Lecture 7

Extrusion

Extrusion
Definition Extrusion is a Bulk Deformation Process in which the work is forced to flow through a die opening to produce a desired cross-sectional shape. It is basically a hot working process, however, for softer materials cold extrusion is also performed. Extrusion is performed in different ways therefore different classifications are available: Direct and indirect extrusion Hot and cold extrusion Impact and hydrostatic extrusion

Direct and indirect extrusion

(Left) Direct extrusion to produce hollow or semi hollow cross section. (Right) Direct extrusion to produce solid cross section. Schematic shows the various equipment components.

Direct & Indirect Extrusion In direct extrusion metal flows in the same direction as that of the ram. Because of the relative motion between the heated billet and the chamber walls, friction is severe and is reduced by using molten glass as a lubricant in case of steels at higher temperatures. At lower temperatures, oils with graphite powder is used for lubrication. In indirect extrusion process metal flows in the opposite direction of the ram. It is more efficient since it reduces friction losses considerably. The process, however, is not used extensively because it restricts the length of the extruded component.

Force and power analysis in extrusion

The ram force, F, is estimated as where Ao is the billet cross-sectional area, and p is the ram pressure,

where Do is the original diameter of the billet, L is the length of the billet in the die, and x is the extrusion strain,

a and b being the empirical constants, usually a=0.8 and b=1.2~1.5. Power required is calculated as P = Fv , where v is the ram velocity.

Impact Extrusion
It is

similar to indirect extrusion. Here the punch descends rapidly on to the blank which gets indirectly extruded on to the punch and to give a tubular section. The length of the tube formed is controlled by the amount of metal in the slug or by the blank thickness. Collapsible tubes for pastes are extruded by this method.

Two examples of products made by impact extrusion. These parts may also be made by casting, by forging, or by machining; the choice of process depends on the dimensions and the materials involved and on the properties desired. Economic considerations are also important in final process selection. (b) and (c) Impact extrusion of a collapsible tube by the Hooker process.

Hydrostatic Extrusion
In this process the friction between container wall and billet is eliminated, however, this process has got limited applications in industry due to specialized equipment & tooling and low production rate due to high set up time.

Cold Extrusion
Cold extrusion is the process done at room temperature or slightly elevated temperatures. This process can be used for most materials-subject to designing robust enough tooling that can withstand the stresses created by extrusion. Examples of the metals that can be extruded are lead, tin, aluminum alloys, copper, titanium, molybdenum, vanadium, steel. Examples of parts that are cold extruded are collapsible tubes, aluminum cans, cylinders, gear blanks. The advantages of cold extrusion are:
No oxidation takes place.
Good mechanical properties due to severe cold working as long as the temperatures created are below the recrystallization temperature. Good surface finish with the use of proper lubricants.

Hot Extrusion
Hot extrusion is done at fairly high temperatures, approximately 50 to 75 % of the melting point of the metal. The pressures can range from 35-700 Mpa . Due to the high temperatures and pressures and its detrimental effect on the die life as well as other components, good lubrication is necessary. Oil and graphite work at lower temperatures, whereas at higher temperatures glass powder is used. Typical parts produced by extrusions are trim parts used in automotive and construction applications, window frame members, railings, aircraft structural parts.