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EXTRUSION LAB

ME 313 Manufacturing Processes

ME313 Metals Processing - Lab

Last Modified by PAN 1/25/05

Extrusion Lab Slide 1

Introduction
Extrusion - a method of forming in which
the material is forced through an
opening having a predetermined
shape.
Main Types
1) Forward (direct)
Extrusion Direction is a variable
considered in this lab experiment
2) Reverse (indirect)

ME313 Metals Processing - Lab

Extrusion Lab Slide 2

Examples
Door & Window Frames.
Aircraft body components.
Structural and Architectural
shapes.

ME313 Metals Processing - Lab

Extrusion and examples of products


made by sectioning off extrusions.
Source: Kaiser Aluminum.

Extrusion Lab Slide 3

Schematic Diagrams
(Direct Extrusion)
Main Components

Ram
Die

Billet
Container

ME313 Metals Processing - Lab

Extrusion Lab Slide 4

Schematic Diagrams
(Reverse Extrusion)
Main Components.

Ram (tube)
Die
Billet
Container

ME313 Metals Processing - Lab

Extrusion Lab Slide 5

Extrusion Forces and Flow


Stages in direct extrusion

Stages.
I) Compaction
II) Sticking Friction
III) Steady State
IV) Dead Metal Zone

Where is the Break


Through Force (BTF) ???
The BTF is located at the
End of II and Start of III
ME313 Metals Processing - Lab

III

IV

Ffriction
Force (lbf)

I II

Fdeformation

Displacement (in)
Extrusion Lab Slide 6

Process Variables
Billet Temperature (Hot , Warm, & Cold)
Today the lab will use Warm Extrusion

Ram Speed (Strain rate sensitivity).


Lubrication
This variable will be considered in this lab experiment

Die Geometry
This variable will be considered in this lab experiment

ME313 Metals Processing - Lab

Extrusion Lab Slide 7

Metal Flow in Extrusion


No Velocity

Analogy to fluid flow,


Stream lines, Velocity
profile
Fluids - no flow across
stream lines
Responsible for DMZ
- Elongated grain structure
- Extrusion Defect called Piping

ME313 Metals Processing - Lab

Extrusion Lab Slide 8

Extrusion Defects
Piping Defect
Dead Metal Zone (DMZ)

Internal Cracking (Chevron)


Surface Cracking

ME313 Metals Processing - Lab

Extrusion Lab Slide 9

Extrusion Experiment
Objectives - To analyze the following variables and
their effects on the extrusion process.
Die Geometry
(G)
Direction of extrusion (D)
Lubrication
(L)
Quantitative Objectives Their influence of the extrusion variables on the magnitude
of the Break Through Force in the extrusion process.
Qualitative Objectives The influence of these variables on the Dead Metal Zone
and the Piping Effect will be visually examined

ME313 Metals Processing - Lab

Extrusion Lab Slide 10

Equipment Used In Lab


Model #
Equipment
Dynamometer
Ordinary Amplifier
XXXXX
Charge Amplifier
Tensile Testing Machine
Software
XXXXX

Serial #

Brand Name

XXXXX

Capacity
20,000 (lbf)
XXXXXX
XXXXXX
60,000 (lbf)

XXXXX

XXXXXX

Other Equipment :
Layout Dye (red)

Extrusion Dies

DAS

Height Gage

Rubber Mallet

Safety Glasses

Eight Split Billets

Shop Rags

Lubrication

ME313 Metals Processing - Lab

Extrusion Lab Slide 11

Procedure
1) Coat the flat surfaces of the billet half with red layout dye
2) Use a height gage to scribe cross hatch lines .100 apart
3) Place the billet in the appropriate die assembly
4) Have the instructor check set-up and start the extrusion
5)

Stop recording data at 0.8 inches

6) Record the, approximate BTF from the dial on the Richle


and record on the computer
7) Repeat the steps for all 8 tests
ME313 Metals Processing - Lab

Extrusion Lab Slide 12

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