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HOLE EXTRUSIONS--PART 1
By: Peter Ulintz

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Saturday, October 1, 2011

A hole extrusion may be designed into a metal stamping for any number of reasons.
The inside diameter of an extrusion may serve as a bearing surface, a pivot point or
an interface for a press-fit with another component. Most often, hole extrusions find
use as screw attachments, usually cut or formed with threading taps or self-tapping
screws.

Some people incorrectly refer to deep-drawn hole-tapping features as extrusions.

The deep-drawn features are produced by gathering a predetermined volume of
material into a bubble, then incrementally reducing the outside diameter while
simultaneously increasing the wall height through multiple redraw stations.
Depending on the process design, deep-drawn features can have wall thicknesses
that are less than, equal to or greater than the original sheetmetal thickness. They
also can achieve greater wall heights than possible with hole extrusions.

Hole extrusions start with a punched hole in a flat surface of the sheetmetal. Then
an extruding punch expands the hole to the required ID, usually in one hit. The
extrusion wall height is the result of the punched hole diameter, the edge quality of
the punched hole, the diameter of the extrusion and the amount of allowable wall
thinning.

Consider, for example, a hole extrusion designed as a bearing hub in a 3.0-mm-

thick part (Fig. 1). The product designer requires an 8.2-mm ID and a minimum wall Fig. 1
thickness of 1.5 mm., with a minimum 3.0-mm extrusion height (h). Is it possible?

To approximate extrusion height, apply the

constancy-of-volume rule: “Material volume is
neither created nor destroyed by deformation.”
This is analogous to forming a hamburger—
squeezing the patty reduces its thickness and
increases its diameter. The volume of beef
doesn’t change; the material is merely
displaced or rearranged. The same holds true
for hole extrusions—as the extruded wall
thickness decreases, wall height increases.

Using the constancy-of-volume rule, calculate

Fig. 2
the volume of material (VM) available to work
with:

VM =[(½ A)2 - (½ B)2] π t, where:

A, inside diameter of the extrusion; B, punched hole diameter; t, material thickness.

Assuming the smallest possible hole diameter that can be punched in the workpiece is equal to the material
thickness:

VM = [(8.2/2)2 - (3.0/2)2] π3.0

= 137.225 mm3

To determine the volume of the extrusion (VE), we treat this as a cylinder with open ends and a constant wall
thickness:

VE = [(½ D)2 - (½ A)2] πh

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1/18/2019 Tooling by Design - Hole Extrusions--Part 1 | MetalForming Magazine
The outside diameter of the extrusion (D) is equal to the inside diameter plus two-times the wall thickness, or 11.2
mm. The desired height (h) of the extrusion is 3.0 mm.

VE = [(11.2/2)2 - (8.2/2)2] π 3.0

= 137.131 mm3

If VM > VE, there is enough material volume to form the extrusion. In this case, VM slightly exceeds VE, so the height
of the extrusion can be made greater than 3.0 mm. If the resulting extrusion height were too high, simply reduce VM
by increasing the diameter of the punched hole.

Once the correct volume of material has been

established, the quality of the punched hole becomes a
prime concern. All hole extrusions start as hole
expansions (Fig. 2), where a punch is forced into a
blanked hole, causing a circumferential elongation or
stretching of the cut edge. Absolute values of expansion
limits depend on the material, tool design, lubrication
and edge quality of the punched hole. Fig. 3, illustrates
the negative impact that cutting-edge damage can have
on hole expansion and hole extruding.

If the amount of stretching required to form the hole

extrusion exceeds the residual stretchability of the cut
edge after punching, consider of one several options
available for restoring edge stretchability:

• Improve the quality of the original cutting operation;

• An additional cut of higher quality; or

Fig. 3
• A shaved cut and deburred break edge.

Next month I’ll present some proven hole-punching methods and extrusion-punch designs for forming extruded holes
in sheetmetal stampings. MF

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