"Improvements in and relating to Dies for Extruding
Aluminium" The invention relates to a method of manufacturing a die for extruding aluminium, and also to dies produced by this method.
Dies for extruding aluminium are conventionally formed by a two-stage process. This process involves cutting a series of recesses in the surface of a metal plate using a frustro-conical rotating cutter so as to form an elongate tapered recess extending along the surface of the plate, and then forming a parallel-sided elongate aperture along the bottom of the tapered recess by means of a wire spark erosion process. It will be appreciated that the plate is therefore formed with an elongate aperture comprising a tapered portion formed by the rotating cutter, and a parallel-sided portion formed by the wire spark erosion process. The thickness of the parallel-sided portion of the aperture controls the speed at which the aluminium passes through the aperture during extrusion, and the side walls of the metal plate defining the parallel-sided portion of the aperture are therefore often referred to as the "bearing" of the die. The depth to which the rotating cutter is sunk into the surface of the plate must be carefully controlled by a skilled operator, and must be varied along the length of the aperture in order to ensure that the thickness of the parallel-sided portion of the aperture varies in the correct manner along the length of the aperture. This
process is time consuming and has the disadvantage of requiring a skilled operator to operate the rotating cutter. Furthermore, the thickness of the parallel-sided portion of the aperture can only be varied in a stepped manner along the length of the aperture, and this can cause undesirable marks to be formed on the outside surface of the aluminium as it is extruded.
The present invention has arisen from attempts to overcome the above-mentioned disadvantages of the prior art.
According to the invention there is provided a method of manufacturing a die for extruding aluminium, comprising the steps of cutting an aperture in a metal plate by means of wire spark erosion, the aperture being tapered so that the width of the aperture varies as the aperture passes through the plate, and then cutting away metal from the plate at the narrow portion of the aperture by means of wire spark erosion so as to form a parallel- sided portion of the aperture, the side walls of the metal plate defining the parallel-sided portion of the aperture acting as a bearing during extrusion of aluminium through the aperture.
It will be appreciated that the aperture thus formed therefore comprises a tapered portion and a parallel-sided portion. It will also be appreciated that the above method removes the need for the use of a rotating mechanical cutter. Furthermore, the relative movement of the wire used for the wire spark erosion and
the metal plate can, be very accurately controlled by means of a computer, and=-the thickness of the parallel-sided portion of the aperture can therefore be accurately varied in a continuous, rather than a stepped, manner. The side walls of the metal plate defining the tapered portion of the aperture may lie in two planes which intersect along a line within the metal plate.
Preferably, the method further comprises the step of, after forming the parallel-sided portion of the aperture, removing metal from the plate at the portion of the tapered portion of the aperture which lies adjacent the parallel-sided portion of the aperture by means of an electrode so as to ensure that the aluminium does not come into contact with the side walls of the metal plate defining the tapered portion of the aperture after passing through the parallel-sided portion of the aperture during extrusion.
This ensures that the aluminium "breaks clean", that is that the outside surfaces of the extruded aluminium formed by the die are smooth.
Ideally, in order to ensure that the aluminium breaks as cleanly as possible when leaving the parallel- sided portion of the aperture, the shape of the portion of the plate removed by the electrode is such that the side walls of the metal plate forming the parallel-sided portion of the aperture are formed with a right-angled edge at the side of the parallel-sided portion which lies adjacent the tapered portion of the aperture.
If it is required to produce strips of aluminium, the aperture may be elongate in the plane of the metal plate.
Preferably, the metal plate is formed from hardened tool steel.
The wire spark erosion is conveniently carried out using a thin brass wire, which may be immersed in, or flushed by, de-ionised water.
The invention also provides a die, produced by the above method, for extruding aluminium, the die comprising a metal plate formed with an elongate aperture having a tapered portion and a parallel-sided portion, wherein the side walls of the metal plate defining the parallel-sided portion of the aperture act as a bearing during extrusion of aluminium through the aperture, and the thickness of the parallel-sided portion varies in a continuous, rather than a stepped, manner along the length of the aperture.
The invention will now be more particularly described, by way of example only, with reference to the accompanying schematic drawings in which:
Figure 1 is a plan view of a die for extruding aluminium;
Figure 2 is a section taken along the line A-A in Figure 1;
Figure 3 shows the first stage in an improved method of forming an aperture in die;
Figure 4 is an alternative embodiment of the
aperture shown in Figure 3;
Figure 5 shows the second stage of forming the aperture; and
Figure 6 shows the third stage of forming the aperture.
The die 1 shown in Figure 1 is formed from a circular plate 2 of hardened tool steel formed with four
U-shaped apertures 4 through which during extrusion hot aluminium is forced so as to simultaneously produce four U-shaped extruded aluminium profiles.
Figure 2 shows the cross-sectional shape of the apertures 4, which comprise a tapered portion 6 formed by two slanting side walls 8 and 10, and a parallel-sided portion 12 formed by two parallel side walls 14 and 16. During extrusion, the aluminium is forced against the front surface 18 of the plate 2, and passes through the aperture 4 in the direction indicated by the arrow labelled 20. After passing through the parallel-sided portion 12 of the aperture 4, the aluminium continues to travel in a straight line and does not come into contact with the side walls 8 and 10 of the tapered portion 6 of the aperture 4. The width w of the side walls 14 and 16 determines the speed at which the aluminium passes through the aperture 4 during extrusion. For this reason, the side walls 14 and 16 of the parallel-sided portion 12 are often referred to as the "bearing" of the die.
The aperture 4 shown in Figure 2 has been formed for many years by a two stage process in which the tapered
portion 6 is first formed by means of a frustro-conical rotating cutter, and the parallel-sided portion 12 is then formed by means of wire spark erosion using a thin brass wire which is immersed in de-ionised water. However, the formation of the tapered portion 6 by this process is tedious and time-consuming since the rotating cutter must be repeatedly moved up and down in order to drill a large number of recesses at spaced intervals along the length of each aperture 4. Furthermore, since it is usually required that the width w of the parallel-sided portion 12 should vary along the length of the aperture 4, the rotating cutter must be sunk into the plate 2 to different depths along the length of the aperture 4. This process requires a skilled operator, and is time-consuming. Furthermore, since the tapered portion 6 is formed by means of sinking a rotating cutter into the plate 2, the width of the parallel-sided portion 12 can only be varied along the length of the aperture 4 in a stepped manner. Such steps in the width w are undesirable, and can cause marks to be formed on the outside of the extruded aluminium profiles.
Figures 3 to 6 show an improved method of producing a die for extruding aluminium. The aperture formed by this method is similar in shape to that shown in Figure 2, and similar parts are therefore represented by the same reference numerals. In the first stage of the method an elongate aperture 4 of generally V-shaped cross- section is formed in the metal plate 2 by means of wire
spark erosion. The process is begun by drilling a narrow hole through the plate in order to pass the wire through the plate. The wire is then controlled by means of a computer so as to first form the slanting surface 22, and then to form the slanting surface 24 of the aperture 4. As shown in Figure 4, there is no reason why the two surfaces 22 and 24 should not lie in planes which intersect within the plate 2, thus providing the aperture 4 with a further tapered portion 26 adjacent the front surface 18 of plate 2. The arrangement shown in Figure 4 is particularly convenient if it is required to form a bearing having a large width w.
Figure 5 shows the second stage in the process, in which a parallel-sided portion 12 of the aperture 4 is formed adjacent the front surface 18 of the plate 2 by means of wire spark erosion. The wire is passed first of all along one side of the aperture 4 so as to form one side wall 32, and then along the other side of the aperture 4 in order to form the other side wall 34 of the parallel-sided portion 12. It will be appreciated that since the first stage of the process is carried out by means of wire spark erosion, the position and inclination of the slanting surfaces 22 and 24 can be accurately and smoothly varied. This enables the width w of the parallel- sided portion 12 to also be accurately and smoothly varied, so that the speed at which aluminium passes through each part of the aperture 4 during extrusion can be precisely determined.
Figure 6 shows the final stage in the process, in which a copper tungsten electrode 30 is used to cut into the slanting surfaces 22 and 24 just above the parallel-sided portion 12. This ensures that the walls 32 and 34 which define the parallel-sided portion 12 of the aperture 4 are formed with right-angled corner edges 36. The right-angled edges 36 ensure that the aluminium "breaks clean" as it leaves the parallel-sided portion 12 of the aperture 4, and that the extruded profile formed by aluminium passing through the die is formed with smooth external surfaces. The third stage of the process is carried out using a cnc die sinker, and the copper tungsten electrode 30 is accurately moved by the machine under the control of a computer programme. In operation, the copper tungsten electrode 30 is submerged in paraffin.