Analysis of Metal Forming

Processes
Dr. Shailendra Kumar
Professor, Mechanical Engineering Dept.
S.V.N.I.T. Surat
 Analysis of Extrusion

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Objective:
Determination of -
1. Work Load (F), and
2. Frictional Power Loss

DETERMINATION OF WORK LOAD FROM STRESS ANALYSIS (Slab Method):

Assumptions:
Same as used in analysis of wire-drawing
As the extrusion die is commonly flat face (i.e. equivalent half cone angle is very large
unlike in the drawing die). Consequently with the same assumptions as in drawing, the
results become highly inaccurate.

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• Assume that the dead zone can be approximated by a half-cone angle of 45 degree.
• The material undergoing deformation can be divided into two regions –
1. Section AA to BB, where the flow of material is considered as a rigid body motion; and
2. Section BB to CC, where the flow is similar to that in a wire-drawing operation (with a
compressive load)

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Determination of Work Load by Energy Consideration:
The mode of material deformation here is assumed to be the same as that in the foregoing
analysis, the only exception being that the frictional stress between the dead zone and the conical
work surface is taken as the shear yield stress k.
Assume the axial velocity at the section BB as VB ,
which is same as the ram velocity.
Hence, the rate of energy input to the conical working zone across
the section BB is –

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Workload F is given by -

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Determination of Frictional Power Loss

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Numerical Problem 1:
Estimate the maximum force required for extruding a cylindrical aluminium billet of 50 mm
diameter and 75 mm length to a final diameter of 10 mm. The average tensile yield stress
for aluminium is 170N/mm2 . What percentage of the total power input will be lost in friction
at the start of the operation?

Solution:
First Approach:
The ram force is maximum just after the start of extrusion process as l is maximum. For the given
dimensions and assuming a 450 dead zone, the value of l at beginning is,

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Second Approach:

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