MECH152-L20-1 (1.

0) - 1

Extrusion
 MECH152-L20-1 (1.0) - 2

Extrusion
A compression forming process in which the
work metal is forced to flow through a die
p
openingg to pproduce a desired cross-sectional
shape.
Pros:
variety of sections possible (hot extrusion)
grain structure and strength enhancement (cold)
close tolerance (cold)
no material wastage.
 MECH152-L20-1 (1.0) - 3

Types
yp of Extrusion
Direct Extrusion
The ram forces the work billet metal to move
forward to p
pass through
g the die opening.
p g
Indirect Extrusion
The die
Th di is
i mounted
t d to
t the
th ram rather
th than
th att the
th
opposite end of the extruder container housing.
 MECH152-L20-1 (1.0) - 4

Direct Extrusion

Friction increases
the extrusion
force.
Hollow section is
formed using a
mandrel.
 MECH152-L20-1 (1.0) - 5

Indirect Extrusion
Metal is forced to flow
through
h h the
h didie in
i an
opposite direction to
the
h rams motion.
i
Lower extrusion force
as the work billet
metal is not moving
relative to the
container wall.
 MECH152-L20-1 (1.0) - 6

Extrusion Processes
Hot extrusion
Keeping
K i ththe processing
i temperature
t t to
t above
b the
th
re-crystalline temperature. Reducing the ram
force, increasing the ram speed, and reduction of
grain flow characteristics. Controlling the cooling
is a problem. Glass may be used as a lubricant.
Cold extrusion
Often used to produce discrete parts. Increase
strength due to strain hardening, close tolerances,
improved surface finish, absence of oxide layer
andd high
hi h production
d ti rates.t
 MECH152-L20-1 (1.0) - 7

Extrusion Analysis
y
Ao
Extrusion ratio, rx
Af
Assuming all sections
are circular, ideal
deformation, no friction,
no redundant work:
ln rx
Ram pressure
p Yf lnrx

Taking into account friction, p Y f (a b ln rx )

where a =0.8
=0 8 and b =1.2
=1 2 to 1.5.
15
 MECH152-L20-1 (1.0) - 8

Extrusion Analysis
y
For direct extrusion, additional pressure, pf, required by the
extruder to overcome the wall friction is related as follows:
p f Do2
pcDo L (1) [equilibrium equation]
4
For the worst case that the friction shear stress at the wall
equals
q to the shear yield
y strength
g of the work metal:
pc Ys Yf (2)
2L
S b (2) iinto (1)
Subs. (1), the
h additional
ddi i l pressure: p f Yf
Do

t t l ram pressure: p Y f x 2 L
Th total
The
Do
The power required: P Fv
 MECH152-L20-1 (1.0) - 9

Ram Force

Variation
V i ti off Ram
R Force
F with
ith
ram stroke and die angle.
 MECH152-L20-1 (1.0) - 10

Extrusion Dies
For the case of non-circular extruded section, a shape factor
has to be introduced:
2.25
Cx
K x 0.98 0.02
Cc
where Kx = shape factor
Cx = perimeter
i t off the
th non-circular
i l extruded
t d d section
ti
Co = perimeter of a circle that has the same cross-
sectional area as the extruded section.
section
For direct extrusion, the extrusion force
2L
p K xY f x
Do
 MECH152-L20-1 (1.0) - 11

Impact
p Extrusion

Forward backward

combination
 MECH152-L20-1 (1.0) - 12

Impact
p Extrusion
Impact extrusion is performed at higher
speeds and shorter strokes than
conventional extrusion.
It is for making discrete parts.
For making thin wall-thickness items by
permitting
p g large
g deformation at high
g speed.
p
 MECH152-L20-1 (1.0) - 13

Hydrostatic
y Extrusion

Using hydrostatic system to reduce the friction and

lower the power requirement.
Sealing is the major problem.
problem
 MECH152-L20-1 (1.0) - 14

Extrusion Defects

a)) Centre-burst: internal crack due to excessive tensile stress

at the centre possibly because of high die angle, low
extrusion ratio.
b) Piping: sink hole at the end of billet under direct extrusion.
c) Surface cracking: High part temperature due to low
extrusion
i speedd andd high
hi h strain
i rates.
 MECH152-L20-1 (1.0) - 15

Wire and Bar Drawing

g

Reducing
R d i theth cross section
ti off a bar,
b rodd or wire
i byb pulling
lli it
through a die.
Bar drawing is generally in a batch mode while the wire
drawing is in general in a continuous mode.
 MECH152-L20-1 (1.0) - 16

Mechanics of Drawing
g
Ao A f
Area reduction in drawing r ; Draft d Do D f
Ao
Ao 1
No friction and true strain ln ln
Af 1 r

The ideal stress Y f Y f ln Ao

Af
A
Taking into account friction and die angle, d Y f 1 ln o
tan
Af
D Do D f Do D f
where 0.88 0.12 , D , Lc
Lc 2 2 sin

The drawing force F A f d A f Y f 1
A
ln o
tan Af
 MECH152-L20-1 (1.0) - 17

Maximum Reduction
Assume perfectly plastic material (n=0), no friction, no
redundant work
work,
Ao Ao 1
d Y f ln Y ln Y ln Y
Af Af 1 r

Then ln Ao A f ln 1 1 r 1
Ao A f 1 1 r e
max 1.0

The maximum possible area ratio Ao A f e 2.7183

The maximum possible reduction rmax e 1 e 0.632

 MECH152-L20-1 (1.0) - 18

Drawing
g Equipment
q p
Good dimensional
control
Good surface finish
Improved mechanical
properties
economic for mass
production
 MECH152-L20-1 (1.0) - 19

Draw Dies

Approach angle about 6 to 20

Back relief angle about 30
 MECH152-L20-1 (1.0) - 20

Tube Drawing
g
N mandrel
No d l

Fi d mandrel
Fixed d l

Floating mandrel