Alun Morgan, Interim Dieshop Manager at BOAL UK Aluminium Extrusions has answered my first 3 questions about the perfect extrusion die.

Thank you Alun for participating in my blog since you have an extended experience in die correction and your view is very interesting to me and the readers: I think that you have corrected and worked with dies from almost every known aluminum die makers. I look forward to receive your feedback on my the next 3 questions: it is only trough the sharing of information that we can all grow in this great ALUEX Family.

So thank you Alun for sharing your ideas with us.

1. When do you consider an extrusion die to be successful?

Answer: The number of trials needed and tons extruded are very important, but I consider an extrusion die to be successful when it can repeatedly achieve the desired speed and KPH without losing shape or dimension during each production run.

2. What is the most important FACTOR or factors in the process of manufacturing a successful die?

Answer: There are several very important factors in the process of manufacturing a successful die.

Firstly, choice of supplier. Every good dieshop manager/corrector will know his suppliers strengths and weaknesses and how to optimize them.

Secondly, communication. I find talking to my point of contact is hugely important. By discussing every factor from steel choice, component thickness, layout ,feed and bearing lengths will all aid in manufacturing a successful die.

Lastly, a successful die is only as good as the correction and care it receives...

3. When a die fails in production, what would you consider to be the moat common cause?

Answer: Again there are several factors that contribute to a die failure.

Most commonly I find die failure can be due to not enough attention during the trial process. Often if a die is "close enough" it will be put forward for production.

Correctors are under pressure to have dies suitable for production in the quickest time possible not leaving them enough time to trial a die in as close to production conditions as possible. Another factor is continuity of conditions.

There are many variables eg: temperature, pressure, speed, alignment and even the human element of the operators.

About Alun Morgan

A Dieshop Manager and Die Technician specialising in aluminium extrusions with manufacturing experience and die design knowledge.
Experience has been gained from working on dies for 49 presses, ranging from 500 to 3550 tonnes, 4” to 11” container size at 23 locations in 16 countries. Producing different alloys from 1000 to 7000 series.
A conscientious individual with the ability to use initiative to successfully problem solve, make decisions to ensure high standards of performance and output to exceed organisational targets.
Responsible for initiating and successfully implementing a Greenfield extrusion facility for an American organisation based in the USA.
Responsible for providing technical support and advice during high profile customer relations exercises, IE: General Motors, Ford and Chrysler.
An active member of quality teams successful in achieving BS5750, ISO9002, Ford Q1 and QS9000 systems.

Find out more about him here: https://www.linkedin.com/alunmorgan

Alun Morgan Interim Dieshop Manager at BOAL UK Aluminium Extrusions

alun morgan