Extrusion

Extrusion is a bulk forming process in which the work metal is forced or compressed to
flow through a die hole to produce a desired cross-sectional shape. Example: squeezing
toothpaste from a toothpaste tube.

Advantages
- Variety of shapes are possible, especially using hot extrusion
- Grain structure and strength properties are enhanced in cold and warm
extrusion
- Close tolerances are possible, mainly in cold extrusion

Types of extrusion
Direct or forward extrusion and
Indirect or backward extrusion

Direct extrusion (Fig. 1)

A metal billet is first loaded into a container having die holes. A ram compresses the
material, forcing it to flow through the die holes.
- Some extra portion of the billet will be present at the end of the process that
cannot be extruded and is called butt. It is separated from the product by
cutting it just beyond the exit of the die.

Fig. 1 Direct extrusion

- In direct extrusion, a significant amount of friction exists between the billet

surface and the container walls, as the billet is forced to slide toward the die
opening. Because of the presence of friction, a substantial increase in the ram
force is required.
- In hot direct extrusion, the friction problem is increased by the presence of
oxide layer on the surface of the billet. This oxide layer can cause defects in
the extruded product.

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- In order to address these problems, a dummy block is used between the ram and the
work billet. The diameter of the dummy block is kept slightly smaller than the billet
diameter, so that a thin layer of billet containing the oxide layer is left in the container,
leaving the final product free of oxides.

Hollow sections like tubes can be made using direct extrusion setup in fig. 2. The starting
billet is prepared with a hole parallel to its axis. As the billet is compressed, the material
will flow through the gap between the mandrel and the die opening.

Fig. 2 Making hollow shapes using direct extrusion

Indirect extrusion
In Indirect extrusion (Fig. 3), the die is mounted to the ram and not on the container. As
the ram compresses the metal, it flows through the die hole on the ram side which is in
opposite direction to the movement of ram.
- Since there is no relative motion between the billet and the container, there is no friction
at the interface, and hence the ram force is lower than in direct extrusion.
- Limitations: lower rigidity of the hollow ram, difficulty in supporting the extruded
product at the exit

Fig. 3 Indirect extrusion: solid billet and hollow billet

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Simple analysis of extrusion
Pressure distribution and billet dimensions in direct extrusion

Assuming the initial billet and extrudate are in round cross-section. An important
parameter, extrusion ratio (re), is defined as below:

A0 - CSA of the initial billet; Af - CSA of the extruded section

True strain in extrusion under ideal deformation (no friction and redundant work) is
given by,

Under ideal deformation, the ram pressure required to extrude the billet through die hole
is given by

Where Yf is average flow stress, and is maximum strain value during the extrusion process
Note: (The average flow stress is found out by integrating the flow curve equation between zero and the final
strain defining the range of forming)

The actual pressure for extrusion will be greater than in ideal case, because of the friction
between billet and die and billet and container wall.

Extrusion dies
- Two important factors in an extrusion die are: die angle, orifice shape.
- For low die angles, surface area of the die is large, resulting in increased friction at the
die-billet interface. Higher friction results in higher ram force.
- For a large die angle, more turbulence in the metal flow is caused during reduction,
increasing the ram force required.
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- The effect of die angle on ram force is a U-shaped function, shown in Figure. So, an
optimum die angle exists. The optimum angle depends on various factors like work
material, billet temperature, and lubrication.

Die materials
For hot extrusion - tool and alloy steels.
Important properties of die materials are high wear resistance, high thermal conductivity
to remove heat from the process.

For cold extrusion - tool steels and cemented carbides.

Carbides are used when high production rates, long die life, and good dimensional control
are expected.

Other extrusion processes

Impact extrusion:
- It is performed at higher speeds and shorter strokes. The billet is extruded through the
die by impact pressure and not just by applying pressure.
- But impacting can be carried out as forward extrusion, backward extrusion, or
combination of these.

forward extrusion Backward extrusion

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 combined extrusion

Hydrostatic extrusion
In hydrostatic extrusion, the billet is surrounded with fluid inside the container and the
fluid is pressurized by the forward motion of the ram.
There is no friction inside the container because of the fluid, and friction is minimized at
the die opening. If used at high temperatures, special fluids and procedures must be
followed.
Hydrostatic pressure on the work and no friction situation increases the material’s
ductility. Hence this process can be used on metals that would be too brittle for
conventional extrusion methods.

This process is also applicable for ductile metals, and here high reduction ratios are
possible.
The preparation of starting work billet is important. The billet must be formed with a
taper at one end to fit tightly into the die entry angle, so that it acts as a seal to prevent
fluid leakage through die hole under pressure.

Hydrostatic extrusion

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Defects during extrusion
Centerburst:
- This is an internal crack that develops as a result of tensile stresses along the center axis
of the workpiece during extrusion. A large material motion at the outer regions pulls
the material along the center of the work. Beyond a critical limit, bursting occurs.
- Conditions that promote this defect are: higher die angles, low extrusion ratios, and
impurities in the work metal. This is also called as Chevron cracking.

Centerburst

Piping: It is the formation of a sink hole in the end of the billet. This is minimized by the
usage of a dummy block whose diameter is slightly less than that of the billet.

Piping

Surface cracking: This defect results from high workpiece temperatures that cause cracks
to develop at the surface. They also occur at higher extrusion speeds, leading to high strain
rates and heat generation. Higher friction at the surface and surface chilling of high
temperature billets in hot extrusion also cause this defect.

Surface cracking