Manufacturing Requirements for Aluminum Profile Extrusion Process Molds

1. Due to the extremely harsh working conditions of aluminum alloy extrusion dies, which must withstand high temperature, high pressure, and high friction during the extrusion process, it is required to use high-strength heat-resistant alloy steel. The processes of smelting, casting, forging, heat treatment, electrical machining, mechanical processing, and surface treatment of these steels are all very complex, which brings a series of difficulties to die manufacturing.

2. In order to improve the service life of aluminum profile extrusion dies and ensure the surface quality of the products, the roughness of the die cavity working area is required to reach 0.8-0.4 μm, and the roughness of the die plane must be below 1.6 μm. Therefore, special polishing processes and polishing equipment need to be used during die manufacturing.

3. Due to the development of extrusion products towards higher, more precise, and sophisticated directions, some profiles and tubes require wall thicknesses reduced to around 0.5mm, with extrusion aluminum product tolerances reaching ±0.05mm. To extrude such ultra-high-precision products, the manufacturing accuracy of the dies needs to reach 0.01mm. Using traditional processes, it is fundamentally impossible to manufacture them; therefore, it is necessary to update the processes and use new specialized equipment.

4. Aluminum profiles have very complex cross-sections, especially ultra-high-precision thin-walled hollow aluminum profiles and multi-hole hollow wallboard aluminum profiles. They require special extrusion die structures, often with multiple shaped cavities on a single die, rapid changes in thickness across sections, complex related dimensions, and numerous rounded corners. This brings many difficulties to die processing and heat treatment.

5. Aluminum profile extrusion products come in a wide variety, with small batch sizes and frequent mold changes, requiring molds to have strong adaptability. Therefore, it is necessary to improve the production efficiency of mold making, minimize the mold-making cycle, quickly modify mold-making processes, accurately produce qualified molds according to drawings, and reduce the workload of mold repair to a minimum.