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Die Performance Optimization through Understanding of the Surface Features

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Die Performance Optimization through Understanding of the Surface Features of Fatigue Fractures

Pawel Kazanowski Hydro Aluminum Cedar Tools, Cedar Springs, Michigan, USA

Track: EXTRUSION/DIE, PRACTICAL - Tooling Performance

ABSTRACT --- The analysis of failures of extrusion dies is a very important
aspect of extrusion die manufacturing. Establishing the cause of failures provides
information for improvements in design, materials selection, operating
procedures, and the use of components. Understanding how to interpret observed
surface features of fatigue fractures provides a basis for meaningful results. In
this paper the emphasis is placed on the macroscopic fracture surface appearance
associated with known loading conditions. The fracture face can provide a range
of information about the causes. It can show the type and direction of the forces
acting on a die, the magnitude and fluctuations of theses forces, and can give a
general indication of the length of time from initiation to final fracture. Several
case studies are described in detail. These studies deal with real failures, in which
the scope of the failure analysis was limited by factors such as the time that could
be devoted to the problem, the expense of the testing desired and particularly
incomplete information about the failure situation. Despite these limitations very
valuable information was gathered and findings were implemented into modern
extrusion die manufacturing processes.

© Extrusion Technology for Aluminum Profiles Foundation (ET Foundation). All rights reserved. No part of The Proceedings may be reproduced in any form without the express written permission of the ET Foundation.