Design of Dies for Multi-Tool-Head Automotive Aluminum Alloy Profiles

01 Preface

In the automotive manufacturing industry, aluminum alloy profiles are widely used in the manufacturing of structural components and parts due to their lightweight, high strength, corrosion resistance, and other advantages. Especially in the production process of multi-tool-head automotive aluminum alloy profiles, the design and manufacturing of dies play a crucial role. Taking 6061-T6 aluminum alloy as an example, this paper delves into the die design and manufacturing process for multi-tool-head automotive aluminum alloy profiles, aiming to improve production efficiency and profile forming rates, thereby bringing significant economic benefits to enterprises. 6061-T6 aluminum alloy, with its excellent mechanical properties and impact resistance, is an indispensable material in automotive manufacturing. However, its relatively poor fluidity and high water supply requirements, coupled with issues such as dragging, strict dimensional tolerances, and difficulty in meeting customer demands for mechanical properties during the extrusion processing of complex aluminum alloy profiles, make reasonable die design and manufacturing crucial to solving these problems.

02 Analysis of Profile Structures 

Common profile structures in automotive aluminum alloy profiles include multiple and asymmetric tool heads, small internal cavity sizes of tool heads, and specific alloy grades. These characteristics pose extremely high requirements for dies and extrusion processes. Taking GYC824 and WYY4467 aluminum profiles as examples, their cross-sectional structures are complex, containing multiple tool heads and ribs, which demand high precision and stability of the dies. The cross-sectional characteristics of GYC824 profiles include multiple and asymmetric tool heads, small internal cavity sizes of tool heads, and an alloy grade of 6061-T6. These characteristics necessitate careful consideration of the number, size, and layout of sub-flow holes during die design to ensure balanced metal flow and die stability. Meanwhile, to meet customer requirements for profile mechanical properties, twist resistance, and strength, it is necessary to select appropriate extrusion presses during die design, ensure die core stability, and minimize pressure. WYY4467 profiles also have complex cross-sectional structures, including multiple tool heads and ribs, as well as strict dimensional tolerance requirements. During die design, special attention should be paid to the design of sub-flow holes to ensure balanced metal flow and profile forming quality.

03 Die Design and Optimization

Given the structural characteristics of the aforementioned profiles, this paper proposes the following die design and optimization strategies:

Selection of Appropriate Extrusion Presses: Based on the weight and cross-sectional structural characteristics of the profiles, select appropriate extrusion presses for production. Generally, for profiles with larger weights and complex cross-sectional structures, larger tonnage extrusion presses are required to ensure production stability and efficiency.

Design and Layout of Sub-flow Holes: The number, size, and layout of sub-flow holes have a significant impact on die performance and profile forming quality. During design, it is necessary to reasonably layout sub-flow holes according to the profile's cross-sectional structure and metal flow requirements to ensure balanced metal flow and die stability. At the same time, the size and proportion of sub-flow holes need to be considered to avoid issues such as uneven flow distribution or wall thicknesses at ribs that fail to meet tolerance requirements.

Design of Die Cores and Die Holes: The design of die cores and die holes has a significant impact on profile forming quality and production efficiency. During design, it is necessary to fully consider the profile's cross-sectional structure and dimensional tolerance requirements, and reasonably design the shape, size, and precision of die cores and die holes. Additionally, the strength and stability of the die must be considered to ensure that die damage or profile deformation does not occur during the extrusion process.

Design of Pressure Relief Angles and Welding Chambers: The design of pressure relief angles and welding chambers is also crucial for profile forming quality and production efficiency. During design, it is necessary to reasonably design the shape, size, and depth of pressure relief angles and welding chambers based on the profile's cross-sectional structure and extrusion process requirements. By reasonably designing pressure relief angles and welding chambers, the pressure on the die during the extrusion process can be reduced, improving profile forming quality and production efficiency.

04 Die Manufacturing and Process Control

During die manufacturing, it is necessary to strictly control the manufacturing process and processing accuracy to ensure that the die's quality and performance meet design requirements. At the same time, the extrusion process must also be strictly controlled, including the adjustment and control of parameters such as extrusion temperature, extrusion speed, and extrusion pressure. By optimizing the manufacturing process and extrusion process parameters, the profile forming quality and production efficiency can be further improved.

05 Conclusion

This paper provides a detailed discussion on the die design and manufacturing process for multi-tool-head automotive aluminum alloy profiles. By selecting appropriate extrusion presses, reasonably laying out sub-flow holes, optimizing the design of die cores and die holes, and strictly controlling the manufacturing process and extrusion process parameters, the profile forming quality and production efficiency can be significantly improved. At the same time, these measures can also bring significant economic benefits and market competitiveness to enterprises.