AHMED MAHDY HAMDY ALI

NAME:

SEC:

SALAH AYYAD

DR:
Define (a) roll gap, (b) neutral point, and (c) draft. roll gap the gap from
when the material comes into contact with the rollers and the material
has no more contact with the rollers.

neutral point; relative sliding between the roll and the

strip along the contact length, L. At one point, called the
neutral point or no-slip point, the velocity of
the strip is the same as that of the roll. To the left of this
point, the roll moves faster than the strip; to the right, the
strip moves faster than the roll
draft; draft is defined as the difference between the initial
and final strip thicknesses,
or (ho -hf). A large draft could cause the rolls to slip. It
can be shown that the maximum draft is a function
of the roll radius, R, and the coefficient of friction, μ,
given by
ho - hf = μ2R
Thus, as expected, the higher the friction and the larger
the roll radius, the greater the maximum possible
draft
2 List the defects commonly observed in flat
rolling.
l defects in flat rolling: (a) wavy edges; (b) zipper cracks
in the

center of the strip; (c) edge cracks; and (d) alligatoring

Wavy edges on sheets (Fig. 13.9a) are due to roll

bending, whereby the strip becomes thinner along
its edges than at its center (see Fig. 13.4a). Because of
volume constancy in plastic deformation, the edges
then have to elongate more than the material at the
center; consequently, the edges buckle because they are
constrained by the central region from expanding freely
in the longitudinal (rolling) direction.
The cracks shown in Fig. 13.9b and c are usually the
result of low material ductility at the rolling
temperature. Because the quality of the edges of the
sheet is important in subsequent forming operations,
edge defects in rolled sheets may have to be removed by
shearing and slitting operations (Section 16.2).
Alligatoring (Fig. 13.9d) is typically caused by
nonuniform bulk deformation of the billet during rolling or
by the presence of defects in the original cast material
3 why is the surface finish of a rolled product better in cold rolling than
in hot rolling? Cold rolling is carried out near room
temperature and, compared with hot rolling, it produces
sheets
and strips with a much better surface finish (because of
lack of scale), better dimensional tolerances, and
enhanced mechanical properties (because of strain
hardening)
4. How is back tension generated?

1. Tensions can be applied to the strip at either the

entry zone (back tension), the exit zone (front
tension), or
both. Back tension is applied to the sheet by a
braking action to the reel that supplies the sheet into
the roll
(pay-off reel). Front tension is applied by increasing
the rotational speed of the take-up reel. Although it
has
limited and specialized applications, rolling also can
be carried out by front tension only, with no power
supplied to the rolls, known as Steckel rolling.
5. What are the advantages of tandem rolling? Pack
rolling?
In tandem rolling, the strip is rolled continuously,
through a number of stands, to thinner gages with
each pass (Fig. 13.12). Each stand consists of a set of
rolls, with its own housing and controls. A group of stands
is called a train. The control of the strip thickness and the
speed at which the strip travels through
each roll gap is critical. Extensive computer controls are
used in these operations, particularly in precision
rolling at high speeds
Pack rolling is a flat-rolling operation in which two or
more layers of sheet are rolled together, thus
increasing productivity. Aluminum foil, for example, is
pack rolled in two layers, where only the top and bottom
outer layers are in contact with the rolls, and hence is
smoother. Note that one side of aluminum
foil is matte, while the other side is shiny. The foil-to-foil
side has a matte and satiny finish, whereas the
foil-to-roll side is shiny and bright; this is because it has
been in contact with the polished rolls during
rolling
. 6 Describe ring rolling. Is there a neutral plane in ring
rolling?

Ring Rolling Process

1. Ring Rolling. In ring rolling, a thick ring is expanded

into a larger diameter and thinner ring. The
ringshaped blank is placed between two rolls, one of
which is driven while the other is idle (Fig. 13.16a).
The
thickness of the ring is reduced by bringing the rolls
closer together as they rotate. Since the volume of
the ring remains constant during deformation
(volume constancy), the reduction in ring thickness
results in its
increase in diameter. The process can be carried out
either at room or elevated temperature. The ring size
can be up to 3 m in diameter
 2.

Neutral Plane in Ring Rolling

Yes, a neutral plane exists in ring rolling. Similar to flat rolling,
the neutral plane refers to a specific location within the
deformation zone where the material's velocity matches the
surface speed of the rolls.

7. How are seamless tubes produced?

1. Starting Material:

 The process begins with a solid metal bar or billet made from
steel, stainless steel, or other suitable materials.

2. Heating:

 The billet is heated to a high temperature in a furnace. This

makes the metal more malleable and easier to shape.

3. Piercing (or Breakdown):

  There are two main approaches for creating the initial hollow
form:
o Piercing: A piercing mill pushes a mandrel (a round
bar) through the center of the hot billet, creating a rough
hollow form.
o Breakdown: Rolling mills with specially designed rolls
can be used to elongate and pierce the billet
simultaneously, forming a hollow shell.

4. Rolling and Reducing:

 The pierced or broken-down shell is then fed through a

series of rolling mills. These mills further reduce the diameter
and wall thickness of the tube while elongating it.
 A mandrel may be used inside the tube during rolling to
maintain its shape and size.

5. Sizing and Finishing:

 The final stages involve processes like:

o Sizing: The tube is passed through additional dies or
rolls to achieve the precise final dimensions.
o Cooling: The hot-rolled tube is cooled down in a
controlled manner.
o Straightening: Any bends or deviations in the tube are
corrected.
o End finishing: The tube ends may be beveled,
threaded, or otherwise modified as required.

6. Inspection:

 Seamless tubes undergo rigorous inspections throughout the

process to ensure they meet quality standards.
Nondestructive testing methods like eddy current testing or
ultrasonic testing are used to detect any internal cracks or
defects
8 Explain the types of deflections that rolls
undergo
The higher the elastic modulus of the roll material, the
smaller is the roll
deflection. As a result of roll deflections, the rolled strip
will now be thicker at its center than at its edges,
known as crown. A common method of avoiding this
problem is to grind the rolls in such a way that their
diameter at the center is slightly larger than at their
edges (called camber). Thus, when the rolls bend, the
strip being rolled will have a constant thickness along its
width (Fig. 13.4b).
For rolling sheet metals, the radius of the maximum
camber is generally 0.25 mm greater than the
radius at the ends of the roll. However, a particular
camber is correct only for a specific load and strip
width. To reduce deflection, the rolls can also be
subjected to external bending by applying moments at
their
bearings.
Because of the heat generated due to the work of plastic
deformation during rolling, rolls can become
slightly barrel shaped, known as thermal camber
9 What is forward slip? Why is it important?
Forward slip in rolling is defined in terms of the exit
velocity of the strip, Vf, and the surface speed of
the roll, Vr, as
Forward slip = Vf – Vr/vr

Forward-slip is used to steepen an approach (reduce height) without

gaining much airspeed, benefiting from the increased drag

10. Why may roller leveling be a necessary operation

A rolled sheet may not be sufficiently flat as it exits the
roll gap, due to factors such as variations in
the incoming material or in the processing parameters
during rolling. To improve flatness, the rolled strip
typically passes through a series of leveling rolls.
Several roll arrangements can be used, as shown in
Fig. 13.8, in which the sheet is basically flexed in opposite
directions as it passes through the sets of rolls.

Forward Slip=VF-VR/VR
Max draft=ho-hf=µ2 *R
F=LWσavg
L=√ R∗Δ h
POWER=2*𝝅*F*L*N/6000
Problems
1. Given: An annealed copper strip 225 mm wide and 25
mm thick
is being rolled to a thickness of 20 mm in one pass. The
roll
radius is 300 mm, and the rolls rotate at 100 rpm. Find:
Calculate the roll force and the power required in this
operation.
W=225mm
Hf=25mm
Ho=20mm
R=300
N=100
F=LWσavg
L=√ R∗Δ h=√ 300∗(25−20)=38.8mm
F=38.8*.001*.225*(80+275/2)=1.55N
P=628kw

2. In previous Example calculate the roll force and the

power for
the case in which the workpiece material is 1100-0
aluminum
and the roll radius, R, is 500 mm.
L=.05m
F=.05*.225*70=.79MN
P=2*3.14*.79*.05*100/6000=413.6KW

3. Estimate the roll force, F, and the torque for an AISI

1020
carbon-steel strip that is 200 mm wide 12 mm thick, and
rolled
to a thickness of 6 mm. The roll radius is 200 mm, and it
rotates
at 200 rpm.
W=200mm
Ho=12mm
Hf=6mm
R=200mm
N=200
L=√ 200∗.001∗( 12−6 )∗.001=.0346m

F=.0346*350*106 *200*.001=2.422MN
6
T=F*L=.0346*2.442*10 =83801.2N.M

4. A rolling operation takes place under the conditions

shown in
the accompanying figure. What is the position, Xn, of the
neutral
point? Note that there are a front and back tension that
have
not been specified. Additional data are as follows:
Material is
5052-0 aluminum; hardened steel rolls; surface
roughness of
the rolls = 0.025 um; rolling temperature = 210°C
Vr*hr*w=vf*hf*wf
1.5*hr=3*2
Hr=4mm
Rcosθ=R-(hf-ho)/2
75*cosθ=75*((4-3)/2)
Θ=6.62
Xn=Rsinθ=8.64mm
5. A flat-rolling operation is being carried out where h. =
6 mm, h f
= 5 mm, w. = 300 mm, R = 250 mm, u = 0.25, and the
average
flow stress of the material is 275 MPa. Estimate the roll
force
and the torque.
ho=6mm
Hf=5mm
W=300mm
σ =275MPa

u = 0.25
µ∗L
F=L*W*σ *[1+ 2∗hav ]=

L=.0158m
Hav=5+6/2=5.5mm
F=1.77MN
T=F*L=1.77*.0158*1000000=27966N.M

1 What is the difference between cold, warm, and

hot forging?
Forging may be carried out at room temperature (cold
forging) or at elevated temperatures (warm or hot
forging), depending on the homologous temperature,
described in Section 1.8. Cold forging requires higher
forces, because of the higher strength of the workpiece
material. The workpiece material must possess
sufficient ductility at room temperature to be able to
undergo the required deformation without cracking.
Cold-forged parts have good surface finish and
dimensional accuracy. Hot forging requires lower forces,
but the dimensional accuracy and surface finish of the
parts are not as good as those in cold forging.

2. Explain the difference between open-die and

impression-die
forging.
In impression-die forging, the workpiece takes the shape
of the die cavity while being forged between two
shaped dies (Figs. 14.6a through c). This process is
usually carried out at elevated temperatures in order to
lower the forging forces and to develop enhanced
ductility of the workpiece. Note in Fig. 14.6c that, during
deformation, some of the material flows outward and
forms a flash

Open-die forging is the simplest forging operation (Table

14.1). Although most open-die forgings generally
weigh 15 to 500 kg, forgings as heavy as 270 metric tons
have been made. Part sizes may range from very
small (such as pins, nails, and screws) to very large [up to
23-m-long shafts for ship propellers]. In its
simplest form, open-die forging can be described by a
metal workpiece blank, placed between two flat dies
(platens), and reduced in height by compressing it (Fig.
14.3), an operation that is also called upsetting or
flat-die forging. The die surfaces may have shallow
cavities or features to make relatively simple forgings
(see also blocker dies, Section 14.3)

3. Explain the difference between fullering, edging,

and blocking.
In fullering, material is distributed away from a die
region; in edging, it is gathered into a localized region.
The part is then formed
into a rough shape by a process called blocking, using
blocker dies. The final operation consists of finishing
of the forging in impression dies, giving the forging its
final shape. The flash is later removed by a trimming
operation (Fig. 14.9).

4. What is flash? What is its function?

The flash has an important role in impression-die forging:
The high pressure and the resulting high
frictional resistance in the flash present a major
constraint on the radially outward flow of the material
in the die; this is due to the friction hill effect, described
in Sec. 14.2. Thus, based on the principle that
the material flows in the direction of least resistance
(because it requires less energy), the material flows
preferentially into the die cavity, eventually filling it
completely
5. Why is the intermediate shape of a part
important in forging
operations?
Workpiece intermediate shapes should be considered so
that die cavities can be filled properly and without any
defects.
An example of the intermediate shapes for a connecting
rod is given in Fig. 14.8a.
6. Describe the features of a typical forging die.

process advantage limitations

Open die Simple and Limited to simple
inexpensive dies; shapes; difficult
wide range of to hold close
part tolerances;
sizes; good machining to final
strength shape necessary;
characteristics; low
generally for production rate;
small quantities relatively poor
utilization of
material; high
degree of skill
required
Closed die Relatively good High die cost, not
utilization of economical for
material; small quantities;
generally machining often
better properties necessary
than open-die
forgings; good di
mensional accuracy; high
production rates; good
reproducibility
7. Explain what is meant by “load limited,”
“energy limited,” and
“stroke limited” as these terms pertain to forging
machines.
These presses operate at constant speeds and are load
limited (load restricted); the press
stops if the load required exceeds its capacity
These presses (Fig. 14.19c) derive their energy from a
flywheel, hence they are energy limited.

. The
speed varies from a maximum at the center of the stroke
to zero at the bottom of the stroke, thus are stroke
limited
8. What are the advantages and disadvantages of
isothermal
forging?
.
Isothermal Forging. Also known as hot-die forging, in
this process the dies are heated to the same temperature
as that of the hot workpiece. Because the workpiece
remains hot, its flow stress and high ductility
are maintained during forming. Thus, the forging load is
low, and the material flow within the die cavity is
improved.
Complex parts can be isothermally forged, with good
dimensional accuracy and to near-net shape
by one stroke in a hydraulic press. The dies are usually
are made of nickel or molybdenum alloys, because of
their resistance to high temperature. The process is
expensive and the production rate is low. It
can, however, be economical for specialized, intricate
forgings, made of such materials as superalloys and
titanium
9. Why is hubbing an attractive alternative to
producing simple
dies?
Hubbing. This process consists of pressing a hardened
punch, with a specific tip geometry, into the surface
of a block of metal. The cavity produced is subsequently
used as a die for forming operations, such as those
employed in making tableware. The die cavity is usually
shallow, but for deeper cavities some material
may be removed from the surface of the block by
machining prior to hubbing (see Figs. 24.2c and d).
10. What is the difference between piercing and
punching?
Piercing. This is a process of indenting, but not breaking
through, the surface of a workpiece with a punch,
in order to produce a cavity or an impression (Fig. 14.13).
The workpiece may be confined in a container,
such as a die cavity, or may be unconstrained. The
surface deformation of the workpiece will depend on
how much it is constrained from flowing freely as the
punch penetrates. Piercing may be followed by
punching to produce a hole in the part; see the slug
above the stationary punch in the central portion of
Fig. 14.9.

punching: Punching is to punch out part of the material in the

middle part of the ingot to form a central channel for subsequent
processing and use. Punching needs to be done after the ingot is
preheated. Punching is generally done with a die, which should
match the size and shape of the

2∗µ∗r
F=σf*3.14*r2*[1+ 3∗h ]

σf=k*€n
€n=ln(ho/hf)
Vf=v0
3.14*rf2 *hf=3.14*ro2*ho
P= σf*e2*µ*(ro-r)/h
Problems

1. Take two solid, cylindrical specimens of equal

diameter, but
different heights, and compress them (frictionless) to
the same
percent reduction in height. Show that the final
diameters will
be the same.
VF=V0
cylindrical -1
K is constant<1~reduction percentage
3.14*rf2 *k*ho=3.14*ro2*ho
Rf^2=ro^2/k ✓
Cylindrical -2
K is constant<1~reduction percentage
3.14*rf2 *k*ho=3.14*ro2*ho
Rf^2=ro^2/k ✓

Rf of Cy1=Rf of Cy2

2. Calculate the room-temperature forging force for a

solid,
cylindrical workpiece made of 5052-O aluminum that
is 100
mm high and 125 mm in diameter and is to be
reduced in
height by 30%. Let the coefficient of friction be 0.15.

Ho=100mm
 Do=125mm
Hf=70mm
µ=.15
3.14*rf2 *hf=3.14*ro2*ho
Rf=74.70mm
K=202mpa
N=.13
€ =ln(100/70)=.35667
σf=k*€n =202*106 *.35667.13=176.6631MPA
2∗.15∗74.70∗.001
F=176.6631*106 *3.14*(74.70*.001)2*(1+ 3∗70∗.001 )=3.4 MN

3 calculate the forging force for A solid cylindrical

workpiece is
150 mm in diameter and 100 mm in height. It is
reduced in
height by 50%, at room temperature, in an open-die
forging
operation with flat dies. assuming that the material
is1100-O
aluminum and that the coefficient of friction is 0.10.
4. Given: A solid cylindrical workpiece made of 304
stainless steel
is 150 mm in diameter and 100 mm in height. It is
reduced in
height by 50%, at room temperature, in an open-die
forging
operation with flat dies. Assume that the coefficient
of friction is
0.2. Find: What is the forging force at the end of the
stroke?
. How does extrusion differ from rolling and
forging?
Forging is a basic process in which the workpiece is
shaped by compressive forces applied through various
dies and tooling.
Rolling is the process of reducing the thickness or
changing the cross section of a long workpiece by
compressive forces applied through a set of rolls
In simple extrusion, a cylindrical billet is forced through a
die (Fig. 15.1) in a manner similar to squeezing
toothpaste from a tube. A wide variety of solid or hollow
cross sections can be produced by extrusion, which
basically are semifinished products

2 Explain the difference between extrusion and

drawing.
Extrusion and drawing have numerous applications in
manufacturing continuous as well as discrete products
from a wide variety of metals and alloys. In simple
extrusion, a cylindrical billet is forced through a
die (Fig. 15.1) in a manner similar to squeezing
toothpaste from a tube. A wide variety of solid or hollow
cross sections can be produced by extrusion, which
basically are semifinished products
A characteristic of extrusion (from the Latin extrudere,
meaning to force out) is that large deformations
can take place without fracture, because the material is
under high triaxial compressive stresses (see Section
2.2.8). Since the die geometry remains unchanged
throughout the process, extruded products typically have
a constant cross section along their length

In drawing, developed between 1000 and 1500 A.D., the

cross section of a solid rod, wire, or tubing
is reduced or changed in shape by pulling it through a
die. Drawn rods are used for shafts, spindles, and
small pistons and as the raw material for fasteners such
as rivets, bolts, and screws. In addition to round
rods, various profiles also can be drawn
3. What is a
dead-metal
zone?
Note the dead-metal zone in Fig. 15.6b and c, where the
metal at the corners essentially remains stationary.

Define the terms (a) cladding, (b) dummy block, (c)

shear dies,
(d) skull, and (e) canning.
dummy block, shown in the
figure, is to protect the tip of the pressing stem,
particularly in hot extrusion.
In indirect extrusion, also called reverse, inverted, or
backward extrusion, the die moves toward the stationary
billet (Fig. 15.3a). Indirect extrusion has the advantage of
having no billet–container friction, since
there is no relative motion; thus, it is used on materials
with very high friction, such as high-strength steels.
In hydrostatic extrusion (Fig. 15.3b), the billet is
smaller in diameter than the container, which is filled
with a fluid, and the pressure is transmitted to the fluid
by a ram. The fluid pressure imparts triaxial compressive
stresses on the billet, thus improving its formability (see
Section 2.2.8). Furthermore, there is much
less workpiece–container friction than in direct extrusion.
A less common type of extrusion is lateral (or side)
extrusion (Fig. 15.3c)
Die design requires considerable experience, as can be
appreciated by reviewing Fig. 15.7.
Square dies, also called shear dies, are used in extruding
nonferrous metals, especially aluminum. These
dies develop dead-metal zones

shear dies, are used in extruding nonferrous metals,

especially aluminum. These
dies develop dead-metal zones, which in turn form an
effective die angle
As a result, a thin shell (skull), consisting mainly of the
outer
oxidized layer of the billet, is left in the container; it is
later removed from the chamber.
a thin-walled container made of a softer and lower
strength metal, such as copper
or mild steel; this procedure is called jacketing or
canning

Cladding in extrusion refers to the process of applying a

layer of one material onto the surface of another material
using the extrusion technique. This process is commonly
used in industries where the properties of one material
need to be combined with those of another to achieve
specific performance characteristics.

5. Why is glass a good lubricant in hot extrusion?

Glass (Section 8.4) is
an excellent lubricant for hot extrusion of steels, stainless
steels, and high-temperature metals and alloys.
In a process developed in the 1940s and known as the S´
ejournet process, a circular glass or fiberglass pad
is placed in the chamber at the die entrance. The hot
billet conducts heat to the glass pad, whereupon a
thin layer of glass melts, is entrained, and acts as a
lubricant. Before the hot billet is directly placed in the
chamber, its cylindrical surface is coated with a layer of
powdered glass, to develop a thin glass lubricant
layer at the billet–chamber interface.
6. What types of defects may occur in (a) extrusion
and (b)
drawing?

Surface Cracking. If extrusion temperature, friction, and

speed are too high, surface temperatures can
rise significantly, which may cause surface cracking and
tearing (fir-tree cracking or speed cracking). These
cracks are intergranular (along the grain boundaries; see
Fig. 2.27), and usually are caused by hot shortness
(Section 1.5.2). Such defects occur especially in
aluminum, magnesium, and zinc alloys; they can be
avoided
by lowering the billet temperature and the extrusion
speed.
Surface cracking may occur also at lower temperatures,
attributed to periodic sticking of the extruded
part along the die land. Because of its similarity in
appearance to the surface of a bamboo stem, it is known
as a bamboo defect. The explanation is that, when the
product being extruded temporarily sticks to the die
land (see Fig. 15.7), the extrusion pressure increases
rapidly; shortly thereafter, it moves forward again, and
the pressure is released. The cycle is repeated
continually, producing periodic circumferential cracks on
the
surface.
Pipe. The type of metal-flow pattern in extrusion shown
in Fig. 15.6c tends to draw surface oxides and
impurities toward the center of the billet, much like a
funnel. This defect is known as pipe defect, tailpipe,
or fishtailing; as much as one-third of the length of the
extruded product may contain this type of defect,
and has to be cut off as scrap. Piping can be minimized
by modifying the flow pattern to be more uniform,
such as by controlling friction and minimizing
temperature gradients within the part. Another method is
to machine the billet’s surface prior to extrusion (so that
scale and surface impurities are removed) or by
chemical etching of the surface oxides prior to extrusion.
Internal Cracking. The center of the extruded product
can develop cracks, variously called center cracking,
center-burst, arrowhead fracture, or chevron cracking
(Fig. 15.16a). Cracking has been attributed to a state of
hydrostatic tensile stress that develops at the centerline
in the deformation zone in the die (Fig. 15.16b); this
condition is similar to the necked region in a tensile-test
specimen (see Fig. 2.23). Such cracks also have been
observed in tube extrusion and in tube spinning (see Fig.
16.49b and c), appearing on the inside surfaces of
tubes. The tendency for center cracking (a) increases
with increasing die angle, (b) increases with increasing
amount of impurities in the material, and (c) decreases
with increasing extrusion ratio and friction
typical defects in a drawn rod or wire are similar to those
observed in extrusion, especially center cracking
(see Fig. 15.16). Another major type of defect in drawing
is seams, which are longitudinal folds in the drawn
product. Seams may later open up during subsequent
forming operations, such as upsetting, heading,
thread rolling, or bending of the rod or wire, and may
cause serious quality-control problems. Various other
surface defects, such as scratches and die marks, may be
due to improper selection of process parameters,
poor lubrication, or poor die condition.
Because they undergo nonuniform deformation during
drawing, cold-drawn products usually have
7. Describe the difference between direct and
reverse extrusion
Direct Extrusion, sometimes called Forward Extrusion, is the
most common type of extrusion. As shown in the figure below, the
process begins by loading a heated billet (only for hot extrusion,
discussed later) into a press cavity container where a dummy
block is placed behind it. Then the mechanical or hydraulic ram
presses on the material to push it out through the die. Then, while
still hot, the part is stretched to straighten. This process is
beautifully animated by Core Materials. Under direct extrusion,
the high friction caused by steels at higher temperatures is
reduced using molten glass as a lubricant while oils with graphite
powder are used for lubrication for low temperatures. The dummy
block protects the tip of the pressing stem (punch or ram) in hot
extrusion. When the punch reaches the end of its stroke, a small
portion of the billet called the “butt end” cannot be pushed through
the die opening

In Indirect Extrusion, the die is located at the end of the

hydraulic ram and moves towards the billet inside the cavity to
push the material through the die. This is illustrated in figure 2
below.
 Figure 3 – In-direct
extrusion (source: Kalpakjian & Schmid)
This process consumes less power due to the static billet
container causing less friction on the billet. However, supporting
the extruded part is difficult when the extrudate exits the die.

8. It is possible to extrude straight gears; can

helical gears also be
extruded? Explain

Yes, helical gears can also be extruded, but with some key
differences compared to extruding straight gears.

Straight Gear Extrusion:

 Straight gears have teeth that are parallel to the axis of

rotation.
 The extrusion process for straight gears is relatively simple.
A gear blank with the desired profile (typically involute) is
pushed through a die that shapes the teeth.
 The die essentially acts like a cookie cutter, forming the gear
teeth as the blank material is forced through.

Helical Gear Extrusion:

  Helical gears have teeth that are angled relative to the axis
of rotation. This creates a smoother, quieter operation
compared to straight gears.
 Extruding helical gears is more complex than straight gears
due to the helical angle.
 A specialized extrusion die with a matching helical profile is
required.
 The extrusion process may involve a mandrel (a rod)
inserted through the center of the gear blank to maintain its
shape and guide the material flow during extrusion.
 Some extrusion techniques for helical gears involve a
rotating die or a rotating mandrel to achieve the helical
pattern on the teeth.

8 What is impact extrusion?

Impact extrusion is similar to indirect extrusion, and the
process often is included in the cold-extrusion
category. The punch descends rapidly on the blank (slug),
which is extruded backwards (Fig. 15.14). Because
of volume constancy, the thickness of the tubular
extruded region is a function of the clearance between
the
punch and the die cavity.
Typical products made by this process are shown in Fig.
15.15a to c. Other examples are collapsible
tubes, some cylindrical computer housings, light fixtures,
automotive parts, and small pressure vessels.
Most nonferrous metals can be impact extruded in
vertical presses and at production rates as high as two
parts per second.
The maximum diameter of parts made is about 150 mm.
The impact-extrusion process can produce
thin-walled tubular sections, with thickness-to-diameter
ratios as small low as 0.005
10. What is the pipe defect in extrusion?

Pipe. The type of metal-flow pattern in extrusion shown

in Fig. 15.6c tends to draw surface oxides and
impurities toward the center of the billet, much like a
funnel. This defect is known as pipe defect, tailpipe,
or fishtailing; as much as one-third of the length of the
extruded product may contain this type of defect,
and has to be cut off as scrap. Piping can be minimized
by modifying the flow pattern to be more uniform,
such as by controlling friction and minimizing
temperature gradients within the part. Another method is
to machine the billet’s surface prior to extrusion (so that
scale and surface impurities are removed) or by
chemical etching of the surface oxides prior to extrusion.
11 List the similarities and differences between direct
extrusion

and drawing

Similarities:
  Both are plastic deformation processes: Both direct
extrusion and drawing involve forcing a material through a
shaping tool (die) to achieve a desired cross-sectional
profile.
 Work hardening: The material experiences work hardening
as it is forced through the die, increasing its strength but also
reducing its ductility.
 Applications: Both processes are used to create various
shapes and products from a wide range of metals, plastics,
and other materials. Examples include tubes, rods, wires,
and various profiles.

Differences:

Feature Direct Extrusion Drawing

Pre-shaped bar or
Material Form Solid billet rod (often pre-
extruded)
Ram pushes the Material is pulled
Force Application material through the through the die by a
die drawing force
Die is typically Die is typically
Die Location stationary at the end attached to the
of the container moving draw ram
Material flow is
Material flows in the
opposite to the
Metal Flow same direction as
direction of the draw
the ram movement
ram
Can achieve
Typically achieves
moderate to high
Reduction Ratio higher reductions in
reductions in cross-
cross-sectional area
sectional area
Surface Finish Surface finish can Generally, better
be good, but may surface finish due to
require additional compressive forces
 processing
Can create a wider Typically limited to
Wall Thickness range of wall creating thinner
thicknesses walls
More versatile for Often used for
creating complex producing wires,
Applications
shapes and hollow rods, tubes, and
profiles simple shapes

12. The extrusion ratio, die geometry, extrusion speed, and

billet

temperature all affect the extrusion pressure. Explain why.

extrusion ratio, R (ratio of the cross-sectional area of
the billet to that of the extruded part, Ao/Af); additional
processing variables are the billet temperature, the speed
at which

13. What is the function of a stripper plate in

impact extrusion?
A plate (solid or movable) used to strip the workpiece or part from the
punch. It may also guide the stock by holding the workpiece down
during a press operation.
Figure 15.14: Schematic illustration of the impact-
extrusion process. The extruded parts are stripped by the
use of a stripper plate, because they tend to stick to the
punch

Problems
1. Given: A round billet made of 70–30 brass is extruded
at a
temperature of 675◦ C. The billet diameter is 125 mm,
and the
diameter of the extrusion is 50 mm. Find: Calculate the
extrusion force required.

2. Estimate the force required in extruding 70–30 brass at

700◦ C
if the billet diameter is 250 mm and the extrusion ratio is
25.
3. Calculate the extrusion force for a round billet 300 mm
in
diameter, made of stainless steel, and extruded at 1000◦
C to a
diameter of 90 mm.
4. A planned extrusion operation involves steel at 1000◦
C with
an initial diameter of 100 mm and a final diameter of 25
mm.
Two presses, one with capacity of 20 MN and the other
with a
capacity of 10 MN, are available for the operation. Is the
smaller press sufficient for this operation? If not, what
recommendations would you make to allow the use of the
smaller press?
Do=100mm
Df=25mm
F=Ao*k*ln(R)
F=3.14*(100*.001/2)2 *390*ln(100/25)=4.24MN
YES sufficient