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
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 εx 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
 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.
Extrusion
xtrusion is the process done at room temperature or slightly elevated
ratures. This process can be used for most materials-subject to designing
enough tooling that can withstand the stresses created by extrusion.
les of the metals that can be extruded are lead, tin, aluminum alloys, co
m, molybdenum, vanadium, steel. Examples of parts that are cold extrud
sible tubes, aluminum cans, cylinders, gear blanks. The advantages of co
ion are:
  •No oxidation takes place.
  •Good mechanical
properties due to severe
cold working as long as
the temperatures created
are below the re-
crystallization
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.