ME477 Fall 2004

3. Extrusion Extrusion
• A compressive forming process in which the
work metal is forced to go through a die opening Die
v, F container
in a shape of desirable cross-section.
work Direct Extrusion
• Direct vs. Indirect
billet
• Hot, warm and cold (Forward Extrusion)
• Solid, Hollow and Semi-hallow parts Ram
• Continuous vs. Discrete
v, F
• Advantage Indirect Extrusion
– Variety of shapes but a uniform cross-section (Backward or Reverse)
– no waste of material
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Extrusion Analysis I Extrusion Analysis II

A In direct extrusion, these is additional pressure, Pf,
• Reduction (extrusion) ratio rx = o to overcome the friction at the container wall.
Af
• Assuming no friction, true strain ε = ln rx p f πDo2
= µpcπDo L = YsπDo L
• Pressure required: p = Y f ln rx 4
where pc = pressure of the billet against the container wall
• With friction, ε x = a + b ln rx where a (~0.8) and b
(1.2-1.5) increase with dies angle Yf
Ys = shear yield strength =
• Indirect Extrusion: p = Y f ε x 2

Ram Pressure
⎛ 2L ⎞ p f = Yf
2L
Direct
• Direct Extrusion: p = Y f ⎜⎜ ε x + ⎟⎟ Do
• Ram Force, F=pAo ⎝ Do ⎠
Indirect
• Power P=Fv
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Ram stroke

Extrusion Dies and Press Die Angle & Orifice Shape

2.25
⎛C ⎞ • Optimum angle depends on work material,
• Shape factor K x = 0.98 + 0.02⎜⎜ x ⎟⎟
⎝ Cc ⎠
billet temperature, and lubrication
Cx=perimeter of the extruded cross-section – Low die angle - surface area is large, leading to
Cc=Perimeter of a circle with the same area increased friction at die-billet interface, which
results in larger ram force
• Formula – Large die angle - More turbulence in metal flow
p = K xY f ε x For Indirect during reduction, which increases ram force
required
⎛ 2L ⎞
p = K xY f ⎜ ε x + ⎟ For Direct • Shape of die orifice affects ram pressure
⎝ D⎠
• Impact & Hydrostatic Extrusion – Simplest shape = circular die orifice
– As cross-section becomes more complex, higher
pressure and greater force are required
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ME477 Fall 2004

Problem 19.25 4. Wire and Bar Drawing

A billet that is 75mm long with diameter=35mm is directly extruded to
a diameter of 20mm. The extrusion die has a die angle of 75°. For the • The cross section of a bar, rod or wire is
work metal, K=600MPa and n=0.25. In the Johnson’s equation, a=0.8
and b=1.4. Determine (a) extrusion ratio, (b) true strain, (c) extrusion pulled while deforming through a die
strain and (d) ram pressure at L=70, 40 and 10mm.
opening.
Bearing Surface
75° (land)

(a) rx=Ao/Af=(352)/(202)=3.0625
(b) ε=lnrx=1.119
35mm 10mm Area Reduction:
(c) εx=a+blnrx=0.8+1.4(1.119)= 2.367
Df F Ao − A f
(d) Yf=600(1.119)0.25/1.25=493.7MPa
r=

Entry
To L=70mm, Did extrusion took place? Do Back Relief
L=70mm; p=493.7(2.367+2(70)/35)=3143.4MPa h=(R1-R)/tan 75 Approach
Approach
(30o) Ao
L=40mm; p=493.7(2.367+2(40)/35)=2297.0MPa = 2.01mm
Angle:α
(6-20o)
Lc Draft: d = Do − D f
L=10mm; p=493.7(2.367+2(10)/35)=1450.7MPa
V=1/3π(R2H-R12(H-h))=1223.4mm
V70mm=pDo2(75-70)/4=4810.6mm
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Drawing Analysis Maximum Reduction per pass

Ao 1
• Mechanics of Drawing ε = ln = ln • For an ideal plastic material
Af 1− r
Ao A 1
ideally σ = Y f ln o
A σ = Y f ln = Y ln o = Y ln =Y
Af Af Af 1− r
⎛ µ ⎞ A
realistically σ = Y f ⎜1 + ⎟φ ln o ⎛A ⎞
⎝ tan α ⎠ Af ln⎜ o ⎟ = ln⎛⎜ 1 ⎞⎟ = 1 ⇒ ε max = 1
⎜A ⎟ ⎝1− r ⎠
where φ = 0.88 + 0.12
D ⎝ f ⎠
Lc Ao
D + Df D − Df = e = 2.7183
D= o and Lc = o Af
2 2 sin α
Draw Force F = A f σ = A f Y f ⎛⎜1 + µ ⎞⎟φ ln Ao
e −1
rmax = = 0.632
⎝ tan α ⎠ Af e
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Problem 19.35 Drawing practice

Bar stock of initial diameter =90mm is drawn with a draft=15mm. The draw • Usually cold working & round cross-sections
Die has an entrance angle=18°, and the coefficient of fraction at the work-die
interface =0.08. The metal behave as a perfectly plastic material with yield • Difference between bar drawing and wire
stress =105MPa. Determine: (a) area of reduction, (b) draw stress, (c) draw drawing is stock size
force required for the operation and (d) power to perform the operation of exit
velocity=1.0m/min. – Bar drawing - large diameter bar and rod stock
– Wire drawing - small diameter stock - wire sizes down
to 0.03 mm (0.001 in.) are possible
(a) r=(Ao-Af)/Ao=(902-(90-15)2)/902=0.3056
(b) ε=ln(Ao/Af)=ln1.440=0.3646 • Preparation of the Work
Yf=k=105MPa – Annealing – to increase ductility of stock
φ=0.88+0.12(D/Lc) =1.288 where D=0.5(90+75)=82.5mm and
Lc=0.5(90-75)/sin18=24.3mm – Cleaning - to prevent damage to work surface and
σd=Yf(1+µ/tanα)φ(lnAo/Af)=61.45MPa draw die
(c) F=Afσd=4117.9(61.45)=271,475N
– Pointing – to reduce diameter of starting end to allow
(d) P=271,475(1m/min)=4524.6W
insertion through draw die
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