In the field of metal processing, extrusion is a widely used forming process, especially suitable for the processing of materials such as aluminum, copper, magnesium, and their alloys. However, in the actual production process, materials are prone to cracking during the extrusion process, which not only affects product quality but also increases production costs and waste rates. Therefore, it is of great significance to conduct in-depth research and take effective measures to prevent material cracking during extrusion.



Firstly, the selection and pretreatment of materials are one of the key factors in preventing cracking. Different materials have different plastic deformation capabilities, and it is crucial to choose raw materials suitable for the extrusion process. For example, aluminum alloys 6063, 6061, etc., are widely used due to their good extrusion properties. In addition, the uniformity of the material and internal defects (such as pores, inclusions) will also affect its extrudability. Therefore, the raw materials should be fully heat treated and surface cleaned before extrusion to improve their plasticity and reduce the risk of cracking caused by stress concentration.



Secondly, the rationality of mold design plays a decisive role in preventing material cracking. Reasonable mold angles, working belt length, and channel design can effectively reduce the resistance of material flow, making the metal flow uniformly and avoiding the generation of cracks due to local stress concentration. In addition, the mold surface should be kept smooth to avoid scratches or wear that can lead to uneven friction force, thereby causing material breakage.



Thirdly, controlling the extrusion temperature and speed is an important means to prevent material cracking. Materials become more plastic at high temperatures, which is conducive to deformation. However, if the temperature is too high, it may cause the material to soften or even melt; if the temperature is too low, it will cause the plasticity to decrease, increasing the risk of cracking. Therefore, the appropriate extrusion temperature range should be set according to the material properties. At the same time, the extrusion speed should not be too fast to prevent the material from cracking due to insufficient plastic deformation.



In addition, the improvement of lubrication conditions should not be ignored. Good lubrication can reduce the friction between the material and the mold, reduce heat generation and the unevenness of material flow, thereby effectively preventing cracking on the surface and inside of the material.



Finally, regular maintenance and inspection of equipment to ensure smooth operation are also important measures to prevent material cracking caused by abnormal stress during the extrusion process.



In summary, through comprehensive measures such as reasonable material selection, optimization of mold design, control of process parameters, improvement of lubrication conditions, and strengthening of equipment management, it is possible to effectively prevent the occurrence of material cracking during extrusion processing, thereby improving production efficiency and product pass rate, and creating greater economic benefits for the enterprise.