Extrusion
180
Manufacturing Processes I
Extrusion
• Introduction
• Material flow
• Mechanics of extrusion
• Extrusion processes
• Defects in extrusion
• Extrusion practice
Manufacturing Processes I 181
Manufacturing Processes I
Extrusion
Compression forming process in which work metal is forced to flow through a
die opening to produce a desired cross-sectional shape
• Process is similar to squeezing toothpaste out of a toothpaste tube
• In general, extrusion is used to produce long parts of uniform cross
sections
• Two basic types:
– Direct extrusion
– Indirect extrusion
Manufacturing Processes I
Introduction
• There are several advantages of the modern process:
• (1) A variety of shapes are possible, especially with hot extrusion
• (2) Grain structure and strength properties are enhanced in cold and warm extrusion
• (3) Fairly close tolerances are possible, especially in cold extrusion
• (4) In some extrusion operations, little or no wasted material is created
• However, a limitation is that the cross section of the extruded part must be uniform
• throughout its length
Manufacturing ProcessesI 183
Manufacturing Processes I
Extrusion process parameter
• Also called the reduction ratio, it is defined as
where R = extrusion ratio; Ao = cross-sectional
Ao
R= area of the starting billet; and Af = final cross-
Af sectional area of the extruded section
Circumscribing-Circle Diameter (CCD)
The maximum size for an extrusion is determined by finding the
smallest circle that will fit around the cross-section, this is called
the circumscribing circle
This diameter, in turn, controls the size of the die required,
which ultimately determines if the part will fit in a given press
For example, a large press can handle 60 cm diameter
circumscribing circles for aluminum and 55 cm diameter circles
for steel and titanium
• Shape factor: the amount of surface area generated per unit mass of extrusion
(Shape factor = Perimeter/CCD)
Manufacturing Processes I
Manufacturing Processes I
Process Variables in Direct Extrusion
Process variables in direct extrusion.
The die angle,
reduction in cross-section,
extrusion speed,
billet temperature, and
lubrication all affect the extrusion pressure
Manufacturing Processes I
Manufacturing Processes I
Direct Extrusion
• Also called forward extrusion
• Starting billet cross section
usually round
• Final shape of extrudate is
determined by die opening
• Extruded rod and ingot
moved in one and the same
direction
• pushing the ingot forward demands high friction force and work
• As ram approaches die opening, a small portion of billet remains thatcannot
be forced through die opening
• This extra portion, called the butt, must be separated from extrudate by cutting it
just beyond the die exit
Manufacturing Processes I
Manufacturing Processes I
Extrusion
Indirect Extrusion
a solid cross section a hollow cross section.
• Also called backward extrusion and reverse extrusion
• no relative movement between the ingot and the container
• friction forces between ingot and container are negligible
• Limitations of indirect extrusion are imposed by
– Lower rigidity of hollow ram
– Difficulty in supporting extruded product as it exits die
Manufacturing Processes I
Manufacturing Processes I
Hydrostatic extrusion
• Pressure applied by fluid
medium
• Reduces friction
Manufacturing Processes I
Manufacturing Processes I
Hot Extrusion
• Extrusion is carried out at elevated temperatures – for metals and
alloys that do not have sufficient ductility at room temperature, or in
order to reduce the forces required.
Manufacturing Processes I
Manufacturing Processes I
Extrusion Processes
• Cold Extrusion
– Room temperature or a few hundred degrees
– Advantages
• Close control of tolerance
• Improved surface finish
• Strain hardening can give some desirable properties
• No oxide layer formation
– High stresses on dies
– Lubrication is very critical (phosphate, wax, etc.)
Manufacturing Processes I 193
Manufacturing Processes I
Extrusion Ratio
Also called the reduction ratio, it is defined as
Ao
rx =
Af
where rx = extrusion ratio; Ao = cross-sectional area of the starting
billet; and Af = final cross-sectional area of the extruded section
• Applies to both direct and indirect extrusion
Manufacturing Processes I
Extrusion Analysis
Ao
Extrusion ratio, rx =
Af
Assuming all sections
are circular, ideal
deformation, no friction,
no redundant work:
= ln rx
Ram pressure
p = Yf lnrx
Taking into account friction,
where a =0.8 and b =1.2 to 1.5. p = Y f (a + b ln rx )
Manufacturing Processes I
Extrusion Analysis
For direct extrusion, additional pressure, pf, required by the
extruder to overcome the wall friction is related as follows:
p f D o2
= pc Do L
4
For the worst case that the friction shear stress at the wall
equals to the shear yield strength of the work metal:
The additional pressure: p c = Ys
2L
pf = Yf
Do
2L
The total ram pressure:
p= f x
Y +
Do
The power required: P = Fv
Manufacturing Processes I
Example 1
A billet 75mm long and 25mm 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) =90⁰. 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.
Extrusion Dies
For the case of non-circular extruded section, a shape factor
has to be introduced:
C x
2.25
K x = 0.98 + 0.02
Cc
where Kx = shape factor
Cx = perimeter of the non-circular extruded section
Co = perimeter of a circle that has the same cross-
sectional area as the extruded section.
For direct extrusion, the extrusion force
p = K x Yf x + 2L
Do
Manufacturing Processes I
Example 9
An L-shaped structural section is direct extruded from an aluminum billet
in which Lo = 250 mm and Do = 88 mm. Dimensions of the cross-section
are given in the figure shown below. Die angle = 90°.
Determine:(a) extrusion ratio, (b) shape factor, and (c) length of the
extruded section if the butt remaining in the container at the end of the
ram stroke is 25 mm.
Example 10
The flow curve parameters for the aluminum alloy of Example 9 are: K =
240 MPa and n = 0.16. If the die angle in this operation = 90°, and the
corresponding Johnson strain equation has constants a = 0.8 and b =
1.5, compute the maximum force required to drive the ram forward at
the start of extrusion.