Manufacturing Processes

Extrusion
• Types:
a) Direct (forward)
b) Indirect (reversed)
c) Hydrostatic
d) Impact (cold)

(c) The container is filled with fluid, and Pressure is transmitted to

the fluid by Ram. (Reduce friction and force)

𝐀𝐨
• Extrusion Ratio: 𝐑 =
𝐀𝐟

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 Manufacturing Processes
• Metal flow in extrusion:
*How the grid
changes with
friction, die
angle, …

a) Most homogeneous flow pattern:

1- Very low friction between billet and container.

2- Very good Lubrication.

b) Friction is high:
Dead metal zone is developed.

c) High shear area is extended further back:

1- From high container wall friction.
2- Material in the central region flows toward the die more
easily than the outer region; leads to EXTRUSION DEFECTS.
What did influence metal flow?
1- Friction (billet, container, die) [harder to control]
2- Thermal gradient in billet [easier to control)

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 Manufacturing Processes
• Mechanics of extrusion:
A. Ideal deformation: (no friction, no redundancy)

̅ 𝒇 ∙ 𝐥𝐧 (𝑨𝒐) ; if perfect plastic (n=0), then use 𝑌𝑓 as yield

𝒑=𝒀
𝑨𝒇

strength: 𝜎𝑦𝑝 .Otherwise, strain hardening material, we use 𝑌̅𝑓

𝐤 ∙ 𝛆𝐧𝐭
̅𝐟 =
𝐘
𝐧+𝟏
𝐅 = 𝐩 ∙ 𝐀𝐨
B. Ideal deformation and friction:
1- Small die angle:
𝐭𝐚𝐧 𝛂 𝐀 𝐨 𝛍∙𝐜𝐨𝐭 𝛂
̅𝐟 ) (𝟏 +
𝐩 = (𝐘 ) (𝐥𝐧 ( ) − 𝟏)
𝛍 𝐀𝐟

F = p ∙ Ao
2- Up to 45° die angle: (dead-metal zone)
𝐀𝐨 𝟐𝐋𝐨
̅𝐟 ) [𝟏. 𝟕 (𝐥𝐧 (
𝐩 = (𝐘 ))] +
𝐀𝐟 𝐃𝐨

F = p ∙ Ao
C. Hot extrusion:
𝐀
𝐩 = 𝐤 𝐞 ∙ 𝐥𝐧 ( 𝐨 ) ; k e → extrusion constant (figure 15.5)
𝐀𝐟

F = p ∙ Ao

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 Manufacturing Processes
D. Cold extrusion: (impact with slug)

̅ 𝒇 ∙ 𝐥𝐧 (𝑨𝒐)
𝒑 = (𝟏𝟏𝟎𝟎) ∙ 𝒀
𝑨𝒇

𝐹 = 𝑝 ∙ 𝐴𝑜

NOTE:

Average strain rate sensitivity component:

̅𝐟 = 𝐂 ∙ (𝛆̅𝐭̇ )𝐦
𝐘
; C → strength coefficient
; m → strain rate sensitivity component
𝟐
𝟔𝐕 𝐃 𝐭𝐚𝐧 𝛂 𝐀
𝛆̅𝐭̇ = ( 𝐨 𝟑 𝐨 𝟑 ) ∙ 𝐥𝐧 ( 𝐨 ) ; 𝑉𝑜 → ram velocity, 𝛼 → die angle
𝐃𝐨 −𝐃𝐟 𝐀𝐟

Poor Lubrication:
𝐕𝐨 𝐀𝐨
𝛆̅𝐭̇ = 𝟔 ∙ 𝐥𝐧 ( )
𝐃𝐨 𝐀𝐟

Optimum die angle:

a = ideal force
b = friction
c = redundant

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 Manufacturing Processes
• Extrusion Defects:
1- Surface cracking:
a- temperature, speed and/or friction are high → cracks(tearing)
b- temperature is low → bamboo stem
to solve → lubrication + controlling temperature
2- Pipe:
Caused by metal flow pattern. → sink hole
3- Internal cracking (center cracking or Chevron or center burst):
because of Hydrostatic tensile stresses that develops at the
centerline in the deformation zone in the die.
Caused by 1- increasing in die angle. 2- Impurities. 3- decreasing
friction. 4- decreasing extrusion ratio.
• Hot extrusion:
Advantages:
1- Reduces force required.
2- No sufficient ductility of metal.
Disadvantages:
1- Die wear.
2- Non uniform deformation of billet.
3- It can develop oxide film [Layers of oxygen]. (To avoid: use
dummy block, which helps eliminate tensions (Skulls) from extruded
part and leave them in container.

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 Manufacturing Processes

• Die angles:
1- Square dies: (shear dies)
are used in extruding non-ferrous metals (aluminum).
It develops dead-metal zones. (Dead metal formed because of Die
angle).
2- Tubes:
can be extruded using a ram fitted with Mandrel that pierces a
hole into the billet.

• Lubrication:
a) Material flow. b) Extrusion
force.
c) Product quality. d) Surface finish
and integrity.

• Cold extrusion: (Impact)

keywords: punch and slug
Advantages:
1- Good control of dimensional tolerances.
2- Improve surface finish.

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 Manufacturing Processes

• Questions:
1- 15.22: Glass is a good lubricant in hot extrusion. Would you use
glass for impression-die forging also? Explain.
Answer: [Glass is an important lubricant during hot extrusions
because it prevents the metals from sticking to the container and
the die. In impression-die forging thick lubricant can prevent the
workpiece from acquiring the die cavity shape and quality and
may prevent forging of desired shapes because of the glass being
trapped in corners of the die].

2- 15.23: How would you go about avoiding center-cracking

defects in extrusion? Explain why your methods would be
effective.
Answer: *center cracking causes have been given in drawing defects, this answer can be used
for extrusion and drawing.

1- Center cracking increases with increasing die angle

2- Center cracking increases with increasing impurities
3- Center cracking increases with decreasing friction
4- Center cracking increases with decreasing extrusion ratio (R).
*(The tendency toward center cracking increases if the two plastic zones do not meet. Note that the
plastic zone can be made larger either by decreasing the die angle or by increasing the reduction in
cross-section / extrusion ratio)

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 Manufacturing Processes

3- 15.24: Table 15.1 gives temperature ranges for extruding

various metals. Describe the possible consequences of
extruding at a temperature (a) below and (b)
above these ranges.
Answer:
● If you extrude below the temperatures:
1- Yield stress will be higher.
2- Ductility will be reduced.
3- Surface cracking. (Bamboo Stem).

● If you extrude at higher temperatures:

1- Greater oxide formation. (Resulting in poor surface finish).
2- Less strain hardening. (Lower strength).
3- Die wear and lubricant viscosity are affected.
4- Surface cracking. (Tearing).

4- 15.25: Will the force in direct extrusion vary as the billet

becomes shorter? If so, why?
Answer:
The initial force is high because the billet is at its full length. As
extrusion progresses, the billet becomes shorter and hence the
frictional force is lower, thus lowering the extrusion force.

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 Manufacturing Processes

5- 15.31: What is the purpose of a dummy block in extrusion?

Explain.
Answer:
1- to avoid the formation of oxide films on the hot extruded
product.
2- to protect the tip of the pressing stem.
(Punch in cold extrusion)
15.39: Estimate the force required in extruding 70–30 brass at
700°C if the billet diameter is 200 mm and the extrusion ratio is
30. (Ke =200 MPa)
Answer:
Given:
𝑘𝑒 = 200 MPa 𝑑𝑜 = 200 mm
700°C indicates hot extrusion R = 30

𝜋𝑑𝑜2 𝜋2002
𝐴𝑜 = = = 31415.9 𝑚𝑚2
4 4
p = k e ∙ ln(𝑅 )
F = p ∙ Ao
F = k e ∙ ln(𝑅 ) ∙ Ao = (200) ∙ ln(30) ∙ (31415.9)
= 𝟐𝟏. 𝟑𝟕 𝐌𝐍

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 Manufacturing Processes

6- 15.42: Calculate the extrusion force for a round billet 250mm

in diameter, made of 304 stainless steel, and extruded at
1000°C to a diameter of 70 mm. (Ke =425 MPa)
Answer:
Given:
𝑘𝑒 = 425 MPa 𝑑𝑜 = 250 mm 𝑑𝑓 = 70 mm
1000°C indicates hot extrusion
𝜋𝑑𝑜2 𝜋2502
𝐴𝑜 = = = 49087.4 𝑚𝑚2
4 4
𝜋𝑑𝑓2 𝜋702
𝐴𝑓 = = = 3848.5 𝑚𝑚2
4 4

A
p = k e ∙ ln ( o )
Af

F = p ∙ Ao
Ao 49087.4
F = k e ∙ ln ( ) ∙ Ao = (425) ∙ ln ( ) ∙ (49087.4)
Af 3848.5
= 𝟓𝟑. 𝟏𝟏 𝐌𝐍

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 Manufacturing Processes

7- 15.43: A planned extrusion operation involves steel at 1000°C

with an initial diameter of 100 mm and a final diameter of 25
mm. Two presses, one with capacity of 20 MN and the other
with a capacity of 10 MN, are available for the operation. Is the
smaller press sufficient for this operation? If not, what
recommendations would you make to allow the use of the
smaller press?
Answer:
Given:
𝑘𝑒 = 425 MPa 𝑑𝑜 = 100 mm 𝑑𝑓 = 25 mm
1000°C indicates hot extrusion
𝜋𝑑𝑜2 𝜋1002
𝐴𝑜 = = = 7854 𝑚𝑚2
4 4
𝜋𝑑𝑓2 𝜋252
𝐴𝑓 = = = 490.9 𝑚𝑚2
4 4

A
p = k e ∙ ln ( o )
Af

F = p ∙ Ao
Ao 7854
F = k e ∙ ln ( ) ∙ Ao = (425) ∙ ln ( ) ∙ (7854)
Af 490.9
= 𝟗. 𝟐𝟓 𝐌𝐍
The smaller press is sufficient. (you can use lubrication)

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 Manufacturing Processes

8- A billet 5 in in diameter and 10 in in long, is extended at 1500°F

at 10 in/sec speed using square dies and assume poor
lubrication. Estimate the force required in this operation if final
diameter is 2 in.
Answer:
Hints:
1- Once you see speed in the question, think of strain rate
sensitivity.
2- poor lubrication → 1- friction. 2- second equation.
Given:
𝑚 = 0.06 𝐶 = 19000 𝑃𝑠𝑖 𝐷𝑜 = 5 in 𝐷𝑓 = 2 in 𝐿𝑜 = 10 in
𝑣𝑜 = 10 𝑖𝑛/𝑠𝑒𝑐

𝜋𝐷𝑜2 𝜋52
𝐴𝑜 = = = 19.63 𝑖𝑛2
4 4

𝜋𝐷𝑓2 𝜋22
𝐴𝑓 = = = 3.14 𝑖𝑛2
4 4
Vo Ao 10 19.63
ε̅ṫ = 6 ∙ ln ( ) = 6 ( ) ∙ ln ( ) = 22 𝑠 −1
Do Af 5 3.14

Yf = C ∙ (ε̅ṫ )m = (19000) ∙ (22)0.06 =22871.7 Psi

̅

Ao 2Lo 19.63 2(10)

̅f ) [1.7 (ln (
p = (Y ))] + = (22871.7 ) [1.7 (ln ( ))] + = 16275.1 Psi
Af Do 3.14 5

F = p ∙ Ao = (162751.1)(19.63) = 𝟑𝟏𝟗𝟒𝟖𝟎. 𝟏 𝒍𝒃

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 Manufacturing Processes
9- Assume round slug of 10 mm diameter and the average flow
stress is 350 MPa is reduced to final diameter of 7 mm.
Calculate force.
Answer:
Given:
round slug → cold (impact) extrusion
𝑑𝑜 = 10 mm 𝑑𝑓 = 7 mm ̅f = 350 Mpa
Y

𝜋𝑑𝑜2 𝜋102
𝐴𝑜 = = = 78.54 𝑚𝑚2
4 4
𝜋𝑑𝑓2 𝜋72
𝐴𝑓 = = = 38.5 𝑚𝑚2
4 4

𝐴 78.54
𝑝 = (1100) ∙ 𝑌̅𝑓 ∙ ln ( 𝑜 ) = (1100) ∙ (350) ∙ ln ( ) = 274685.728 MPa
𝐴𝑓 38.5

𝐹 = 𝑝 ∙ 𝐴𝑜 = (274685.728)(78.54) = 𝟐𝟏. 𝟔 𝑴𝑵

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 Manufacturing Processes
10- Calculate the force required in direct extrusion of 1100-O-
aluminum from a diameter of 150 mm to 100 mm.
Assume that the redundant work is 30% of the ideal work of
deformation and friction work is 25% of total work.
Answer:
Given:
do = 150 mm df = 100 mm k = 180 MPa n = 0.20
1- Calculate the ideal force:
πd2o π1502
Ao = = = 17671.5 mm2
4 4
πd2f π1002
Af = = = 7854 mm2
4 4
n
d2o 1502 0.20
k ∙ (ln 2 ) (180) ∙ (ln )
k ∙ εnt df 1002
̅
Yf = = = = 143.8 MPa
n+1 n+1 (0.20) + 1
Ao 17671.5
p=̅
Yf ∙ ln ( ) = (143.8) ∙ ln ( ) = 116.6 MPa
Af 7854
Fideal = p ∙ Ao = (116.6)(17671.5) = 2.06 MN

Ftotal = Fideal + 0.25Ftotal + 0.3Fideal = 2.06 + 0.25Ftotal + (0.3 × 2.06)

*Using calculator Ftotal = 𝟑. 𝟓𝟕𝟏 𝐌𝐍

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