Lecture 6

Production Engineering

1st Year Marine Fall 2007

Extrusion and Drawing of Metals
 Direct-Extrusion

Figure 15.1 Schematic illustration of the direct-extrusion process.

9-MN (1000-ton) Hydraulic-Extrusion Press

Figure 15.17 General view of a 9-MN (1000-ton) hydraulic-extrusion press.

Source: Courtesy of Jones & Laughlin Steel Corporation.
 Types of Extrusion

Figure 15.3 Types of extrusion: (a) indirect; (b) hydrostatic; (c) lateral;
Types Of Extrusion

FIGURE 6.49 Types

of extrusion. (a)
direct; (b) indirect;
(c) hydrostatic; (d)
impact.
 Extrusion

FIGURE 6.51 Schematic illustration of three

different types of metal flow in direct extrusion.

FIGURE 6.50 Extrusion and

examples of products made by
sectioning off extrusions.
Source: Kaiser Aluminum.
 Process Variables in Direct Extrusion

Figure 15.4 Process variables in direct extrusion. The die angle, reduction in cross-section,
extrusion speed, billet temperature, and lubrication all affect the extrusion pressure.
 Extrusion of Seamless Tube

FIGURE 6.60 Extrusion of a seamless tube. The hole in the billet may be
prepunched or pierced, or it may be generated during extrusion.;
 Extrusion-Die Configurations

Figure 15.7 Typical extrusion-die configurations: (a) die for nonferrous metals; (b) die
for ferrous metals; (c) die for a T-shaped extrusion made of hot-work die steel and
used with molten glass as a lubricant. Source: (c) Courtesy of LTV Steel Company.
 Extrusion of Complicated Shapes

FIGURE 6.61 (a) An extruded 6063-T6 aluminum ladder lock for aluminum
extension ladders. This part is 8 mm (5/16in.) thick and is sawed from the
extrusion. (See Fig. 6.50.) (b) Components of various dies for extruding intricate
hollow shapes. Source for (b): K. Laue and H. Stenger, Extrusion-Processes,
Machinery, Tooling, ASM International, 1981. Used with permission.
 Design of Extruded Cross-Sections

Figure 15.9 Poor and good examples of cross-sections to be extruded. Note the
importance of eliminating sharp corners and of keeping section thicknesses uniform.
Source: J.G. Bralla (ed.); Handbook of Product Design for Manufacturing. New York:
McGraw-Hill Publishing Company, 1986. Used with permission.
Extrusions and Products Made from Extrusions

Figure 15.2 Extrusions and

examples of products made by
sectioning off extrusions.
Source: Courtesy of Kaiser
Aluminum.
 Extrusion of Heat Sinks

Figure 15.10 (a) Aluminum extrusion used as a heat sink for a printed circuit board. (b)
Die and resulting heat sink profiles. Source: Courtesy of Aluminum Extruders Council.
 Cold and Impact Extrusion
FIGURE 6.56 Examples of cold
extrusion. Arrows indicate the
direction of material flow.
These parts may also be
considered as forgings.

FIGURE 6.57 (a) Impact extrusion of

a collapsible tube (Hooker
process).(b) Two examples of
products made by impact extrusion,
these parts may also be made by
casting, forging, and machining,
depending on the dimensions and
materials involved and the properties
desired. Economic considerations are
also important in final process
selection.
 Cold Extrusion Examples

Figure 15.11 Two examples of cold extrusion. Thin arrows

indicate the direction of metal flow during extrusion.
 Cold-Extruded Spark Plug

Figure 15.12 Production steps for a

cold-extruded spark plug. Source:
Courtesy of National Machinery
Company.
Figure 15.13 A cross-section
of the metal part in Fig 15.12
showing the grain-flow pattern.
Source: Courtesy of National
Machinery Company.
 Impact-Extrusion Process

Figure 15.14 Schematic illustration of the impact-extrusion process. The extruded

parts are stripped by use of a stripper plate, because they tend to stick to the punch.
 Impact Extrusion

Figure 15.15 (a) Impact extrusion of a collapsible tube by the Hooker process. (b)
and (c) Two examples of products made by impact extrusion. These parts also may be
made by casting, forging, or machining. The choice of process depends on the
materials involved, part dimensions, and wall thickness, and the product properties
desired. Economic considerations also are important in final process selection.
 Chevron Cracking

FIGURE 6.59 (a) Deformation zone in extrusion, showing rigid and plastic zones.
Note that the plastic zones do not meet, leading to chevron cracking. The same
observations are also made in drawing round bars through conical dies and
drawing flat sheet plate through wedge-shaped dies. Source: After B. Avizur. (b)
Chevron cracking in round steel bars during extrusion. Unless the part is
inspected properly, such internal detects may remain undetected and possibly
cause failure of the part in service.
 Formulas
Analytical Formulas
Ao
Extrusion ratio , R= Ideal Pressure , p=Y ln R
Af
Extrusion pressure including friction at the dies∧ for small die angles
p=Y 1  
tan  cot 
[ R −1 ]
°
Assuming sticking friction∧metal flows along a 45 die angle


p=Y 1.7 R
2L
Do  , L is the friction length before the die.

Empirical Formulas
Extrusion pressure , p=Y  ab ln R 
Extrusion pressure , p=K e ln R
K e is extrusion constant that is determined experimentally
Extrusion Force

Extrusion force, F = Ao Y ln
 
Ao
Af

Figure 15.5 Extrusion constant k for

various metals at different
temperatures. Source: After P.
Loewenstein
 Extrusion Pressure

FIGURE 6.52 Schematic

illustration of typical
extrusion pressure as a
function of ram travel: (a)
direct extrusion and (b)
indirect extrusion. The
pressure in direct extrusion
is higher because of
frictional resistance in the
chamber as the billet moves
toward the die.
FIGURE 6.53 Schematic illustration of
extrusion force as a function of die angle: (a)
total force; (b) ideal force; (c) force required for
redundant deformation; (d) force required to
overcome friction. Note that there is an
optimum die angle where the total extrusion
force is a minimum.
 Example

1. Compute the required load to extrude a 100 mm aluminium diameter billet to a 40 mm solid bar
knowing that
 =219  0.283 MPa

The material is indirectly extruded =0.2 . (Assume the extrusion angle =450 )

2. Solve 1 for a sticking friction condition

 Solution 1)

2
A
 
D
Extrusion ratio , R= o = o =6.25
Af Df

=ln R=1.83

n
K
Y = =202.5 MPa
n1

 
p=Y 1
1 

[ R −1 ]=538 MPa

F = p Ao =4.23 MN
 Solution 2)


p=Y 1.7 R
2L
Do  , L is the friction length before the die.

p=Y  1.7 R  =2.15GPa

F= p Ao =16.9 MN ≈4× F =0.2

Ideal deformation case no losses

p=Y ln R=371 MPa

F = p Ao =2.9 MN