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The Fixed Dummy Block

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The Fixed Dummy Block

Paul Robbins and Dennis Van Dine, CASTOOL Tooling Solutions,
Dr. V.I. Johannes, BENCHMARKS, and
Shigeyoshi Takagi, Techno-Consul BENCHMARKS (Japan)

Track: DIE DESIGN AND TECHNOLOGY - Technology in Practice

ABSTRACT --- The replaceable fixed dummy block is used on most aluminum extrusion
presses. However, operating conditions such as aluminum alloy and dies, physical size,
unit pressure, temperature and cycle time vary greatly from press to press. To ensure
proper performance, CASTOOL has used finite element analysis and practical
experimentation to provide an understanding of the factors affecting dummy block
design. The replaceable fixed dummy block is now an essential part of an automatic
aluminum extrusion press. Its performance is measured in terms of its ability to operate
with minimum effect on the extrusion process, without disturbing the aluminum alloy
coating in the liner, and the number of extrusion cycles before replacement or major
maintenance. Properly designed, maintained and operated replaceable fixed dummy
blocks remain on the extrusion press for many thousands of press cycles. Products
(alloys and dies) can run on any given press. This paper reviews the research and
development conducted by CASTOOL Tooling Solutions into the factors affecting the
design and operation of this critical element of press tooling.

© 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.