DESIGN CONSIDERATION FOR METAL FORMING

1.EXTRUSION: extrusion is a process with high potential it can be performed in hot or cold
conditions in forward extrusion the billet is required to move forward resulting in large frictional loss
and high punch load the container is also subjected to high radial stresses.

The forgoing difficulties can overcome by backward extrusion where the billet remains stationary the
load is independent of the billet length

a).IMPACT EXTRUSION: this process eminently suited for making thin walled cans. This process is limited
to soft and ductile material and performed under cold conditions see fig.5.21.

b)CONVENTIONAL EXTRUSION: when making parts that have constant cross-sections , the extrusion
process is usually more economical and faster than machining ,casting or fabricating the shapes by
where he wants. Nevertheless, there are some design guidelines that must be take in to consideration
when designing and extruded sections.

1.the circle size, i.e. the diameter of the smallest circle that will enclose the extruded cross-sections can
be 31 inch, when extruding light metals.

2.solid shapes easiest to extrude. Semi-hollow and hollow shapes are more difficult to extrude,
especially if they have thin walls or include abrupt changes in wall thickness.

3. wall thickness must be kept uniform .if not ,all transitions must be streamlined by generous radii at
the thick-thin junctions.

4.sharp corners at the root of die tongue should be avoided when extruding semi-hollow sections.

5.a complicated sections should be broken in to a group of simpler sections, which are assembled after
separate extrusion process. In such a case the sections should be designed to simplify assembly, for
example, they should fit, hook or snap together. Screw slots or slots to receive tightening materials such
as plastics may also be provided.

C).ALUMINUM IMPACT EXTRUSION : in order to obtain good designs of aluminum impact extrusion, all
factors associated with the affecting the process must be taken to account, example are alloy selection,
tool design and lubrication . this is added to the general consideration of mechanical design. The
following are some basic guidelines and design examples:

1.use alloys that apply in the desired case and have lowest strength .

2.an impact extrusion should be symmetrical around the punch.

3. threads, cuts, projections and so on made are made by subjecting the impact extrusions to further
processing.
4.for reverse extrusion, the ratio of maximum length to internal diameter must not exceed eight, to
avoid failure of long punches .

5.a smaller outer corners radius must be provided for a reverse extrusion, on the contrary, the inner
corner radius must be kept as small as possible.

6. the thickness of the bottom near the wall must be 15 per cent more than the thickness of the wall
itself, to prevent shear failure.

7. the inside bottom should not be wholly flat. To avoid the possibility of the punch skidding on the
billet, only 80 per cent of it at the most can be flat.

8.external and internal bosses are permitted, provided they, are co-axial with the part. However, the
diameter of the internal boss should not be more than one-fourth of the internal diameter of the shell.

9.longitudinal ribs, whether external or internal, on the full length of the impact extrusion are
permitted. They should preferably be located in a symmetrical distribution. However, the height of each
rib must not exceed double the thickness of the wall of the shell. The main function of ribs is to provide
stiffness to the wall of shells. Sometimes, they are also used for other reasons, such as to provide
locations for drilling and tapping(to assembly the parts), to enhance by cooling by radiation, and to
provide appropriate gripping surface.

10. an impact extrusion can have a wall with varying thickness along its length, i.e. it can be multiple
diameter part . however, internal steps near the top of the product should be avoided, since they cause
excessive loading wear of the punch.

11. remember that is sometimes impossible to obtain the desired shape directly by impacting. However,
an impact extrusion can be considered as an intermediate product, which can be subjected to further
working or secondary operations like machining, flange upsetting nosing, and necking or ironing.