1) Correct die numbering. Die, suffix, backing, pad and feeder plate numbers are important. If the number on the die is wrong, it can be a loading and running error, leading to major problems. Also, the date and vendor ID are needed. Advanced factories now use lasers to put computer identification codes.
2) Check for metal chips or shavings from the manufacturing process. These tiny metal chips can hide in the weld chamber area or work belt area of the die and form die lines in the extruded product or may form.
3) Check that the die and related tooling meet Rockwell hardness standards. Although most die manufacturers check this thoroughly, it is not impossible to be off by a few Rockwell C points.
4) Tool diameter, thickness and step size. It is better to be safe than sorry. Checking the tool size will prevent the tool from getting stuck in the die ring or coming loose, causing misalignment and/or aluminum seeping into unwanted spaces, butt shear forces hitting the tool surface, etc.
5) Pinout of the die opening. This will tell you what the tool deflection on the die is, which is very useful for future dies. It will provide accurate information to zero in the minimum weight per foot, thus allowing for the maximum weight per die.
6) Support tool clearance. Check backing, shim, subshim and platen openings for interference. It is best to grind in some clearance, which will reduce the possibility of clogging and/or possible damage to the components.
7) Proper support for overhangs, etc. Make sure the backing and supports have proper support to eliminate as much tool deflection as possible and minimize the chance of tool breakage.
8) Proper exit size, check that the step behind the work band has proper clearance. Key tongues, screw bosses, etc. should have a minimum clearance. Too much clearance will cause the die to collapse and squeeze out the scrap. A blanking of approximately 0.040 inches (0.10 mm) is considered normal.
9) Proper die support. On the tongue, you want maximum support for best results. In areas with small or long tongues and screw bosses, a zero degree back taper is usually required.
10) Work band finish. Check the die work belt for: Wire cut lines, scratches from files, gauge pins or emery paper. Scratches from shipping Rail EDM or milling relief Burrs on the exit side of the work belt; it is best to catch one of these points and check before sampling or attempting a batch extrusion order.
11) Work belt flatness, verticality. The importance of these cannot be overstated.
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