Instructor : Prof. Dr.

Omar Badran

Prepared by:
Dr. Naseer Ahmed
Department of Mechanical Engineering
College of Engineering, Taibah University
Department of Mechanical Engineering

ME-321 Manufacturing Process I

ME 321
Manufacturing
Process I

Extrusion

Department of Mechanical Engineering

ME-321 Manufacturing Process I

A compression forming process in which the work metal is forced

to flow through a die opening to produce a desired crosssectional shape.
Pros:
variety of sections possible (hot extrusion)
grain structure and strength enhancement (cold)
close tolerance (cold)
no material wastage.

Types of Extrusion

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Two principal types of extrusion are

Direct Extrusion
Indirect extrusion
Another classification is by working temperature
Cold extrusion
Warm extrusion
Hot extrusion
Also
Continuous process
Discrete process

Types of Extrusion

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Direct Extrusion
The ram forces the work billet metal to move forward to
pass through the die opening.
Indirect Extrusion
The die is mounted to the ram rather than at the opposite
end of the extruder container housing.

Direct Extrusion
ME-321 Manufacturing Process I

Department of Mechanical Engineering

Indirect Extrusion
ME-321 Manufacturing Process I

Department of Mechanical Engineering

Extrusion Processes

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Hot extrusion
Keeping the processing temperature to above the recrystalline temperature. Reducing the ram force, increasing
the ram speed. 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.

Continuous vs Discrete Processing

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Continuous processing is approached by producing very long

sections in one cycle, but these operations are ultimately limited
by the size of the billet that can be loaded into the extrusion
container. These processes are more accurately described as
semi-continuous operations.
In Discrete extrusion operation a single part is produced in each
extrusion cycle. Impact extrusion is an example of the discrete
processing case.

Analysis of Extrusion
Ao
Af

Assuming all sections

are circular, ideal
deformation, no friction:

ln rx
Ram pressure, Johnsons formulae

p Y f ln rx

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

where a =0.8 and b =1.2 to 1.5.
The value of a and b tends to increase with
increasing die angle

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Extrusion ratio, rx

x a b ln rx

Analysis of Extrusion
For direct extrusion, The ram pressure:

Ram force in indirect or direct extrusion

F pAo
Power required to carry out the extrusion operation is

P Fv
F = ram force, N; v = ram velocity, m/s; P = power, J/s

Department of Mechanical Engineering

ME-321 Manufacturing Process I

2L

p Y f x
Do

Example

Department of Mechanical Engineering

ME-321 Manufacturing Process I

A billet 75 mm long and 25 mm in diameter is to be extruded in a

direct extrusion operation with extrusion ratio rx = 4.0. The
extrudate has a round cross section. The die angle (half-angle) =
90o. The work metal has a strength coefficient = 415 MPa, and
strain hardening exponent = 0.18. Use the Johnson formula with
a = 0.8 and b = 1.5 to estimate extrusion strain. Determine the
pressure applied to the end of the billet as the ram moves
forward.

Complex Cross Section

Department of Mechanical Engineering

ME-321 Manufacturing Process I

A complex extruded cross section for a heat sink (photo

courtesy of Aluminum Company of America)

Extrusion Presses

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Either horizontal or vertical

Horizontal more common
Extrusion presses - usually hydraulically driven, which is
especially suited to semi-continuous direct extrusion of long
sections
Mechanical drives - often used for cold extrusion of individual
parts

Impact Extrusion

backward

combination
Department of Mechanical Engineering

ME-321 Manufacturing Process I

Forward

Impact Extrusion

Department of Mechanical Engineering

ME-321 Manufacturing Process I

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 large deformation
at high speed.

Hydrostatic Extrusion

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Using hydrostatic system to reduce the friction and lower

the power requirement.
Sealing is the major problem.

Extrusion Defects

Department of Mechanical Engineering

ME-321 Manufacturing Process I

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

at the centre possibly because of high die angle and
impurities in the work metal.
b) Piping: sink hole at the end of billet under direct extrusion.
c) Surface cracking: High part temperature due to high
extrusion speed and high strain rates.