English
English
In the booming development of the aluminum profile processing industry, aluminum extrusion molds, as key tools, directly determine production efficiency and product quality based on their performance. However, the aluminum extrusion mold industry is currently facing a serious pain point - the contradiction between mold life and cost. This contradiction not only constrains the production efficiency of enterprises, but also poses a challenge to the sustainable development of the entire industry.
The short lifespan of molds means that companies need to frequently replace them, which undoubtedly increases production costs. According to industry data, some companies spend 10% to 15% of their production costs annually on mold replacement. Meanwhile, frequent replacement of molds can also lead to production interruptions, reduce production efficiency, and increase the rate of defective products. The need to reduce costs may also lead companies to compromise on mold material selection, manufacturing processes, and other aspects, further shortening the lifespan of molds and forming a vicious cycle.
The reasons for the contradiction between mold lifespan and cost are multifaceted. From the perspective of mold materials, choosing the appropriate material is crucial. For example, some companies choose lower priced mold steel, such as Cr12MoV mold steel, in order to reduce costs. Its carbon content is as high as 1.5%, and it has high brittleness, which is prone to cracking and shortens the life of the mold. Mold steel with high toughness, such as LG mold steel, although has 8-9 times the toughness of DC53 and can effectively solve cracking problems, its price is relatively high, which makes many companies hesitate under cost pressure.
The manufacturing process is also a key factor affecting the lifespan and cost of molds. The manufacturing accuracy, surface quality, and heat treatment process of molds all have a significant impact on their performance. For example, there is significant tensile stress on the surface of the mold after electrical discharge machining. Without tempering treatment, microcracks are prone to occur, causing stress concentration, reducing the fatigue strength of the mold, and shortening its lifespan. Reasonable tempering treatment will also increase certain costs.
To solve this contradiction, enterprises can start from multiple aspects. In material selection, we should not only focus on cost, but also consider the performance of the material comprehensively. For some production scenarios that require high mold life, choosing high-performance mold steel, such as LG mold steel, although requires a large initial investment, can effectively reduce overall costs in the long run due to the extended mold life.
Optimizing manufacturing processes is equally important. In the process of mold manufacturing, improving processing accuracy, ensuring smooth mold surface, reducing micro defects, can effectively improve mold life. For molds that have undergone electrical discharge machining, tempering treatment is carried out to remove residual tensile stress and improve the fatigue resistance of the mold. Reasonably control the heat treatment process parameters, such as in the quenching process, the heating rate in the high-temperature section should be fast, and the insulation time should not be too long to prevent the extrusion mold from overheating or overheating; Timely temper after quenching to avoid cracking.
Strengthening the maintenance and management of molds is also an effective means to reduce costs and extend their lifespan. Establishing a comprehensive mold maintenance system, regularly inspecting, maintaining, and repairing molds, promptly identifying and resolving potential problems, can prevent small problems from escalating into major malfunctions, thereby extending the service life of molds.
The contradiction between mold life and cost in the aluminum extrusion mold industry is a complex issue that requires comprehensive measures from multiple aspects such as material selection, manufacturing processes, and maintenance management by enterprises. Only through continuous optimization and innovation can we effectively reduce costs, improve the competitiveness of enterprises, and promote the development of the aluminum extrusion mold industry towards high-quality and sustainable direction while ensuring the service life of molds. I believe that with the continuous advancement of technology and the continuous exploration of the industry, this pain point will gradually be solved, injecting new vitality into the development of the aluminum profile processing industry.
