TVP,
The cracking/pitting has happened on all dies from day 1 so it's not a single time occurrence.
1. The flow stress of the billet should be the same, we call out all our material to have the same low temper from Sapa (Alcoa).
2. The die sleeve which is the D2 has a round outer diameter...
Yes we specialize in this process and have many other parts. Predominantly we do round parts, but we have a couple rectangle and square sizes and it is these that give us a hard time. With the round parts the general rule of thumb is we can hit a max length that is 10x the diameter of the...
No impact extrusion is not a deep draw process, so the top corner radius is insignificant. You can view our process or at least get an idea of what is happening at this page http://www.jlometal.com/the_process/default.asp
We place a billet or slug of aluminum into a die and in one hit we form...
I have a square D2 die that is experiencing die fatigue in the corners which have a .143R. Here is a picture of the fatigued corner [http://files.engineering.com/getfile.aspx?folder=06041405-c0cb-4946-922e-63e1423fec33&file=DSCN0788.JPG], the die square measures 1.5" AF. The die is used in...
TVP, great info thanks for the links I will need to order those documents soon. We have done some finite element simulation using Deform software, but it was only to look for shear in material flow. Every fall Deform offers a Die Process Modeling Workshop at Marquette University in Milwaukee...
I am a ME doing die design for impact extrusion/cold forging tooling for aluminum. I am working on a secondary die for an impact extruded 1" square can that forms a shoulder on the closed end of the part, it is a square shoulder that requires approximately 32 tons to form. The die is a piece...
