MFDP1 L03 Bar Extrusion ENIM 2019

Mise en forme par déformation plastique 1
Special Processes of Forming Technology
MECA 2
Lecture 3: Bar Extrusion Processes
2019-20
Dr.-Ing. habil. Sami Chatti
Content
L3 – Bar extrusion processes
Conventional bar extrusion processes
Curved profile extrusion
Twisted profile extrusion
Composite extrusion
Extrusion of profiles with variable properties
Chip extrusion
2019 L03 – Bar extrusion 3.2
1
Content

Introduction
Bar extrusion process
Analytical modeling of the extrusion force
Material
Process limits
Tools and applications
Composite extrusion
Chip extrusion
Classification of extrusion processes

according to DIN 8583
Bulk forming
Indentation /
Extrusion Drawing Forging Rolling
Impression
Cold forging/
Reducing Bar extrusion
Extrusion
F F
Punch Punch
d0
Workpiece d0
Punch
F d0
d1
 Work-
h
 piece
Die
d1 d1
2
Definition according to DIN 8583-6
Bar extrusion is the forming of a billet which is enclosed by a

container through a die, primarily to produce extrudates with a
solid or hollow cross-section.
Production of long products
Properties:
– Constant cross-section in axial direction
– Open profiles, solid profiles, hollow profiles
Extrusion profiles with different shapes and materials
3
Historical development of bar extrusion
1797: Patent of Joseph Bramah

„Press for producing tubes of certain diameters and lengths
without seams made of lead and other soft metals“
1820: Construction of hydraulic press for the extrusion

of lead (Thomas Burr)
1894: Modification of the processes for the extrusion of copper

and brass (Alexander Dicks)
(Source: www.key-to-nonferros.com)
Hydraulic extrusion press from 1895
(Source: Bauser/Sauer/Siegert)
4
Content

Introduction
Material
Process limits
Composite extrusion
Chip extrusion
Most important bar extrusion processes
Direct bar extrusion
Indirect bar extrusion
Hydrostatic bar extrusion
10
5
Direct bar extrusion
Billet Container Die holder

Ram
Dummy block Die

11
Process steps of direct bar extrusion
Insertion of the preheated

billet
Upsetting of the billet in the

press container
Extrusion up to predetermined
discard length
Moving back the container and

ram and shearing off the discard
12
6
Indirect bar extrusion
Container Billet Hollow ram Die holder
Disc Die Hollow ram holder
13
Process steps of indirect bar extrusion
Insertion of the preheated billet

and die
Upsetting of the billet in the

container
discard length

shearing off the discard
14
7
Seal Die
Hydrostatic medium
(pressure fluid) Extrudate
Ram
Container Billet
15
Process steps of hydrostatic bar extrusion
Insertion of the billet and

positioning of the container
Entry of the ram and filling

the hydrostatic medium
discard length
Fluid removal

shearing off the discard
16
8
Comparison of the bar extrusion processes (1)
Direct bar extrusion Indirect bar extrusion
Extrudate moves in the direction of Extrudate moves in the opposite

the ram direction to the ram
Billet moves relatively to the tool No friction between billet and container
Friction between container and billet Lower ram forces are required
Requires higher forces than indirect Smaller cross-section and shorter
extrusion product due to used hollow ram
Flexible design possibilities of the die Lower die design flexibility

Extrudate moves in the direction of the
ram
Lower friction as a result of the active fluid
Lower ram forces
Difficult sealing
Lower die design flexibility
Rarely used
Reduced temperature range
17
Comparison of the bar extrusion processes (2)
18
9
Material flow during direct bar extrusion
Micro etching of a discard Extrusion ratio

A0 d 02
R 
A1 d12
(Source: Güzel 2012)
19
Flow types of bar extrusion
Flow type S, Flow type A, Flow type A1

direct extrusion direct extrusion (aluminium extrusion, indirect)
Aluminium “sticks”
No friction Low friction
Flow type B, Flow type C, Flow type B1
Flowextrusion
direct type B Flow extrusion
direct type C (aluminium extrusion, direct)
(Source:
Valberg 2009)
High friction Billet colder High friction

Billet warmer Compared to B longer shear zone
(Source: Dürrschnabel 1968)
20
10
Content

Introduction
Material
Process limits
Composite extrusion
Chip extrusion
21
Extrusion ratio and true strain
LPR
d0
v0
LD
Extrusion ratio True strain Forming zone

A d2 A d0  d1
R  0  02 max  ln 0 LD 
A1 d1 A1 2  tan 
Mean strain rate Die entry angle of flat die

R 1
LD
1
 
LD 0  dz  LD  v0 2  90
22
11
Forming zones and extrusion force graph
for direct bar extrusion
WUpset : Initial build up of load

WDeform : Overcoming of gliding resistance
Wid : Ideal forming energy
WFricS : Energy share shearing zone
WRedW : Energy share redundant work
WFricC : Friction at container
L0 : Initial billet length
LEB : Effective billet length
LD : Discard length
23
Ram stroke during billet upsetting
Ram stroke during upsetting

d B2
s1  l B (1  ) (Volume constancy)
d 02
l B Billet length
d 0 Container diameter
d B Initial billet diameter
Upsetting
24
12
Total forming force for direct bar extrusion
Bar extrusion with lubrication: (from Siebel equation)
Ftotal  Fid  FRedW  FFricC  FFricS
2   2L   2 * 
  A0  kfm  max     A0  kfm  tan     A0  kf,0   EB    A0  kfm  max  
3   r0   sin2 
(with µ* = 0.5 for shearing zone)
 2 tan  2 LEB  kf,0 1 

 Ftotal  A0  kfm  max  1    
 3max r0  max  kfm sin2 
Bar extrusion without lubrication:

(µ = µ* = 0.5 and α = 45°)
 2 LEB  kf,0 
 Ftotal  A0  kfm   2max   
 3 r0  kfm 
Wid : Ideal forming energy

WFricS : Energy share shearing zone
WRedW : Energy share redundant work
WFricC : Friction at container
25
Example: extrusion force (1)

Extrusion of an aluminium alloy (EN AW-6082) at 450°C (average process
temperature in the material) with 31 mm/s ram velocity.
From the billet (Ø 150 mm) a round rod with 50 mm diameter is extruded
through a flat die.
The billet length is 380 mm, the discard is supposed to have a length of 50 mm.
Question: What is the extrusion force?
Extrusion force: Effective billet length 380 mm  LEB  50 mm
Container cross-section
Flat die a = 45°
 2 tan  2 LEB  kf,0 1 
Ftotal  A0  kfm  max  1    
 3max r0  max  kfm sin2 
Container radius
2
A0 150
True Strain  max  ln  ln  ln(9)  2.197
A1 50 2
26
13
Example calculation: extrusion force (2)
Determining the yield stress and friction factor
Material: EN AW-6082, AlMgSi1
Friction Factor: (sticking)

  0.5
Strain rate:
R 1 9 1 1
   v0   31 mm s  5
LDC 50 mm s
Yield stress:
k f ,0   0;   0;   450 C   44 MPa

42 MPa
 1 
k f,1    5 ;   2.197;   450 C 
 s 
 42 MPa
kf ,0  k f ,1
 k fm   43 MPa
2
Source: Akeret, R.
Untersuchungen über die Warmverformbarkeit
von Aluminiumlegierungen. 1967
27
Example calculation: extrusion force (3)

Result
Ftotal  Fid  FFricC  FFricS  FRedW
 N 
LEB  mm   44
150 2  N  2 mm 2 
Ftotal  mm  43
2
  2  2.197   
4 mm 2  3 N
75 mm  43 
8  mm 2 
7
Extrusion force in MN
6
5 FFricC
4
FRedW
3
FFricS
2
1 Fid
0
0 30 60 90 120 150 180 210 240 270 300 330
Ram stroke in mm
28
14
Content

Introduction
Material
Process limits
Composite extrusion
Chip extrusion
29
Materials for extrusion
Unit Magnesium Aluminium Titanium Steel Copper Lead
Density 1.74 2.7 4.5 7.85 8.92 11.38
Melting point
Spec. heat capacity
Electrical conductivity 106 22.6 37.7 2.34 9.93 4.84
Thermal conductivity 21.9 80.2 35.3
Modulus of elasticity
Tensile strength
Price
30
15
Material aluminium
Aluminiumlegierungen
Aluminium alloys
Wrought alloys
Knetlegierungen Cast alloys
Gusslegierungen
(plastische
(plastic (Formfüllungsvermögen
(mould filling properties
Verformbarkeit)
formability) und and
die Vergießbarkeit)
castability)
Heat-treatable
Aushärtbare NichtNot
aushärtbare
heat-
Legierungen
alloys Legierungen
treatable alloys
Alloys for extrusion
31
Wrought aluminium alloys
Series Type of alloy Properties Application

1xxx Pure aluminium good formability and corrosion resistance food packaging
tensile strength: 69-186 N/mm2 drinks packaging
2xxx Al + Cu (Mg, Pb, Bi) high strength (also at increased temp.) airplanes
tensile strength: 186-448 N/mm2 transport systems
3xxx Al + Mn (Mg) medium strength, good formability packaging
tensile strength: 110-282 N/mm2 heat transmission
4xxx Al + Si good flow characteristics, medium strength piston

tensile strength: 127-379 N/mm2 complex forged party
5xxx Al + Mg (Mn) very good corrosion resistance, civil industry
low strength, good weldability marine
tensile strength: 124-351 N/mm2 vehicle construction
6xxx Al + Mg + Si very good extrudability, medium strength civil industry
tensile strength: 124-400 N/mm2 shipping; autom. manufac.
7xxx Al+Zn+(Mg)+(Cu) very high strength aerospace
tensile strength: 202-606 N/mm2 vehicle construction
8xxx Al + all other alloying high conductivity, strength and hardness electrics
elements (z.B. Fe, Li) and tensile strength: 117-241 N/mm2 bearing applications
new tech. (rapid solidi-
fication, metallic glass) aerospace
hardening by strain hardening

Density: 2.7 .. 2.8 g/cm³ hardening by heat treatment
32
16
Grain structure development during extrusion
Extrusion billet: cast structure/ globular microstructure (a)

With flowing in the die: grains are stretched (b)
With increasing strain: fibrous, elongated grain structure (c)
33
Structure development during extrusion

Measurements and visualisation of the microstructure development is
possible through the Electron-Back-Scatter-Diffraction-Method (EBSD)
Determination of the crystal structure and orientation through diffraction
pictures ("Kikuchi-Maps") in the scanning electron microscope
Same colour = same grain orientation
Development of the grain size

and orientation, EN AW-6082
after extrusion
(Source: Güzel 2012)
34
17
Structure development after bar extrusion
Directly after extrusion fine, elongated structure (a)
If the extrusion profile remains at an elevated temperature level: static
recovery and recrystallisation processes begin (b)
A coarse-grained, globular structure arises (c)
a) Stretched, b) Grain growth c) Coarse grains
strongly orientated
35
Content

Introduction
Material
Process limits
Composite extrusion
Chip extrusion
36
18
Extrudability of different aluminium alloys
Circumscribing circle
dc = 220 mm
Min. wall thickness in mm

Strength in MPa
Minimum
S-Values at RT wall thickness
Rm
Rp0,2
100 Extrudability index

(Extrusion velocity)
(Source: Støren )
37
Producible minimum wall thicknesses

Alloy design. Profile circumscribed circle diameter [mm]
type 1)
Extrusion press capacity

[MN]
1) a: Solid and semi-hollow profiles, b: Hollow profiles with even wall thickness
c: Hollow profiles with uneven wall thickness
(Source: Ostermann)
38
19
Limits of the extrudability
Heating up due to the forming energy in the area of the

tool inlet edges can lead to melting
Mechanical and chemical properties of the profile can be affected
negatively
No sufficient
extrusion
force
Extrusion ratio
Melting
Working Area
Billet operating temperature Melting

(Source: Ostermann) point
39
Content

Introduction
Material
Process limits
Composite extrusion
Chip extrusion
40
20
Layout of an extrusion press
Ram
Dummy block
Billet
Die set
Pressure plate
Extudate
Container
Backup plate Tool holder (cassette)
(Source: Müller )
41
Die set
Pressure plate Backup ring

Pressure Bolster
ring
Backer Backer
Die Die
Extrudate
Dummy block
Ram
Billet
Die ring Die ring
Liner
Container
Die slide Die slide
(Source: Ostermann )
42
21
Classification of extrusion dies
Porthole dies
Tools for
hollow profiles
Flat dies
Complexity
Tools for open

(semi-hollow)
profiles
Tools for solid

profiles
43
Flat face die
Simple dies for the production of solid profiles and open

profiles
Pocket Source: Giansun
The material flow is controlled by

• pockets
• Length of the bearing land
Enlarged bearing
44
22
Tools for the production of hollow profiles
Extrusion with Porthole dies

fixed mandrel
Extrusion
Pressblockbillet Stempel
Ram mit Dorn
with mandrel
www.siemens-kg.de Discard
Matrize Short
Dorn Dornplatte Rezipient
vvWZ Die Mandrel plate
Tool mandrel
Container
Tragarm
Support arm
Einlauf(port)
Inflow
Hohlprofil
Hollow profile
Führungsfläche
Bearing
vTool
WZ
Tote Zonen
Dead Fließlinien
zones Flow lines Al-Block
Al-billet
45
Video: Die Design and Optimization

Collaborative Research Center DFG Transregio 10
B1: Die design
46
23
Applications: Motor vehicles and rail traffic
ICE-Power head
BMW Z8
Aluminium power rails

Audi A8
Alcan
47
Applications: Shipping and aviation
Boeing 747
Airbus
Ostermann
48
24
Applications: Architecture and construction profiles
Bosch&Rexroth
SAPA Altec
49
Content
Composite extrusion
Chip extrusion
50
25
Lightweight profile structures in
traffic systems
51
Conventional process chain for manufacturing

of curved profiles
Ram Profile
Extrusion
Container Billet Die Backup plate
Stretching
F F
Stretch bending Three - roll - bending
F F
Bending
F F
52
26
Curved profile extrusion –
process principle and realisation
Strand
Guiding
Ram tool
Container Billet Die Backup plate
53
Special extrusion press for CPE
Characteristics
Tool package in pressure plate
Wide opended pressure plate at the front
Press force: 10 MN
Ram speed: 0,1 - 10 mm/s
Billet length: 250 - 300 mm
Diameter of container: 146 mm
Profile radius (const.): min. 500 mm
Circumscribed circle max. 130 mm
Pressure Recess for

plate tool package
Minimal Collision with

Funded by the radius press
German Research Foundation (DFG) (500 mm)
for investigation of the collaborative
research center SFB/TR10.
54
27
Three-dimensional curved profile extrusion -
manufacturing of a BMW C1 side roof frame
BMW C1
roof frame
Original BMW C1
space frame
55
3D-curved profile extrusion
Enhancement to the
three-dimensional
application
Additional vertical linear axis
Enclosing guiding tool
Gimble-mounted guiding tool
No profile support
Influence of gravity Profile Vertical axis Guiding tool
Discs for enclosed guiding

For circular For square
task:
(material: graphite) tube profile
56
28
Gravity compensation by a robot-moved
second guiding tool
57
Video: 3D curved profile extrusion
Vide
o
58
29
Content
Composite extrusion
Chip extrusion
59
Introduction and Motivation
Complex twisted profiles

Example: Screw rotors
High energy efficiency
Low weight
Compact form
Conventional
manufacturing:
Casting of a semi-finished product
Milling to a highly precise geometry Supercharger
Disadvantages:
High manufacture complexity
High manufacture time
High material loss because of milling
60
30
Alternative processes
Die with Internal Guiding Tool for

Twisting Channel External Twisting
Helical Profile Extrusion (HPE) Twisted Profile Extrusion (TPE)

Constant twisting angle Variable twisting rates
Forming based on die geometry Forming based on tool feed
Simple process control motion angle
Simple die design
61
Twisted Profile Extrusion (TPE)
When the requested twisting

angle is achieved this remains
constant during extrusion
62
31
Concept of a guiding tool (TPE)
Rotary lever
Upper body
Material flow
Lower body Guiding disc
Concept of Guiding Tool for TPE Realization

Manual rotating
Guiding disc exchangeable
63
Twisted Profile Extrusion (TPE) -

experimental investigations
Deviation of the cross section

Average deviation
Deviation in mm
Measuring points
Analysis of the cross section

Average deviation below 0.7 mm
Maximum twisting angle 30° / 100 mm
64
32
Twisted Profile Extrusion (TPE) -
influence of the friction on the profile surface
DLC TiAlSN
Guiding disc in graphite Coated steel Discs

Good friction condition with hot aluminum High breaking strength
Low twist angle (30° / 100 mm) Higher twist angle (40° / 100 mm)
Low grinding traces on the surface deep grinding traces
Disc broken by more twisting Aluminum welded on the disc
65
Content
Composite extrusion
Chip extrusion
66
33
Composite extrusion: motivation
High Lightweight potential through composite

extrusion for linear and curved profiles made
of Aluminium and magnesium alloys
Optimal combination of the

material properties of different
materials
67
Possible fields of application
Body structures regarding....
Stiffness Strength
Space frame profiles Fuselage – frames and stringers
Boats – frames and stringers
(Audi)
(Airbus)
Crash
Bumpers
Side impact beams Fatigue
A- and B-columns Fuselage – frames and stringers
68
34
Methods of composite extrusion
Extrusion of Composites Extrusion of Common Billets
Particle reinforced Co- Composite power Magnesium

billets extrusions tracks anodes
Expensive billet costs Use of conventional billets

High punch forces Integration of strength as
High tool wear well as functions
69
Composite profile extrusion
Sealing element
Container liner
Supply element
Welding chamber
Billet Die
Reinforcing
element
Supply channel Continuously

reinforced
profile
Ø 9 mm 20x5 mm 56x5 mm 22x14x2 mm

70
35
Cross-section development for reinforced
profiles
Reinforcing volume
Bar 48 x 3 mm, 11 RE Complex shapes
Square 50 x 50 x 5 mm, 13 RE
Bar 56 x 5 mm, 3 RE
Bar 56 x 2 mm, 6 RE
Double-T 56 x 56 x 5 mm, 14 RE
Bar 56 x 5 mm, 6 RE
Basic shapes
Round bar Bar 20 x 5 mm,

9 mm, 1 RE 2 RE Tube 44 x 5 mm, 4 RE
71
Tool design
72
36
Embedding of functional elements
Enhanced potential of composite profiles for

Signal transfer
Data transfer
Monitoring
73
Embedded isolated-electric conductor
74
37
Composite extrusion: animation
75
Video: Composite Extrusion

Composite extrusion

ak_0206_pt
76
38
Content
Composite extrusion
Chip extrusion
77
Functionally graded profiles
Motivation
Hot aluminum extrusion:
– Straight, semi-finished products, mass production
– Integration of functionalities
– Constant cross section
– Homogeneous material properties
Extruded aluminum profiles as structural components:

– Extruded profiles  constant cross section
– Structural component  loading conditions are varying
locally
Challenge:
– Constant cross section = compromise between functionality and component design
– Preventing local oversizing = preventing increased use of resources
78
39
Objective
Integration of processing steps into the process chain of hot

aluminum extrusion for the manufacturing of function-
adapted structural components
– Locally adapted materials properties
– Locally adapted geometries New
State of the art
Process chain
Semi-finished product manufacturing Hot forming Heat treatment
79
Functionally graded profiles

Functional gradation by hot forming
Extrusion with in-line electromagnetic compression Product
Patent application DE 10 2009 039 759.0
Vide
o
80
40
Subsequent processing of open sections
Principle
– Design as a continuous rolling process
– Hot forming by using heat of extrusion
– New process:
corrugating subsequent
to hot extrusion
Dimensioning and design

Deform 3D
81
Subsequent processing of open sections
Setup Process control

– Synchronisation between extrusion
and rolling speed
– Pivot-mounted roll stand
– Process control of the rotational
speed of the rollers
Vide
o
82
41
Content
Composite extrusion
Chip extrusion
83
Chip Extrusion
Extrusion of Aluminum Chips Primary Aluminum Production (from Alumina):
Energy Requirement approx. 200 GJ per Ton
Aluminum Profile of Primary Aluminum*
Chips
 9,7 ton CO2**
Secondary Aluminum (from Scrap):

Energy Requirement approx. 20 GJ per Ton
of Secondary Aluminum*
4,8 ton CO2**
Chip Extrusion
20 % Material Lost
Chip-
Billet Punch Recycling by Direct Extrusion of Aluminum
Chips:
Energy Requirement approx. 3,2 GJ per Ton
of Extruded Aluminum Profile***
Compacted  380 kg CO2***
Chips No Material Lost
*H. G. Schwarz, Uni Erlangen
** “Environmental Profile Report for the European Aluminium Industry”, European Aluminium Association (04/ 2008)
*** V. Güley, IUL, Technische Universität Dortmund
84
42
Hot extrusion of aluminum chips
85
Video: Process chain bar extrusion

Process chain
86
43
Appendix: German for Production Engineers
English Français English Français

Ecoulement du
Extrudate Barre filée Material flow
matériau
Bar extrusion Filage Quenching Trempe
Billet Billette Direct extrusion Filage direct
Dummy Block Grain de poussée Indirect extrusion Filage inverse

Curved profile Filage de profilés
Container Conteneur
extrusion cintrés
Twisted profile Filage de profilés
Ram Fouloir/Poinçon
extrusion tordus
Composite Filage de profilés
Upsetting Refoulement
extrusion composites
Discard Culot de filage Chip extrusion Filage de copeaux
87
44

MFDP1 L03 Bar Extrusion ENIM 2019

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MFDP1 L03 Bar Extrusion ENIM 2019

Uploaded by

Copyright:

Available Formats

Mise en forme par déformation plastique 1

Special Processes of Forming Technology

Lecture 3: Bar Extrusion Processes

Dr.-Ing. habil. Sami Chatti

L3 – Bar extrusion processes

Conventional bar extrusion processes

Curved profile extrusion

Twisted profile extrusion

Extrusion of profiles with variable properties

2019 L03 – Bar extrusion 3.2

L3 – Bar extrusion processes

Classification of extrusion processes

2019 L03 – Bar extrusion 3.4

Bar extrusion is the forming of a billet which is enclosed by a

2019 L03 – Bar extrusion 3.5

Production of long products

Extrusion profiles with different shapes and materials

2019 L03 – Bar extrusion 3.6

1797: Patent of Joseph Bramah

1820: Construction of hydraulic press for the extrusion

1894: Modification of the processes for the extrusion of copper

2019 L03 – Bar extrusion 3.7

Hydraulic extrusion press from 1895

2019 L03 – Bar extrusion 3.8

L3 – Bar extrusion processes

Most important bar extrusion processes

Direct bar extrusion

Indirect bar extrusion

Hydrostatic bar extrusion

2019 L03 – Bar extrusion 3.10

Billet Container Die holder

Dummy block Die

2019 L03 – Bar extrusion 3.11

Process steps of direct bar extrusion

Insertion of the preheated

Upsetting of the billet in the

Moving back the container and

2019 L03 – Bar extrusion 3.12

Container Billet Hollow ram Die holder

Disc Die Hollow ram holder

2019 L03 – Bar extrusion 3.13

Process steps of indirect bar extrusion

Insertion of the preheated billet

Upsetting of the billet in the

Moving back the container and

2019 L03 – Bar extrusion 3.14

2019 L03 – Bar extrusion 3.15

Process steps of hydrostatic bar extrusion

Insertion of the billet and

Entry of the ram and filling

Moving back the container and

2019 L03 – Bar extrusion 3.16

Direct bar extrusion Indirect bar extrusion

Extrudate moves in the direction of Extrudate moves in the opposite

Hydrostatic bar extrusion

Comparison of the bar extrusion processes (2)

2019 L03 – Bar extrusion 3.18

Micro etching of a discard Extrusion ratio

(Source: Güzel 2012)

2019 L03 – Bar extrusion 3.19

Flow types of bar extrusion

Flow type S, Flow type A, Flow type A1

High friction Billet colder High friction

L3 – Bar extrusion processes