Extrusion Notes

ME 6222: Manufacturing Processes and
Systems Prof. J.S. Colton GIT 2011

1
ver. 1
Deformation Processing -
Extrusion
2
Overview
Equipment
Characteristics
Mechanical Analysis
direct extrusion
indirect extrusion
Redundant work
Defects
3
Geometry (90
o
die)
D
1

D
2

p
dead zone
45
o
angle
4
Equipment
5
Extrusion
6
Equipment
7
Extrusions
8
9
Characteristics
Similar to closed die forging
Forging
slug (bulk) is forging
flash (extrusion) is waste
Extrusion
extrusion (flash) is part
billet (bulk) is waste
10
Types
Direct
Indirect
Tubular
Hydrostatic
Cold Impact
11
Types
1 direct
2 indirect
3 heading (forging also)
12
Flow types
Laminar
Turbulent
redundant work
can bring outside of billet into
center
leaving the skin keeps outside
scale out of final extrusion
13
Steel extrusion
T
processing
= 2100 to 2400
o
F (1150 1315
o
C)
T
melting
= 2500 - 2800
o
F (1370 1540
o
C)
Die ~ 400
o
F (205
o
C)
Obviously Hot
above recyrstallization point
Lubricants
glass (viscous lube ) 0.001 thick
MoS
2

graphite
14
Mechanical Analysis
D
1

D
2

p

dead zone
45
o
angle
external
friction
internal
friction
x
15
Assumptions
Metal deforms uniformly
D
1
to D
2

No redundant work
Cant use slab analysis
die angles too great
friction too high
Dead zone sets up at 45 degrees
16
p

t
friction

Upper bound analysis
Work input by external forces
= plastic work expended

friction external
compress work to plastic
friction internal pressure
W
W
W W

+
+
=
17
Rate of work = Power
Work rate = Power
Work rate = Area stress velocity
18
Pressure work input
Power = A p v
ram moves at velocity, v
ram

ram p
v p
D
W =
4
2
1
t

19
Internal frictional work input
Work determined by integrating rate of
frictional work dissipation at each cross
section from D
2
to D
1
t
friction
= t
flow

v
i
is in x-direction
D
D + dD
dx
dL=dD/\2
45
o
|
|
|
.
|
\
|
=
}
1
2
D
D
i flow f
DdL v W t t

20
Volumetric flow rate

where D, A
i
, v
i
are instantaneous
i i ram
v A v A Q = =
1
ram i
v
D
D
v
2
1
|
.
|
\
|
=
21
2
1
2
1
ln
2
D
D
D v
W
flow ram
f
=
t t

}
=
1
2
2
2
1
D
D
flow ram
f
D
dD
D v
W
t t

22
Plastic work to compress input
Power = u
p
x Area x velocity

hence
c t c o
flow p
d u volume Energy 2 / = = =
}
2
1
ln 2
D
D
= c
ram flow pw
v
D
D
D
W
|
|
.
|
\
|
|
|
.
|
\
|
=
4
ln 4
2
1
2
1
t
t

23
Total work input (without external friction)
reducing
2
1
2
1
2
1
2
1
2
1
ln
2
4
4
ln 4
4 4
D
D
v
D
D
D
v
D
v p
D
flow
ram
flow ram ram
+
|
|
.
|
\
|
=
t
t
t
t t
2
1
ln 414 . 3
2 D
D p
flow
=
t
24
Extrusion ratio (r
e
)
Reduction in area (RA) is large
it is not sensitive for classification
Use r
e
instead
RA D
D
r
e
=
|
|
.
|
\
|
=
1
1
2
2
1
25
Extrusion pressure (without external friction)
2
2
1
2
1
ln 707 . 1 ln 414 . 3
2
|
|
.
|
\
|
= =
D
D
D
D p
flow
t
e
flow
r
p
ln 707 . 1
2
=
t
26
Billet - wall friction
Assume limiting case:
friction stress = shear flow stress
t
f
= t
flow

t
flow

t
flow

27
Additional pressure due to billet - wall
friction
x D
D
p
flow
=
A
1
2
1
4
t t
t
1
2
2 D
x p
flow
=
A
t
t
flow

t
flow

28
Direct extrusion pressure
1
2
2 2 2 2 D
x p p p p
flow flow flow flow
x
+ =
A
+ =
t t t t
1
1 2
1
2
ln 707 . 1
2
2
ln 414 . 3
2
D
x
r
p
D
x
D
D p
e
flow
x
flow
x
+ =
+ =
t
t
29
Indirect extrusion
No wall- billet interaction
Include wall - dead zone
interaction
assume: friction stress = shear
flow stress
t
f
= t
flow
Same result as direct
extrusion
without external friction
dead
zone
D
1

D
2

t
flow

30
Additional pressure due to billet-
dead zone friction
1
2
1
2 D
D p
flow
=
A
t
D
1

dead
zone
D
2

t
flow

t
flow

( )
|
.
|
\
|

= A
2 4
2 1
1
2
1
D D
D D p
flow
t t
t
31
Indirect Extrusion Pressure
|
|
.
|
\
|
+ =
|
|
.
|
\
|
+ =
1
2
1
2
2
1
1 ln 707 . 1
2
1 ln 414 . 3
2
D
D
r
p
D
D
D
D p
e
flow
flow
t
t
32
1
2
+
= = =
n
K
Y
n
flow flow
c
o t
Strain hardening
(cold below recrystallization point)
Not plane strain (Tresca)
average flow stress:
due to shape of element
33
Strain rate effect
(hot above recrystallization point)
Not plane strain (Tresca)
( )
rate strain average where
C Y
m
flow flow
=
= = =
c
c o t
2
|
|
.
|
\
|
=
2
1
3
2
3
1
2
1
3
2
3
1
2
1
ln
tan 12
ln
tan 6
D
D
D D
D v
r
D D
D v
ram
e
ram
o o
c
|
|
.
|
\
|
= =
2
1
1 1
ln
12
ln
6
D
D
D
v
r
D
v
ram
e
ram
c
(dead zone approx.

large extrusion ratio
o = 45
o
)
due to shape of element
34
Direct vs. Indirect Extrusion
a = direct, b = indirect
Redundant
work
(squashing
dead zone)
set-up
35
Strain rate derivation
For a billet radius, R
1
,
as a function of distance, x, from
the entrance
x
r R
=
1
tano
o tan
1
= x R r
A
dA
d = c
2
r A t = dr r dA = t 2
r
dr
d
2
= c
dx dr = o tan
o
R
1
r

x
36
Strain rate derivation
|
.
|
\
|
|
.
|
\
|

= =
dt
dx
r dt
d o c
c
tan 2
ram
v
dt
dx
=
r
v
ram
o
c
tan 2
=
2
2
1 1
r
R v
v
ram
=
flow rate is constant
37
Strain rate
( )
3
1
2
1 1
3
2
1 1
tan
tan 2 tan 2
o
o o
c

=
=
x R
R v
r
R v

38
Average strain rate derivation
From the ram velocity, v
ram
|
|
.
|
\
|
=
4
2
1
D
v
t
V
ram
t
Volume of deformation zone, V
|
|
.
|
\
|
+ + =
4 4 4 3
2 1
2
2
2
1
D D D D h
V
t
2
1
tan
2 1
D D
h
= o
( )
o
t
tan
1
24
3
2
3
1
= D D V
t
c
c =
o
D
1
D
2
h
D
1
-D
2
39
Average strain rate derivation
time to fill deformation zone, t
o
t
tan
1
6
4
2
1
3
2
3
1
2
1
=
|
|
.
|
\
|
=
D v
D D
D
v
V
t
ram
ram
2
2
2
1
ln ln
D
D
r
e
= = c
average strain
t
c
c =

40
Average strain rate
|
|
.
|
\
|
=
2
1
3
2
3
1
2
1
3
2
3
1
2
1
ln
tan 12
ln
tan 6
D
D
D D
D v
r
D D
D v
ram
e
ram
o o
c
Approximation for dead zone: D

1
>> D
2
and o = 45
o
|
|
.
|
\
|
= =
2
1
1 1
ln
12
ln
6
D
D
D
v
r
D
v
ram
e
ram
c

41
Example 1-1
You are forward, cold extruding Al-1100 (K =
140 MPa, n = 0.25), 10-cm diameter billet to a
diameter of 5-cm at 1 m/min. The billet is
initially 25 cm long
The ram is made of a high-strength steel with
a yield stress of 1.5 GPa.
Determine the extrusion force and power.
Determine the safety factor for indenting the
ram.

42
Example 1-2
The equations we use are:
1 2
1
2
ln 414 . 3
2 D
x
D
D p
flow
x
+ =
t
1
2
+
= =
n
K
Y
n
flow
c
t
|
|
.
|
\
|
=
2
1
ln 2
D
D
c
1 +
= = =
} }
n
K
d K d u
n
p
c
c c c o
because
43
Example 1-3
We need to determine the dead-zone length to
subtract from the initial billet length.
so
x = l dead zone length
x = 0.25 0.025 = 22.5 cm
45
2.5 cm
5 cm
2.5 cm
2.5 cm
44
Example 1-4
Substituting values
39 . 1
5
10
ln 2 ln 2
2
1
=
|
.
|
\
|
=
|
|
.
|
\
|
=
D
D
c
( )
MPa
n
K
Y
n
flow
6 . 121
1 25 . 0
39 . 1 140
1
2
25 . 0
=
+
=
+
= =
c
t
|
|
.
|
\
|
+ =
1 2
1
2
ln 414 . 3 2
D
x
D
D
p
flow x
t
MPa P
extrusion
834
10
5 . 22 2
5
10
ln 414 . 3 6 . 121
max ,
=
|
.
|
\
|

+ =
45
Example 1-5
Safety factor against indenting the ram
to determine the press-fit failure, we would
need the dimensions of the extrusion die and its
material
8 . 1
834 . 0
5 . 1
max ,
= = =
GPa
GPa
n
extrusion
y
o
o
( ) MN Area P F
extrusion extrusion
6 . 6 1 . 0
4
10 834
2
6
= = =
t
kW m MN speed F Power 110 sec 60 min/ min / 1 6 . 6 = = =
46
Redundant work
A = d
m
/L
d
m
= (D
1
+ D
2
) / 2
p = Q
r
o
flow

p
D
1

D
2

L (contact length)
47
Redundant work factor (Backofen)
(frictionless)
Q
r
=

48
Defects
Surface materials drawn
into center
pipe, tail pipe

Surface materials
extruded
eliminate by leaving
skin
49
Chevron Cracking
50
Chevron cracking defect
Hydrostatic tension
outer layer in compression
inner layer in tension, if
entire part is not plastic
eliminate by using a fluid
hydrostatic compression
reduces friction

51
Defects
Surface speed cracking
high friction
temperature
speed

52
Summary
Equipment
Characteristics
Mechanical Analysis
direct extrusion
indirect extrusion
Redundant work
Defects
53

Extrusion Notes

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Extrusion Notes

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ME 6222: Manufacturing Processes and

Systems Prof. J.S. Colton GIT 2011

ME 6222: Manufacturing Processes and

ME 6222: Manufacturing Processes and

Internal frictional work input

ME 6222: Manufacturing Processes and

ME 6222: Manufacturing Processes and

(dead zone approx.

ME 6222: Manufacturing Processes and

ME 6222: Manufacturing Processes and

Approximation for dead zone: D

ME 6222: Manufacturing Processes and

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