Q1) Extrusion is a process used to create

objects of a fixed cross-sectional profile. With

details discuss the theory and principles.
Theory:
Extrusion process uses a force to cause pressure on a
metal in a container then a desired cross section
shape comes out of a die.

Principles:
1- The process begins by heating the stock material (for
hot or warm extrusion).
2- It is then loaded into the container in the press.
3- A dummy block is placed behind it where the ram
then presses on the material to push it out of the die.
4- Afterward the extrusion is stretched in order to
straighten it.
5- If better properties are required then it may be heat
treated or cold worked.
Q2) The process begins by heating the stock
material (for hot or warm or cold extrusion). In
detail discuss the main differences.
Hot extrusion
 It is done above the material's recrystallization
temperature to keep the material from work
hardening and to make it easier to push the material
through the die.
 Most hot extrusions are done on horizontal hydraulic
presses.

Cold extrusion
 Cold extrusion is done at room temperature or near
room temperature.
 The advantages of this over hot extrusion are the lack
of oxidation, higher strength due to cold working, closer
tolerances, and better surface finish.

Warm extrusion
 Warm extrusion is done above room temperature, but
below the recrystallization temperature of the material.

 Choosing the method to use depends on the material

and it's ductility.
 Q3) Discuss the direct extrusion, Indirect and
the hydrostatic extrusion processes.
 Direct, indirect and hydrostatic extrusion have the same
principles the only difference is the technique used in each
of them.
 In the direct extrusion:
It works by placing the billet in a heavy walled container. The
billet is pushed through the die by a ram or screw.

 In the indirect extrusion:

The ram pushing the billet moves in the opposite direction of
the metal extruded.
The main advantage of the indirect extrusion:

 A 25 to 30% reduction of friction, which allows for extruding

larger billets, increasing speed, and an increased ability to
extrude smaller cross-sections.
 In the hydrostatic extrusion
The billet is completely surrounded by a pressurized liquid,
except where the billet contacts the die. This process can be
done hot, warm, or cold, however the temperature is limited by
the stability of the fluid used. The process must be carried out
in a sealed cylinder to contain the hydrostatic medium. 
Q4) Give details of complete practical
applications of the extrusion technology in
practice.
Extrusion is used in the industry of :

1-food:  instant foods and snacks,

along with its already known uses in
plastics and metal fabrication.

2- Drug carriers:
in pharmaceutical products,
extrusion through nano-porous,
polymeric filters is being used to
produce suspensions of lipid
vesicles liposomes or transverses wi
th a particular size of a narrow size
distribution.
3- Extrusion is also is used in
automobiles and construction
equipment, railings, window frame
members, structural parts etc.
 Mansoura University
Faculty of engineering

Production engineering and mechanical

design department

Technical report

In

Extrusion process

:By
.Ziad Sayed Fadali