EXTRUSION Contents oo 5.0 Introduction; 5.1 Shapes that can be extruded ; 5.2 Application of extruded parts ; 5.3 Materials used for extrusion ; 5.4 Types of extrusion [!) Direct extrusion i) Indirect extrusion J; 5.5 Variables in extrusion process 1) Type of extrusion 2) Extrusion ratio, 3) Working temperature, 4) Speed of deformation, 5) Frictional force ; 5.8 Some details of extrusion ; 5.7 Relationship between variables in extrusion; 5,8 Special types of extrusion process i) Impact Extrusion, i) Hydrostatic extrusion, il) Extrusion of brittle materials, iv) Tube extrusion, v) Closed cavity extrusion vi) Powder extrusion ; 5.9 Metal Flow pattem in extrusion ; 5.10 Defects in extruded products ; 5.11 Analysis for extrusion Worked Problems , QuestionsExtrusion 173 5.0 Introduction Extrusion is a process in which a hot billet is forced through a constricted opening (die opening) to get across section, uniform or non uniform (regular or irregular) in continuous lengths. The billet is forced through the die opening under high pressure. The requisite pressure can be obtained by mechanical or hydraulic presses. Compressive stresses are built up during extrusion which in turn effectively reduces the cracking tendency of metals. Hot billet is placed in the container near the die opening and ram is forced against it to make the metal plastically flow through the opening. The metal takes the shape of the die opening. Cold extrusion is also done in certain metals. 5.1. Shapes that can be extruded Any geometrical regular cross section, tubes, channels, I, Z, T sections and many more complicated shapes can be produced. MOe®MerGiwtyvViezG Fig. 5.1 Range of cross sections that can be extruded 5.2 Application of extruded parts Aircraft, Chemical industry, Automobile, Retrigeration, Furnitures, Textile, Motor body Building, Agriculture etc., make use of extruded parts. 5.3 Material used for extrusion Aluminium alloys are extensively extruded Cu, Mg alloys come next. However, Ni, SS, Alloy steels can also be extruded. 5.4 Types of extrusion i) Direct or Forward ii) Indirect or Backward iii) Special types (a) Impact extrusion (b) Hydrostatic extrusion (c) Tube extrusion (d) Powder extrusion Extrusion can be done in Horizontal or vertical position. In the following, paragraphs the details of extrusion process is discussed.Manufacturing Process - Ii 180: i) Direct extrusion - Die Product D, =Dia of the cylinder Cylinder Hot Billet Fig. 5.2 Indirect or Backward Extrusion Consists of a cylinder with a die at one end and a plunger at the other, end Plunger is connected to the press through which pressure is applied. F is the applied force on the billet. Hot billet is placed in the cylinder and plunger is actuated. The pressure acting on the billet forces it through the die. Hot billet has to move along the cylinder walls & has to overcome friction the direction of movement of the product is the same as that of the plunger. Fig. 5.1 Shows the arrangement. ii) Indirect extrusion Consists of a cylinder closed at one end with a hollow plunger. Hot metal is placed in th cylinder and plunger is actuated. Now, Hot metal is forced through the die fixed at end of aholloy plunger. F is the force applied on the billet,181 Extrusion As the plunger moves forward, the metal is forced through the die and moves opposite to the direction of movement of the plunger. No relative motion between the cylinder walls and the billet. Friction for the power required is less than in direct extrusion. Fig. 5.2 shows the arrangement. ‘s are lower and 5.5 Variables involved in Extrusion process 1) Type of extrusion (Direct or indirect) 2) Extrusion Ratio (E R) 3) Working Temperature 4) Speed of deformation (Ram Speed) 5) Frictional force between the die and container with the hot billet wall 1. Type of Extrusion Extrusion process can be Direct or Indirect as mentioned already. Fig. 5.3 shows the variation of Extrusion pressure as a function of ram speed. Extrusion pressure (EP) is the ratio of applied force acting per unit area of the cylinder. eps, Ram speed or plunger speed or Deformation speed is the speed at which the plunger is moving against the billet. It is the velocity of plunger movement. It can be seen that there is rapid rise in pressure during initial portion. It is due to the initial compression of the billet in filling the cylinder. This is same for both types of Extrusion. 2 5 Direct g 3 é S| Indirect 2 | 2 5 Ram speed Fig. 5.3 Variation of extrusion pressure & Ram speed In direct extrusion the metal follows through the die at the max value of pressure. As the extrusion continues the pressure required to maintain flow decreases progressively with decreasing length of the billet in the cylinder.182 Manufacturing Process - I 4 In indirect extrusion there is no relative motion between the billet and the cylinder wall. ‘Therefore the extrusion pressure is approximately constant with increasing ram travel and represents the stress required to deform the metal through the die. At the end of the stroke the pressure builds up rapidly and it is usual to stop the ram travel so as to leave a small discard in the container, and avoid hitting the wall of the cylinder. 2. Extrusion Ratio (ER) ER is the ratio of the area of cross section of the cylinder to the area of cross section of the extruded product. Its value varies from 30:1 to 40:1 for steel and 400:1 for Aluminum. If this ratio is low, mixing of the metal will be improper. If this ratio is high, excessive pressures are built up and extrusion will not be possible, the die may fail. Cylinder Plunger Product fen Hot billet = Vp A, = ™%D? D, Extrusion ratio ER = Ac eS AD, Fig. 5.4 Details for Extrusion Ratio Extrusion pressure (Pe) : It is the ratio of extrusion force to the cross sectional area of the billet. extrusion force = —6a Pe = ~ sea of billet Sa Ac Extrusion force F = K.A,. In 77 — 69} where Ac = area of C.S of the billet Ae = area of C.S of the product K = extrusion constant, depends on stress, friction and homogeneity of deformation.Extrusion 183 Cold working Extrusion pressure (emperical) Ac Pog = o [isto 4°+08] --- (5.4) where ©, = mean Y.S of the material 3. Working Temperature Hot extrusion of metal is done to take advantage of the decrease in flow stress or deformation resistance with increasing temperature. But hot working introduces oxidation of metal and tools. Softening of die and tool occurs. Adequate lubrication is difficult to provide. Hence, it is advantageous to use the minimum temperature which will provide suitable plasticity to the metal. Deformation resistance Temperature _ Fig. 5.5 Deformation Resistance Vs Temperature As the temperature of extrusion increases deformation resistance of the metal decreases. The metal becomes soft and hence can be easily extruded. 4. Speed of Deformation (Ram Speed) or Plunger Speed Ram in the cylinder is used to force the hot billet through the die opening. The speed of ram is the same as speed of deformation of the metal. Increasing the ram speed produces increase in the extrusion pressure. Low extrusion speeds result in cooling of billets and the pressure required for deformation increases. Higher the ram speed, higher will be the heat generated due to friction (internal heating). Selection of proper extrusion speed and temperature is arrived at by trial & error for each alloy and billet size, There are emperical relation available. 5. Frictional force Fretion is a very important aspect existing between two contact surfaces having relative motion.184 Manufacturing Process - Ill ‘The presence of friction is due to the contact surfaces of the die and the billet. Frictional force increases the pressure required for deformation. Excess friction may obstract metal flow and produce cracks. Hence, lubrication is done at the contact sur faces. 5.6 Some details of extrusion Extrusion can be vertical type or horizontal type. Extrusion press capacity : 3— 20 Mn (300 — 2000 T) Extruded shapes : 5-200 mm dia rods, upto 800 mm inside dia tubes, with 1.5 to 8 mm wall thickness All polygonal shapes, structural shapes. Ram speed : 20 - 40 M/min. Extrusion ratio : 40: 1 to 400 : 1 [for hot extrusion of steel and Aluminimum respectively] Operating pressure : 5000 = 20 N/mm? (approx) Die material : High alloy steel or tool steel (to withstand high thermal shock, stresses and oxidation) Direct or indirect extrusion - vertical or horizontal type Dies used : Flat faced die ee entrance a= 45°to60° Conical die Flat faced die Fig. 5.6 Extrusion dies 5.7 Relationship between variables in extrusion In the following paragraphs the relationship associated with process variables are discussed, ‘The process variables, Extrusion pressure, speed of extrusion, billet temperature and extrusion ratio are related through a single graph as shown in the Fig, 5.7 i) Speed of extrusion High speed : Metal gets heated faster. Therefore, Lower ER is to be employed as less timeis available for heat transfer, Slow speed : Billet may become stiffer. Hence needs higher extrusion Ratio. Therefore The billet needs to be heated in the cylinder.Extrusion 185 High pressure —Max extrusion ratio Low pressure Max extrusion ratio Extrusion Rati Billet Temperature a Fig. 5.7 Relationship between Extrusion ratio & Billet temperature For the same extrusion ratio initial temperature of billet should be low for high speeds of Ram and vice versa ii) Extrusion pressure For the same ER — high extrusion pressure needs low billet temperature. High pressure ~ Billet is forced faster, temperature increases and hence need low billet temperature. Low extrusion pressure needs high billet temperature. Low pressure — Billet moves slower, loss of temperature occurs and hence need higher billet temperature. Beyond certain extrusion pressure, billet becomes too stiff to be extruded, Beyond certain velocity billet starts to melt Both pressure and speed impose limit on extrusion. The limit of maximum extrusion can be obtained by the intersection of the curves. P—For high speed - Low pressure Q ~ For low speed - High pressure Ac Extrusion force Pe = KA, In3> 2.(515) Ac = area of billet Ae = area of product K = extrusion constant depends on friction, inhomogenity in deformation & stress.186 Manufacturing Process «Ill a a 5.8 Special types of extrusion processes ‘There are several extrusion processes used in practice for a specific purpose utilizing some parameters which are beneficial to the extrusion of metal. Some of them are discussed in the following paragraphs. i) Impact extrusion This type of extrusion is used for producing thin hollow containers. ‘Thin tubes used in storing medicines, tooth paste and other pasty type of materials are produced by this process. Ttis acold extrusion process It consists of a die with a blind hole as shown in the figure. 5.7. A billet cut to size is placed in the hole. Only soft metals like Aluminium, Tin, lead etc can be extruded by this process. A heavy punch is located co-axially above the die at a known height. There is an annular clearance between the punch and die periphery. This clearance corresponds to the thickness of the tube required. As the punch is allowed to fall down on the billet, the PE is converted to KE. As the punch makes contact with the billet with an impact, the metal starts flowing plastically along the annular space and a tube is formed. The punch is then withdrawn and the tube is taken out (D+ dDY + 0,77 D+ p(n } sin o up | —— | cos a = 0 --- (5.6) fh 4 cos. cosa. Neglecting the product of dD. do, & dD* we get mH dr aot aa —6,.2D. dD. D? do, + p.nD.dx.tan 0 + pp MD.dx = 0. mD + by 4 «owe get, 26, dD + D.do, — 4.D .dx.tan &— 4D dx =0 20, -dD + D.do, ~ 2 p.dD ~ 2pp. cot a. dD=0 aDT2 D.do,+2[o,-p (1 +p. cot a] dD =0 tan = Do, +2[0,-p—p w.cot 0) dD=0 (5.7) Po Cylindrical stresses dean, cote 1 “Gp Gy <. dD = 2dx tana and from V,,, Mises Criteria *192 Manufacturing Process - Ill from Von Mises criteria, 6, — 6, = 9, ~9,-CP) = 6, -O,+p = 9, --- (5.8) From (5.7) & (5.8) we get Dado, + 2[0,- (6, + 5,) - (6, + 6) 1, cot a] dD =0 DG, + 2-6, ~ Gu. cot &— G,.[L. cot a] dD = 0 D.do, ~ 2[6, (1 +H. cot O.) + 0, p. cot &] dD = 0 -- 6.9) do. _ dD [oo (tu-cot er) +o,.10 cota] ~ D do 2dD pee Ene in) Sie, ¢ B= --- (5.10) [+ B)5, +85.) D where B= cot @ (5.10) 1 Integrating 5 In [Bo, + (1 +B) 9] =2 In D + C (constant) Solution is given by Bo, + 9, (1 +B) atExit, 6,=0, D=Da 2.046, (1+B) = CD® Cp* = (5.11) " o,(1+ B) Cs (5.12 Da® (5.12) «. Equation (5.11) Becomes Bo, +0, (1+ B) = py? mo, « oss 0-2)" -o,008 rp ye = ou a\( 2) “1 entry on at D=D, 0,=0,b a oH |IH0, oo(l+B)|(D.)"_ ln Ob =~ B D. ~~ (5.13) s 5 5 1 = up =shear ys. ty ~~ (5.14)193 Extrusion ‘Total extrusion form for equilibrium no a, ou( 205} = ou( £02) +(nD,.A)t --- (5.15) t <— 8 _—-4p, on L Cylinder f cone Extrusion drawing Fig. 5.15 Stress distribution in extrusion Tu fey <. Work done in extrusion F= (: Dp. + ao 54) --- (5.16) For extrusion R> Lalways. i extrusion ratio ER = Equation (5.11) at D=Da o,= 6,,=0 0-0, (1 +B) = C.D?" C= -- (5.17) « Equation (5.11) Bo, ~ 9, (1 + B) = C.D" becomes pw Bo,—0,(1 +B) = ~ 01+ Bhp --- (5.18) @ D=D,,0,=0,,Manufacturing Process - Ii 194. ‘i aig _ Bf, -( DY | B Da CY) ; 1+B 2B" “(Fyre since o,, = —ve (compresion) fais vacua --- (5.20) Entry Fig. 5.16 Extrusion forces & their analysis , is compressive for extrusion, stress is compressive at the die opening ¢. Equation (5.19) is re-written as. 2 -CALGY] cue 09) (te) sa Worked Problems Problem : 5.1 Estimate the maximum force required for extruding acy dia and 75 mm length to a final diameter of 10 mm. Take pt = 0.15 Tensile YS, 6, = 170 Nimm? lindrical aluminium billet of 50 mm195 Extrusion Just after the extrusion is initiated (i.e., after the container is filled and the metal just starts coming out of the die) the ram force is maximum as Z is maximum. Length of billet at the beginning = 75 mm ; Db = 50 mm ; Da = 10 mm Assuming 45° dead Zone L=75-dx; = 75-20; L=55 mm dx (D,- Di) / from cot @ = (A) dx = 2 } (7 cota, } cot 4s 20 (1) = 20 mm 5; = 0.15 (1) = 0.15 B=pcota;=0.15 cot 4 Ferro = ae Stress atthe eniry O, = S| BND, 2015) a rn 2045 (32) -'| O15 10 - 10 2 5 -1) 015 . O, = 809 N/mm? Hence, Max.force.required. for extruding Rn 0, Fo = —D;.0, +—*.nD,.L qo ys! % FE (50) (809) + TO (5055) B = 2436.44 kNManufacturing Process «Ill 196 QUESTIONS Extrusion 5,1. What is extrusion ? clearly explain. 5.2. What range of products can be manufactured by extrus| sketches 5.3 What are the applications of extruded products ? 5.4 What metals/alloys can be extruded ? 5.5 How is extrusion process classified 2 5.6 Differentiate between Direct & Indirect extrusion process. 5.7 What are the special type of extrusion methods ? List them. 5.8 What is the principal of Impact extrusion? Explain with a neat sketch. What met could be impact extruded ? What are the application ? Explain the prineipal, application, metal that can be extruded in jon, Show typical cross section with tals/alloys 5. © (i) Hydrostatic extrusion (ii) Powder extrusion 5.10 Explain with neat sketches how seamless tubes/pipes are produced by extrusion s? Explain each one of them clearly process. 5.11 What are the variables associated with extrusion proces: 5.12 How are extrusion dies classified ? Show the same with sketches clearly. 5.13 How is speed of extrusion and extrusion ratio related as a function of billet temperature Explain 5.14 How is extrusion pressure and extrusion ratio related as a function of billet temperatu Explain. 5.15 Explain the metal flow pattern with and without friction in & Forward extrusion process. 5.16 Write a note on defects in extrusion products Objective type of Questions Answer according to each question 5.1 Extrusion makes use of pull force. 5.2 Indirect extrusion makes use of hollow ram 5.3 Extrusion ratio indicates the ratio of billet dia to the extruded part diameter. 5.4. High speed of ram and High extrusion ratio give the best quality product 5,5 Slow ram speed and low extrusion ratio is best suited for extrusion 5.6 Foragiven extrusion ratio the initial billet temperature should be high for high ram g 5.7 Seamless tubes can be produced by extrusion.Extrusion 197 5.8 Brittle metals can be extruded by special method. Yes / No 5.9 Metal flow pattern in extrusion and rolling are the same. Yes / No 5.10 A variety of complex contours can be produced by extruding aluminium. Yes /No : Answers 5.1 False 5.2 True 5.3. Yes 5.4 No 5.5. False 5.6 False 3.7 Yes 5.8 Yes 5.9 No 5.10 Yes