Professional Documents
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of Metals
Chapter 15
Topics
Types of Extrusion :
Direct Extrusion (or) Forward Extrusion – Billet is placed in a
chamber and forced through a die opening by a hydraulically-driven ram or
pressing stem.
Fig : Types of metal flow in extruding with square dies. (a) Flow pattern obtained at low friction, or in indirect
extrusion. (b) Pattern obtained with high friction at the billet-chamber interfaces, (c) Pattern obtained at
high friction, or with cooling of the outer regions of the billet in the chamber. This type of pattern, observed
in metals whose strength increases rapidly with decreasing temperature, leads to defect known as pipe, or
extrusion defect.
Die Design and Die Materials
Fig : (a) An extruded 6063-T6 aluminum ladder lock for aluminum extension ladders. This parts is 8mm thick and
is sawed from the extrusion, (b)-(d) Components of various dies for extruding intricate hollow shapes.
Cross-sections to be extruded
Fig : Poor and good examples of cross-sections to be extruded. Note the importance of eliminating sharp
corners and of keeping section thickness uniform.
Impact Extrusion
• Similar to indirect extrusion
• Punch descends rapidly on the blank, which is extruded backward
Fig : 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.
Examples of Impact Extrusion
Fig : (a) Two examples of products made by impact extrusion. These parts may also be made by casting, by forging,
or by machining; the choice of process depends on the dimensions and the materials involved and on the
properties desires. Economic considerations are also important in final process selection. (b) and (c) Impact
extrusion of a collapsible tube by the Hooker process.
Hydrostatic Extrusion
• The pressure required for extrusion is supplied through and incompressible fluid medium
surrounding the billet
• Usually carried at room temperature, typically using vegetable oils as the fluid
• Brittle materials are extruded generally by this method
• It increases ductility of the material
• It has complex nature of the tooling
Fig : (a) Chevron cracking (central burst) in extruded round steel bars. Unless the products are inspected, such internal
defects may remain undetected, and later cause failure of the part in service. This defect can also develop in the
drawing of rod, of wire, and of tubes. (b) Schematic illustration of rigid and plastic zones in extrusion. The
tendency toward chevron cracking increases if the two plastic zones do not meet. Note that the plastic zone can be
made larger either by decreasing the die angel or by increasing the reduction in cross-section (or both).
Drawing Process
• In this process the cross section of a round rod or wire is typically reduced or
changed by pulling it through a die
• Die angle has great influence on the drawing force and the quality of the drawn
product
Drawing FORCE :
F = Yavg Af In (Ao/Af) ; Yavg – average true stress of the material in the die gap
Fig : Examples of tube-drawing operations, with and without internal mandrel. Note that a variety of
diameters and wall thickness can be produced from the same initial tube stock (which had been made
by other processes).
Die Materials
Types of Lubrication
a) Wet drawing : Dies and Rods are completely immersed in
lubricant
b) Dry drawing : Surface of the rod to be drawn is coated
with a lubricant
c) Coating : Rod or Wire is coated with a soft metal that acts
as a solid lubricant
d) Ultrasonic Vibration of the dies and mandrels.
Defects and Residual Stresses
Typical defects are
• center cracking
• seams