Extrusion

• Developed in the late 1700s for producing lead pipe

• A round billet is placed in a chamber and forced through a

die opening by a ram

• The die may be round or of various other shapes.

• Railings for sliding doors, window frames, aluminum

ladders, tubing.

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 Extrusion

• Extrusion can carried out cold or at elevated

temperatures.

• 4 basic types of extrusion:

a) Direct extrusion
b) Indirect extrusion
c) Hydrostatic extrusion
d) Impact extrusion

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 Extrusion

a) Direct extrusion (forward extrusion) is similar to forcing

toothpaste through the opening of a tube.

b) Indirect extrusion (reverse, inverted, or backward

extrusion), the die moves toward the billet and there is no
relative motion at the billet-container interface, except at
the die.
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 Extrusion

c) Hydrostatic extrusion the container is filled with a fluid

that transmits the pressure to the billet. There is no
friction along the container walls.

d) Impact extrusion is a form of indirect extrusion and is

particularly suitable for hollow shapes.
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 Extrusion

Chapter 6: Bulk Deformation Processes

Manufacturing Processes for Engineering Materials
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 Extrusion
• The extrusion ratio is defined as
A0
R Ao = cross-sectional area of the billet
Af Af = area of the extruded product

• Complexity of an extrusion is described by shape factor.

Part Perimeter
Shape Factor 
Part Area

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 Mechanics of extrusion
• Equations developed to find the extrusion force and how
it can be minimized.
1. Ideal force, no friction
• Through work of plastic deformation and external work
done,  A0  Ideal force
 p  u  Y ln  Y ln R 
A  F  pA0
 f 
Note that for strain-hardening materials, Y should be replaced by the average
flow stress, Y
2. Ideal force, with friction
• When material flows along a 45° “die angle”,
 2L 
Chapter 6: Bulk Deformation Processes 
p  Y 1.7 ln R  
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 D0 
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 Mechanics of extrusion
3. Actual forces
• Empirical formula has been developed.

p  Y a  b ln R  a = 0.8
b = 1.2 ~ 1.5

4. Optimum die angle

• 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
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 Example 6.5
Strain rate in extrusion

Chapter 6: Bulk Deformation Processes

Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
 Example 6.5
Strain rate in extrusion

Chapter 6: Bulk Deformation Processes

Manufacturing Processes for Engineering Materials
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 Mechanics of extrusion
5. Force in hot extrusion
• Average true-strain rate that material undergoes is given
by  6V0 0 tan 
D 2
 ln R
D D
3
0
3
f

• With poor lubrication the true strain rate reduces to

6V0
  ln R
D0
• Pressure increases rapidly with ram speed.

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 Mechanics of extrusion
5. Force in hot extrusion
• Ke is used to estimate the force in hot extrusion.
p  K e ln R

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 Example 6.6
Force in hot extrusion
A copper billet 12.7 cm in diameter and 25.4 cm long is extruded at 1088.7 K at
a speed of 25.4 cm/s. Using square dies and assuming poor lubrication, estimate
the force required in this operation if the extruded diameter is 5.08 cm.

Solution
12.7 2
Extrusion ratio is R 2
 6.25
5.08
625.4 
Average true-strain rate is   ln 6.25  22 s -1
12.7 
Assume that an average value for C is 131.00039 MPa and
that m = 0.06,
  C m  131220.06  157.69 MPa
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 Example 6.6
Force in hot extrusion
Solution

Assuming that Y   ,
 2L   225.4 
p  Y 1.7 ln R    157.691.7 ln 6.25    1121.3335 MPa
 D0   12.7  
Therefore,

 25.42
F   p  A0   1121.3335  1,451,495.6 kg
4

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