Extrusion
Dr. Mohammad I. AbuShams
Extrusion
• Extrusion can carried out (cold) or at elevated
temperatures (hot).
• 4 basic types of extrusion:
a) Direct extrusion
b) Indirect extrusion
c) Hydrostatic extrusion
d) Impact extrusion
Extrusion
• The extrusion ratio is defined as
A0 Ao = cross-sectional area of the billet
R
Af Af = area of the extruded product
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
In ideal case the material could be:
work done, (1) perfect plastic (n=0), then we use 𝑌𝑓
or 𝒀𝒇 as yield strength: 𝜎𝑦𝑝
(2) Strain hardening material, then we
𝐴0 use 𝑌ഥ𝑓 .
ഥ
p= 𝑌𝑓 . ln( ) (NOT 𝑌𝑓 = 𝑘 . 𝜀𝑡𝑛 ), why?
𝐴𝑓 𝑘 . 𝜀𝑡𝑛
𝑌ഥ𝑓 =
𝑛+1
𝐹 = 𝑝 . 𝐴0
2. Ideal force, with friction.
• Small die angle:
Radian
1
tan 𝛼 𝐴0 𝜇 cot 𝛼 cot 𝛼 =
p= 𝑌ഥ𝑓 . 1 + . (ln ) −1 tan(𝛼)
𝜇 𝐴𝑓
𝐹 = 𝑝 . 𝐴0
𝑘 . 𝜀𝑡𝑛
• With 𝛼 up to 45𝑜 with dead-metal zone: 𝑌ഥ𝑓 =
𝑛+1
𝐴0 2𝐿𝑜
𝑝 = 𝑌ഥ𝑓 . 1.7(ln ) + )
𝐴𝑓 𝐷𝑜
𝐹 = 𝑝 . 𝐴0
3. Force in hot extrusion
𝐴0
p= 𝑘𝑒 . 𝑙𝑛
𝐴𝑓
𝑘𝑒 ≡ extrusion constant (from figure 15.5)
𝐹 = 𝑝 . 𝐴0
4. Force in cold extrusion (impact with slug)
𝐴0
P = 1100 . 𝑌ഥ𝑓 . 𝑙𝑛
𝐴𝑓
𝐹 = 𝑝 . 𝐴0
5. Average strain rate sensitivity component:
𝑌ഥ𝑓 = 𝐶 (𝜀ഥ𝑡ሶ ) 𝑚 C ≡ Strength coefficient
m≡ strain rate sensitivity component
• Average true-strain rate that material undergoes is given by (all
cases): Radian
Vo ≡ ram velocity
• With poor lubrication the average true strain
rate reduces to:
Mechanics of extrusion
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
Defects in extrusion
1. Surface cracking
• If extrusion temperature, speed, and/or friction are
high. (surface temperature becomes excessive);thus,
extruded part will have cracks (tearing) along grain
boundaries.
• If extrusion temperature is low; extruded part stick in
die causes bamboo stem.
2. Pipe
Defects caused by metal flow pattern.
The metal flow pattern will draw surface oxides and impurities toward
the centre of billet makes a sink hole.
Defects in extrusion
3. Internal cracking (called: centre cracking or Chevron or centre burst)
Because of Hydrostatic tensile stresses that develops at the centreline in the
deformation zone in the die
Caused by: 1- increasing in die angle / 2- increasing in impurities
