Metal forming : Extrusion and Drawing Introduction

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 Metal forming : Extrusion and Drawing Push-through processes

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 Metal forming : Extrusion and Drawing Extrusion : Definiton

EXTRUSION: A compression forming process in which the work metal is forced

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to flow through a die opening to produce a desired cross-sectional shape.
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variety of sections possible (hot extrusion)

grain structure and strength enhancement (cold)
close tolerance (cold)
no material wastage by sectioning off process

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 Metal forming : Extrusion and Drawing Classification of extrusion by product geometry
A- Semifinished part extrusion

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B- Product extrusion

Production steps and grain flow pattern

for a cold extruded spark plug.

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 Metal forming : Extrusion and Drawing Extrusion of semifinished products

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 Metal forming Materials for Hot Extrusion

Applications: Transportation, construction, mechanical, and electrical industries.

durable goods, industrial equipment, heating and air conditioning applications,
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Practically all metals can be extruded.

Extrudability varies with the deformation properties of the metal.
Hard metals require higher billet temperatures and extruding pressures as well
as sturdier presses and dies.

Lead and tin :

high ductility and easy to extrude. maximum temperature of about 300 C.
Principal applications include pipes, wire, tubes, and sheathing for cable.
Molten lead is used instead of billets for many applications.

Aluminum and aluminum alloys :

Ideal materials for extrusion, and the most commonly extruded.
Billet temperatures about 300 to 595 C depending on the alloy.
Principal applications include parts for the aircraft and aerospace industries, pipes,
wire, rods, bars, tubes, hollow shapes, cable sheathing, architectural and
structural sections, and
automotive trim.
Sections can be extruded from heat-treatable high-strength aluminum alloys.
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 Metal forming Extrusion material
Magnesium and Magnesium :
Application in aircraft, aerospace, and nuclear power industries.
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longer heating periods are usually necessary to ensure uniform temperatures
throughout the billets.

Copper and copper alloy :

Widely used for wire, rods, bars, pipes, tubes, electrical conductors and
connectors, and welding electrodes.
Billet temperatures vary from about 595 to 995 C .
High pressures (690 MPa, or 100 ksi, or more) are necessary for the extrusion of
many copper alloys.
Steels :
High billet temperatures about (995 to 1300 C).
Necessary to use glass as a lubricant or some other high-temperature lubricant .
Excessive tooling wear.
High ram speeds are required to minimize contact time between the billets
and the tooling.
Products produced include structural sections (generally required in small
quantities) and tubes with small bores.
For economic reasons, steel structural shapes, especially those needed in large
quantities, are better suited to the rolling process. 7
 Metal forming Conventional hot extrusion

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 Metal forming : Extrusion and Drawing Direct and Indirect hot extrusion
Direct Extrusion:
The die and ram are at opposite ends of the extrusion stock,
and the product and ram travel in the same direction. Also, there
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is relative motion between the extrusion stock and the die.

The metal billet is placed in a container and driven through the die by
the ram.
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.
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 Metal forming : Extrusion and Drawing Direct and Indirect hot extrusion

Direct Extrusion:
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Friction increases the extrusion force.

Hollow section is formed using a mandrel.

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 Metal forming : Extrusion and Drawing Direct and Indirect hot extrusion

Indirect Extrusion:
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the die is at the ram end of the stock and the product
travels in the direction opposite that of the ram

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.
Hollow ram limits the applied load.

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 Metal forming : Extrusion and Drawing Load versus displacement in hot extrusion

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(a) direct. (b) indirect extrusion ; 1: billet; 2: container; 3: die; 4: stem; 5: dummy block; 6: die backer.

Typical load versus ram displacement curves extrusion processes.

(a) direct (Curve 1) and indirect (Curve 2)
(b) Division of the work of deformation. A: work of upsetting; B:work needed to initiate deformation;
C: work of deformation; D: work needed to overcome friction and shearing in direct extrusion
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 Metal forming : Extrusion and Drawing Conventional hot extrusion presses

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 Metal forming : Extrusion and Drawing Conventional hot extrusion presses

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 Metal forming : Extrusion and Drawing Conventional hot extrusion presses

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Most extrusions are made with hydraulic presses.
These can be classified based on the direction of travel of the ram.
1) Horizontal presses
2) Vertical presses

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 Metal forming : Extrusion and Drawing Conventional hot extrusion machine

Horizontal extrusion presses

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(15- 50 MN capacity or upto 140 MN) (1MN=100 ton)
Used for most commercial extrusion of bars and shapes.
Disadvantages:
deformation is non-uniform due to different temperatures between top and
bottom parts of the billet.

600 Tonne, DUISBURG, HYDRAULIC EXT PRESS

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 Metal forming : Extrusion and Drawing Conventional hot extrusion presses

Vertical extrusion presses (3- 20 MN capacity)

Chiefly used in the production of thin-wall tubing.
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Advantages:
Easier alignment between the press ram and tools.
Higher rate of production.
Require less floor space than horizontal presses.
uniform deformation, due to uniform cooling of the billet in the container.

Requirements:
Need considerable headroom to make
extrusions of appreciable length.
A floor pit is necessary.

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 Metal forming : Extrusion and Drawing Extrusion speed

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Ram speed
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Require high ram speeds in high-temperature extrusion (like

steel extrude) due to heat Transfer problem from billet to tools.

Ram speeds of 0.4-0.6 m/s for refractory metals and requires a hydraulic

accumulator with the press.

Ram speeds of a few mm/s for aluminum

and copper due to hot shortness and

requires direct-drive pumping systems to

maintain a uniform finishing temperature.

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 Metal forming : Extrusion and Drawing Extrudability

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 Metal forming : Extrusion and Drawing Ram speed and temperature in hot extrusion

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 Metal forming : Extrusion and Drawing Ram speed and temperature in hot extrusion

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 Metal forming : Extrusion and Drawing Ram speed and temperature in hot extrusion

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 Metal forming : Extrusion and Drawing Ram speed and temperature in hot extrusion

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 Metal forming : Extrusion and Drawing Ram speed and temperature in hot extrusion

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 Metal forming : Extrusion and Drawing Extrusion Dies

Die design is at the heart of efficient extrusion production.

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shock, and oxidation.

Die design consideration

Wall thickness: different wall thicknesses in
one section should be avoided.
Simple shapes: the more simple shape the
more cost effective.
Symmetrical: more accurate.
Sharp or rounded corners: sharp corners
should be avoided.
Tolerances: tolerances are added to allow
some distortions (industrial standards).

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 Metal forming : Extrusion and Drawing Extrusion Dies

Die design consideration

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Poor and good examples of cross-sections to be extruded.

Eliminating sharp corners.
Keeping section thicknesses uniform.
Avoid unbalanced die tongue.

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 Metal forming : Extrusion and Drawing Extrusion Dies

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 Metal forming : Extrusion and Drawing Extrusion dies

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of Technology Die materials

Dies are made from highly alloy tools steels or ceramics (zirconia, Si3N4 ).

Wall thickness as small as 0.5 mm (on flat dies) or 0.7 mm (on hollow dies)

can be made for aluminium extrusion.

Heat treatments such as nitriding are required (several times) to increase

hardness (65-70 HRC). This improves die life.

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 Metal forming : Extrusion and Drawing Extrusion dies
1) Flat-faced dies
There are two general types of extrusion dies:
2) Dies with conical entrance angle
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1) Flat-faced dies 2) Dies with conical entrance angle

Metal entering the die will form a Requires good lubricants.

dead zone and shears internally
to form its own die angle. Decreasing die angle causes
increasing homogeneity, and lower
A parallel land on the exit side extrusion pressure (but beyond a
of the die helps strengthen the point the friction in the die surfaces
die and allow for reworking of becomes too great.
the flat face on the entrance side
of the die without increasing the For most operation, 45 < < 60
exit diameter.
More common for steel parts
More applicable for light alloy 29
 Metal forming : Extrusion and Drawing Extrusion dies
Typical arrangement of extrusion tooling
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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 entire assembly is sealed against the container on a conical seating
surface by pressure applied by a wedge.
A liner is shrunk in a more massive container to withstand high pressures.
The follower pad is placed between the hot billet and the ram for protection
purpose. Follower pads are therefore replaced periodically since they are subject
to many cycles of thermal shock.

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 Metal forming : Extrusion and Drawing Extrusion dies
Typical arrangement of extrusion tooling
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 Metal forming : Extrusion and Drawing Die material and hardness

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 Metal forming : Extrusion and Drawing Extrusion tools

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 Metal forming : Extrusion and Drawing Extrusion pattern and die angle

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 Metal forming : Extrusion and Drawing Extrusion tools

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Chevron cracks formed during extrusion of steel rods.

Note the very low reduction and high die angle
a) Centre-burst: internal crack due to excessive tensile stress at the
center 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

speed and low strain rates.

High temperatures generated

cause incipient melting,
which causes cracking. 35
 Metal forming : Extrusion and Drawing Extrusion of components

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 Metal forming : Extrusion and Drawing Free extrusion

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 Metal forming : Extrusion and Drawing Extrusion of components

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 Metal forming Drawing

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 Metal forming Extrusion

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 Metal forming drawing
Commercial wiredrawing often employs in the range of
6 to 10 and drawing reduction of about 20 percent
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 Metal forming Extrusion

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 Metal forming Extrusion

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