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At any given time, I'm likely to have a number of projects in the works, which means that they're all in various stages of abandonment at any given time. In my most recent large project, I finally feel like I'm getting the opportunity to work with materials that have genuine hacker street cred, such as T-slot extruded aluminum profiles, which I've wanted to do for quite some time. This is referred to as the Industrial Erector Set by 80/20, which also has their own version of it, and it is something that we have all seen before in various forms. It's also notable for the interesting projects that people have built with it, ranging from CNC machines to trade show displays, and, on rare occasions during these pandemic times, even as sneeze guards in retail establishments.

Working with aluminum T-slot profiles is a pleasure because they are strong, lightweight, and easily connected with a wide range of fasteners, making them a versatile material. They are also infinitely configurable and reconfigurable, which enables them to adapt to changing requirements without requiring any additional programming. Even though specifying a material for a project is not inexpensive, it may be a worthwhile investment when you consider how much time it saves during the fabrication process when compared to other alternatives. However, I've been on the lookout for more affordable alternatives due to the anticipated blow to the bottom line of my wallet's finances.



While the extrusion process is a multistep process, it's possible that the die design is the most important step. In order to function properly at high temperatures, dies must be capable of withstanding massive forces while maintaining dimensional stability. extruded aluminium tubing dies begin their lives as round bars of tool steel that can be as large as a meter in diameter, but are more commonly around 30 cm in diameter. Extrusion dies are used to extrude plastic materials into extrusion dies, which are used to extrude plastic into dies. It is necessary to use extrusion dies in order to extrude plastic materials into extrusion dies, which are necessary in order to extrude plastic materials into extrusion dies. As a result, dies are typically thin in profile when compared to their diameter to achieve this effect. Due to the fact that the more time aluminum is forced to travel through the die, the more friction it experiences as it travels through the die is increased. Given that a greater amount of friction results in more force, the result is larger presses, more wear on the dies, and higher overall costs.

Most die design engineers and machinists are employed by specialty manufacturers who design and manufacture dies for a variety of different applications, according to the Bureau of Labor Statistics. The majority of the time, a CNC lathe is used to rough out a blank before it is subjected to a series of CNC milling operations to finish it. The steps involved in converting a design into a die are described in detail in this section of the document. The process of electric discharge machining (EDM) is widely used during the manufacturing process to achieve the fine detail required for a smooth finish, as well as the precise geometry required to control and direct the flow of aluminum through the die.

The lumen of a pipe is a common location for extruded aluminium pipe holes, and in the case of our 80/20 profiles, the negative space between the T-slot holes and the central bore is also a common location. It is necessary for the die to be able to create features that necessitate parts of the die floating in the incoming flow of softened metal so that they can be properly formed in order for it to function properly. These features are suspended from arms that span the gap between the die's upstream and downstream portions, which allows diemakers to achieve this result. In order to ensure that the metal flows around them and joins together in a smooth, continuous stream of material with no voids, the arms' shape and surface finish must be carefully considered. If this is not done correctly, it could result in a weak final product.

When constructing a die, it is necessary to keep in mind the hydrodynamic forces that are exerted by and upon the flowing metal during the design process. Even though the exit side of the die is nearly identical in size and shape to the finished extrusion, the entrance side of the die is diametrically opposed to the exit side in terms of material and shape. According to some estimates, the reduction of friction forces between the metal and the die accounts for half of the total energy expended during the  of aluminum into the die. In order to counteract these forces, anything that can be done to mitigate them is equivalent to depositing money into your bank account. It is critical that the metal is guided into the final shape as smoothly and easily as possible once it has been introduced into the die. A contributing factor is the fact that die designers use extremely generous draft angles across the width of their die, as depicted in the illustration, as one of the reasons for this.


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