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Definitions:-
What is extrusion?
Example;
The top of the tube represents the die and determines the shape of the
extrusion, while the paste may be considered to be the billet.
o First, raw material, in the form of small plastic pellets, is placed in the
hopper.
o The barrel is a heated hollow steel cylinder, sort of like a really thick
pipe. An auger-type screw rotates inside of the barrel.
o The screw's rotation takes the plastic pellets and pushes them forward,
into the barrel. As the pellets move towards the front of the barrel,
frictional and electrical heat from the barrel melt the plastic. After the
plastic is melted, the rotating screw continues to act as a pump and
forces the molten plastic through a die.
o The die is usually a piece of steel with the shape of the desired part
machined into it.
o Once the melted plastic exits the die, it is shaped like the finished
product.
Once cool, the product can be rolled up, cut into sections, packaged, or
can go on to secondary operations.
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Extrusion equipments
There are many different variations of extrusion equipment. They vary by four
major characteristics:
1. Movement of the extrusion with relation to the ram. If the die is held
stationary and the ram moves towards it then its called "direct
extrusion". If the ram is held stationary and the die moves towards the
ram its called "indirect extrusion".
Direct extrusion
The metal billet is placed in a container and driven through the die by
them.
The dummy block or pressure plate, is placed at the end of the ram in
contact with the billet.
Friction is at the die and container wall requires higher pressure than
indirect extrusion.
Indirect extrusion
The hollow ram containing the die is kept stationary and the container with the
billet is caused to move.
Friction at the die only (no relative movement at the container wall) _ requires
roughly constant pressure.
• Disadvantages:
(3- 20 MN capacity)
Hydrostatic extrusion
In the hydrostatic extrusion process the billet is completely surrounded by a
pressurized liquid, except where the billet contacts the die. This process can
be done hot, warm, or cold, however the temperature is limited by the stability
of the fluid used. The process must be carried out in a sealed cylinder to
contain the hydrostatic medium. The fluid can be pressurized two ways:
advantages:
disadvantages:
The billets must be prepared by tapering one end to match the die
entry angle. This is needed to form a seal at the beginning of the cycle.
Usually the entire billet needs to be machined to remove any surface
defects.
Containing the fluid under high pressures can be difficult.
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Drives
o Direct-drive oil presses are the most common because they are reliable
and robust. They can deliver over 35 MPa (5000 psi).
o Accumulator water drives are more expensive and larger than direct-
drive oil presses, plus they lose about 10% of their pressure over the
stroke, but they are much faster, up to 380 mm/s (15 ips).
o Because of this they are used when extruding steel. They are also
used on materials that must be heated to very hot temperatures for
safety reasons.
Ram speed
• Ram speeds of a few mm s-1 for aluminium and copper due to hot
shortness _ requires direct-drive pumping systems to maintain a
uniform finishing temperature.
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Die design:-
Die design consideration
Die materials
• Dies are made from highly alloy tools steels or ceramics (zirconia, Si3N4 ).
(for cold extrusion _ offering longer tool life and reduced lubricant used, good
wear resistance).
• Wall thickness as small as 0.5 mm (on flat dies) or 0.7 mm (on hollow dies)
can be made for aluminium extrusion.
1) Flat-faced dies
2) Dies with conical entrance angle.
1) Flat-faced dies
• Metal entering the die will form a dead zone and shears internally to form its
own die angle.
• A parallel land on the exit side of the die helps strengthen the die and allow
for reworking of the flat face on the entrance side of the die without increasing
the exit diameter.
• The die stack consists of the die, which is supported by a die holder and
a bolster, all of which are held in a die head.
• The follower pad is placed between the hot billet and the ram for protection
purpose. Follower pads are therefore replace.
• The higher the temperature of the billet, the greater the effect of low
extrusion speed on the cooling of the billet.
• Therefore, high extrusion speeds are required with high-strength alloys that
need high extrusion temperature.
References: -
Oberg, Erik; Jones, Franklin D.; Horton, Holbrook L.; Ryffel, Henry H.
(2000), Machinery's Handbook (26 th. ed.), New York: Industrial Press
Inc., ISBN 0-8311-2635-3 .
http://www.wikipedia.org/