Extrusion

The Process
Extrusion is the process of squeezing metal in a closed cavity through a tool, known as a die using either a mechanical or hydraulic press.

Dies
The extrusion die is a steel disk with an opening, the size and shape of the intended cross-section of the final extruded product as indicated below.

The extrusion process is often likened to the squeezing of tooth paste from a tube, as is illustrated :

The top of the tube represents the die and determines the shape of the extrusion, while the paste may be considered to be the billet.

Billet
The billet is the starting stock for the extrusion operation.Extrusion billets may be a solid or hollow form, commonly cylindrical, and is the length charged into the extrusion press container.

Extrusion operations typically take place with billet heated. However,during the extrusion, the billet is still solid.

The actual extrusion process begins when the ram starts applying pressure to the billet within the container, as is shown:

This process generally produces long straight metal parts. The cross-sections that can be produced vary from solid round, rectangular, to L shapes, T shapes.

Most commonly aluminium alloys are used in the production of extruded materials. However it should be noted that plastics and other metals such as lead, tin, copper, titanium, molybdenum, vanadium, steel can be extruded.

Extrusion often minimizes the need for secondary machining,and as a result could result in financial savings. However extruded objects are not of the same dimensional accuracy or surface finish as machined parts.

References:
www.efunda.com http://wwwmaterials.eng.cam.ac.uk/mpsite/process_encyc/nonIE/metal_extrusion.html