Mayank patel

Aim:- seminar report in extrusion process

Definitions:-

Extrusion is the process by which long straight metal parts can

be produced. The cross-sections that can be produced vary from solid round,
rectangular, to L shapes, T shapes. Tubes and many other different types.
Extrusion is done by squeezing metal in a closed cavity through a tool, known
as a die using either a mechanical or hydraulic press.

What is extrusion?

Example;

The extrusion process is often likened to the squeezing of tooth paste

from a tube, as is illustrated:

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.

Extrusion is the process by which a block/billet of metal is

reduced in cross section by forcing it to flow through a die orifice under
high pressure.
 Mayank patel

 How extrusion process done?

A picture of an extruder manufacturing line is shown above.

o First, raw material, in the form of small plastic pellets, is placed in the
hopper.

o The hopper rests on top of the barrel.

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.

o Next, it is pulled through some sort of cooling apparatus, which usually

cools with air or water.

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".

2. The position of the press, either vertical or horizontal.

3. The type of drive, either hydraulic or mechanical.

4. The type of load applied, either conventional (variable) or hydrostatic.

 Mayank patel

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.

 Hollow ram limits the applied load.

 Mayank patel

 Horizontal extrusion presses

 (15- 50 MN capacity or upto 140 MN)

 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.

 Vertical extrusion presses

 (3- 20 MN capacity)

 Chiefly used in the production of thin-wall tubing.

 Mayank patel

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:

1. Constant-rate extrusion: A ram or plunger is used to pressurize

the fluid inside the container.
2. Constant-pressure extrusion: A pump is used, possibly with a
pressure intensifier, to pressurize the fluid, which is then pumped to
the container.

advantages:

 No friction between the container and the billet reduces force

requirements. This ultimately allows for faster speeds, higher reduction
ratios, and lower billet temperatures.
 Usually the ductility of the material increases when high pressures are
applied.
 An even flow of material.
 Large billets and large cross-sections can be extruded.
 No billet residue is left on the container walls.

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.
 Mayank patel

Drives

o Most modern direct or indirect extrusion presses are hydraulically

driven, but there are some small mechanical presses still used. Of the
hydraulic presses there are two types: direct-drive oil presses and
accumulator water 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 They supply a constant pressure throughout the whole billet. The

disadvantage is that they are slow, between 50 and 200 mm/s (2–8
ips).

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.

o Hydrostatic extrusion presses usually use castor oil at pressure up to

1400 MPa (200 ksi). Castor oil is used because it has good lubricity
and high pressure properties.

Factors affecting extrusion process

Ram speed

• Require high ram speeds in high-temperature extrusion due to heat

transfer problem from billet to tools.

• Ram speeds of 0.4-0.6 m s-1 for refractory metals _ requires a

hydraulic accumulator with the press.

• 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.
 Mayank patel

Die design:-
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.

• Size to weight ratio:

• Tolerances: tolerances are added to allow some distortions (industrial standards).

• Die design is at the heart of efficient extrusion production.

• Dies must withstand considerable amount of stresses, thermal shock, and

oxidation.

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.

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

hardness (1000-1100 Hv or 65-70 HRC).
This improves die life. _ avoiding unscheduled press shutdown.
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There are two general types of extrusion dies:

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.

2) Dies with conical entrance angle

• requires good lubricants.

• decreasing die angle increasing homogeneity, lower extrusion pressure (but

beyond a point the friction in the die surfaces becomes too great.

• for most operation, 45’ < α < 60’

 Mayank patel

Typical arrangement of extrusion tooling

• 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 replace.

Ram speed, extrusion ratio and temperature

• A tenfold increase in the ram speed results in about a 50% increase

in the extrusion pressure.

• Low extrusion speeds lead to greater cooling of the billet.

• 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.

•The selection of the proper extrusion speed and temperature is best

determined by trial and error for each alloy and billet size.
 Mayank patel

Relationships between extrusion ratio, temperature and pressure

• For a given extrusion pressure, extrusion ratio R increases with increasing

Extrusion temperature.

• For a given extrusion temperature, a larger extrusion ratio R can be obtained

with a higher extrusion extrusion pressure.

Extrusion temperature ↑ Extrusion ratio (R) ↑ Extrusion pressure↑

Relationships between extrusion speed and heat dissipation

• extrusion speeds↑, heat dissipation↓

• extrusion speeds↓, heat dissipation↑, allowable extrusion ratio↑

 References: -

 Drozda, Tom; Wick, Charles; Bakerjian, Ramon; Veilleux, Raymond F.;

Petro, Louis, Tool and manufacturing engineers handbook: Forming, 2,
SME,ISBN 0872631354,http://books.google.com/books?
id=9ty5NPJ0UI4C .

 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 .

 Suranaree University of Technology’s seminar slide on extrusion.

http://www.wikipedia.org/