes can help regulate the speed at which metal exits the die, ensuring even flow and reducing defects.
Mold repair personnel must be well-versed in inspection techniques to accurately identify the root causes of product defects and implement effective corrections. The initial metal flow distribution is typically determined by the mold designer during the design and manufacturing process. Once the mold is produced, this distribution is generally fixed. However, designers should aim for a balanced and reasonable distribution to avoid uneven flow velocities across different sections of the profile, which can complicate mold repairs and, in severe cases, make them impossible.
While the initial metal supply is set, the frictional resistance between the metal and the die can still be adjusted to influence the flow rate. This friction consists of three main components: the contact friction between the metal and the die surface, the friction along the die hole's working belt, and the internal friction between metal particles. By improving these friction conditions, it is possible to fine-tune the metal flow.
Factors such as the amount of metal supplied, the friction conditions, the length of the working belt, and the extrusion speed all contribute to controlling the metal's exit velocity from the die. Mold correction primarily focuses on adjusting the metal flow distribution, friction characteristics, and working belt length to achieve a more uniform metal flow, ultimately resulting in a high-quality extruded profile.
To address issues caused by uneven metal flow, it's essential to study how to balance the flow rate across different sections of the profile. This principle is fundamental in both mold design and the daily operations of molders. Although various factors influence the metal's exit speed, they can be broadly categorized into two main aspects:
a. Whether the metal flow is appropriately distributed across all parts of the profile, meaning the ratio of the cross-sectional area of each section matches the corresponding metal supply.
b. The impact of frictional resistance on the flow. When more metal is supplied to a particular area, the friction is reduced, leading to a faster extrusion speed in that section, and vice versa.
In summary, the key to repairing aluminum extrusion dies lies in accurate analysis, proper judgment, and rational adjustment of the metal flow rate.
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