Extrusion Die Mandrel

Name: Extrusion Mandrel Tool for Aluminum Profiles – Frigate
Price: 249.00 USD
Availability: InStock

Extrusion Die Mandrel geometry directly impacts melt flow symmetry and pressure balance. Non-uniform designs often lead to weld line misplacement, variable wall thickness, and dimensional instability. Our mandrels feature flow-tuned profiles with mathematically optimized entry and land zones that stabilize velocity gradients and ensure homogeneous material distribution across asymmetrical dies.

Material Specification

H13, H11, DIN 1.2344, Tungsten Carbide (for high-wear/high-temp applications)

Hardness (HRC)

46-50 HRC (H13), 48-52 HRC (H11), 80-85 HRA (Tungsten Carbide)

Surface Finish (Ra/RMS)

Working Surface – 0.2–0.4 µm, Non-Critical Areas – 0.8–1.6 µm

Dimensional Tolerances

Profile – ±0.02 mm, Critical Dimensions – ±0.05 mm, Overall Length – ±0.1 mm

Mandrel Profile Geometry

As per 3D CAD Model (STEP/IGES) with ±0.01 mm profile tolerance

Product Description

Tool degradation due to high-pressure extrusion and abrasive materials reduces operational uptime. Extrusion Die Mandrel surfaces are treated with diffusion-hardened layers such as nitriding or advanced PVD coatings, improving resistance to galling, abrasive wear, and plastic deformation under cyclic thermal and mechanical loading.

Bearing Length and Taper

Bearing Length – 3-8 mm (aluminum), 1-3 mm (steel); Taper – 1°–3° (entry angle)

Mounting/Alignment Features

Threads – ISO Metric (e.g., M12-M30), Alignment Pins – H7/g6 fit, Flatness – 0.02 mm/m

Cooling/Heating Channels

Diameter – 6-12 mm, Position Tolerance – ±0.5 mm, Max Temp Variation – ±5°C

Coating/Surface Treatment

Nitriding (0.1–0.3 mm depth), Plasma Nitriding, or AlCrN Coating (for aluminum extrusion)

Certification Standard

ISO 9001, NADCA #207-2003 (Die Casting), AMS 2759 (Heat Treatment), DIN EN ISO 4957 (Tool Steel)

Technical Advantages

Extrusion processes generate non-linear thermal expansion across die components. Each Extrusion Die Mandrel is manufactured using materials with closely matched coefficients of thermal expansion and machined to micron-level concentricity tolerances to maintain alignment under dynamic thermal loads, minimizing radial runout and internal die stress.

Friction between the melt and mandrel surfaces introduces shear heating and flow disruption. Each Extrusion Die Mandrel undergoes fine polishing and sub-micron surface conditioning at the bearing and land interfaces to reduce boundary layer drag, ensuring smoother extrudate surfaces and minimizing material adhesion.

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Industry Applications

Aluminum Tube Extrusion

Used to form hollow aluminum profiles with uniform wall thickness and concentricity for heat exchangers, pipes, and structural components.

Copper Conductor Sheathing

Enables precision extrusion of insulating and protective layers over copper conductors, ensuring consistent dielectric clearance and radial material distribution.

Medical Catheter Manufacturing

Forms multi-lumen and microbore polymer tubes with tight tolerances, critical for fluid delivery and minimally invasive surgical device applications.

Polymer Film Layering

Supports annular flow distribution in multilayer film extrusion for barrier packaging, ensuring uniform melt layering across complex co-extrusion systems.

Plastic Pipe Production

Shapes internal diameter during high-throughput extrusion of pressure-rated HDPE and PVC pipes for fluid transport in infrastructure systems.

Hollow Fiber Membrane Fabrication

Used in spinning dies for membrane extrusion, controlling bore fluid geometry in desalination and gas separation hollow fiber systems.

High-Precision Modular Assembly

Frequent die changeovers introduce tolerance stack-up and axial misalignment risks. Extrusion Die Mandrel configurations are designed with keyed or indexable assemblies to support repeatable positioning and rapid reconfiguration, enabling high process reliability across multi-die platforms with minimal calibration effort.

Back pressure must be stabilized to avoid flow surges and die swell effects. Each Extrusion Die Mandrel incorporates internal flow balancing cavities, pressure attenuation features, or tailored relief zones engineered using computational flow modeling to maintain consistent back pressure throughout varying throughput regimes.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure concentricity in multi-component Extrusion Die Mandrel assemblies?

Frigate uses high-precision CNC turning and wire-EDM to maintain concentricity within ±5 microns across mandrel components. Each mating surface is ground and aligned using dowel-pin indexing and hydraulic clamping for repeatability. During assembly, concentricity is verified with CMM inspection to avoid radial displacement under load. This ensures stable internal flow paths during extrusion of critical hollow profiles.

What process does Frigate use to prevent mandrel tip deformation under thermal and pressure stress?

Frigate selects tool steels like H13 or PM-grade materials with high thermal fatigue resistance and compressive strength. Tips are vacuum heat-treated and tempered to achieve optimal hardness without brittleness. Simulation-based stress analysis is done to predict load zones and refine tip geometry. These steps prevent mandrel tip bulging, cracking, or premature wear during extrusion.

How does Frigate optimize flow behavior in asymmetrical die designs using Extrusion Die Mandrels?

Frigate designs mandrel land and bridge geometries based on melt rheology and flow path requirements. CFD analysis is used to simulate flow symmetry across off-center profiles or non-circular shapes. Flow restrictors or asymmetrical relief grooves are added to balance material velocity. This enables precise wall thickness control and weld line placement in complex extrusions.

How are Frigate’s mandrels tailored for high-viscosity polymer extrusion?

Frigate adjusts mandrel taper, entry angles, and land lengths to reduce shear stress during high-viscosity melt flow. Polished surfaces (Ra < 0.2 µm) minimize drag and material hang-up. Coatings like DLC are applied to reduce friction and thermal degradation of polymers. These features stabilize throughput and improve extrudate quality under viscous flow conditions.

What steps does Frigate take to ensure repeatable mandrel performance across high-volume production cycles?

Mandrel blanks are serialized and manufactured in controlled batches to maintain geometry across units. Tooling fixtures are used for consistent setup and alignment in extrusion lines. Frigate performs dimensional inspection on each mandrel using 3D scanning and profile measurement tools. This guarantees consistent die gap and internal flow conditions across repeated production runs.

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Extrusion Die Mandrel

Material Specification

Hardness (HRC)

Surface Finish (Ra/RMS)

Dimensional Tolerances

Mandrel Profile Geometry

Product Description

Bearing Length and Taper

Mounting/Alignment Features

Cooling/Heating Channels

Coating/Surface Treatment

Certification Standard

Technical Advantages

Let's Get Started

Industry Applications

High-Precision Modular Assembly

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Extrusion Die Mandrel

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Extrusion Die Mandrel

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