Aluminum Extrusion Troubleshooting

Die pushing hard

Problem Description

Die requires unusually high force to extrude material.

Cause–Correction Mapping
  • Basic design of porting/flow
    Cause in: Die

      Corrections

    • Volume of port has to be greater at die face than at port entry; funnel aluminum flow ‘out’, releasing the ports, rather than ‘in’ when aluminum enters the die approximately 3 to 5 degrees of increase if possible.

  • Bearing length too long
    Cause in: Die

      Corrections

    • Shorten bearing length.

  • Die too cold
    Cause in: Die

      Corrections

    • Bring die to proper temperature.

  • Improper selection of die design
    Cause in: Die

      Corrections

    • Evaluate die design and implement redesign.

  • Porting too small
    Cause in: Die

      Corrections

    • Make porting larger.

  • Web is too thick
    Cause in: Die

      Corrections

    • Make webs thinner.

  • Web travel/stroke too long
    Cause in: Die

      Corrections

    • Make web travel/stroke shorter on next.

Please note that the information provided in this article is intended to be a general guide to the causes and corrections of Die pushing hard in aluminum extrusion. However, it is important to note that the specific cause and correction of any particular defect will vary depending on the specific extrusion process, alloy, and other factors. Therefore, it is important to consult with an experienced and professional engineer to ensure that the correct diagnosis is made and the most suitable correction is chosen.