English
English
In the field of aluminum profile production, aluminum extrusion molds are key tools whose performance directly affects production efficiency and product quality. However, in the actual production process, various problems often arise with aluminum extrusion molds, which troubles many enterprises. Today, we will delve into these common problems and their underlying causes.
1、 Production efficiency related issues
Mold wear: During long-term use, the mold frequently comes into contact and rubs against aluminum, causing the surface of the mold, especially the parts in contact with aluminum, to gradually wear down. This will not only shorten the service life of the mold and increase the production cost of the enterprise, but also make it difficult for the dimensional accuracy and surface quality of the molded products to meet the requirements. For example, after continuous production for a period of time, a certain aluminum profile factory found that the key parts of the mold had obvious wear and tear, and the size deviation of the produced products was increasing. The mold had to be replaced frequently, which seriously affected the production schedule.
Mold blockage: During the extrusion molding process of aluminum materials, blockage may occur at the exit of the mold, causing the extrusion process to be obstructed or even forced to stop. Unreasonable mold export design, inability to adapt to the flow characteristics of aluminum materials, or poor quality of aluminum materials containing impurities, may all cause blockage problems. A factory once experienced frequent blockages during the extrusion process due to defects in the mold export design, which not only delayed production but also caused a large amount of raw material waste.
2、 Product performance related issues
Dimensional deviation: During the extrusion process of aluminum profiles, it is common to encounter situations where the product dimensions are not up to standard. The reasons for this problem are quite complex, and mold deformation is one of them. During extrusion, the enormous static pressure can cause elastic deformation of the mold. When extruding aluminum profiles with high temperature and strength, the mold is also prone to plastic deformation, resulting in smaller mold holes and product size deviations. In addition, cooling shrinkage and elastic recovery can also cause changes in the size of the product after it is molded, and uneven metal flow can result in a reduction in the end face size and irregular shape of the product.
Surface defects: The surface of extruded aluminum profiles may have scratches, bubbles, large caps, and other defects. Scratches may be due to the surface of the mold not being smooth enough, or foreign objects being mixed in during the extrusion process; Bubbles may be related to the gas content in the aluminum material, as well as factors such as extrusion temperature and speed; The problem of the large cap may be caused by the unevenness of the mold end face, the large outer circle of the feeding chamber, the unpolished water outlet and other internal problems of the mold, or it may be related to process parameters such as extrusion temperature and extrusion ratio. When the end face of the mold is uneven or has defects, it will cause gaps in the locking surface, leading to aluminum flow and resulting in a large cap phenomenon.
Reverse deformation and warping: Reverse deformation refers to the deformation of aluminum material that does not conform to the design shape of the mold when it flows in the mold. This is usually caused by the mold temperature being too high or the extrusion speed being too fast, resulting in abnormal fluidity of the aluminum material. The phenomenon of warping refers to the shape bending and unevenness of aluminum profiles after extrusion molding, mainly caused by uneven cooling or external forces during the extrusion process. For example, during the production process of a certain enterprise, due to the unreasonable design of the cooling system, the aluminum profiles produced showed serious warping and could not meet the customer's usage requirements.
The common problems of aluminum extrusion molds involve multiple aspects of production and product performance, and their root causes cover multiple links such as mold design, manufacturing, use, and process parameter control. Only by deeply understanding these problems and their root causes, taking targeted measures to solve them, such as optimizing mold design, strengthening mold maintenance, and strictly controlling process parameters, can enterprises effectively improve production efficiency, ensure product quality, and stand undefeated in fierce market competition.
