Abstract
Extrusion is a very popular and multi-faceted manufacturing process. A large number of products for the automotive, aerospace, and construction sectors are produced through aluminum extrusion. Many defects in the extruded products occur because of the conditions of the dies and tooling. The problems in dies can be due to material issues, design and manufacturing, or severe usage. They can be avoided by maintaining the billet quality, by controlling the extrusion process parameters, and through routine maintenance. Die problems that occur on a day-to-day basis are mostly repairable and are rectified through various types of die correction operations. These defects and repair operations have not been reported in detail in the published literature. The current paper presents an in-depth description of repairable die defects and related die correction operations in metal extrusion. All major die defects are defined and classified, and their causes, preventive measures, and die correction operations are described. A brief frequency-based statistical study of die defects is also carried out to identify the most frequent die corrections. This work can be of direct benefit to plant engineers and operators and to researchers and academics in the field of metal extrusion.
Highlights
Because of its versatility and net-shape ability, extrusion is a very common manufacturing process, especially for aluminum alloys
Die problems can be prevented by controlling the billet quality and extrusion process parameters [12]
Die and product defects and related die corrections have been explained in the previous section
Summary
Because of its versatility and net-shape ability, extrusion is a very common manufacturing process, especially for aluminum alloys. Many product defects in extrusion have their root in problems related to dies and tooling. Some of these are related to die design, die material, and die manufacturing, while others occur during the service life of the die [5,6,7,8,9,10]. The latter include improper support tooling, improper temperature, erosion, pitting, billet material quality, friction, etc. Common reasons for die failure are cracks, bearing washout, chip-off, deflection, fracture, and wear [13,14,15,16]
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