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Cold Extrusion

Presented byN. M. Sudarshan, 0110, PGTE, School of Postgraduate Studies, NTTF.

School of Postgraduate Studies, NTTF 2001-2002

Cold Extrusion
PROCESS Chipless method wherein components are formed by striking a cold slug of metal contained in a die cavity. Metal slug is forced to flow by plastic deformation under compression around a punch. The wall thickness is controlled by clearance between punch and die.
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Cold Extrusion

Impact Extrusion Cold Extrusion

: :

Non-ferrous Ferrous

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Cold Extrusion
METHOD OF EXTRUSION Backward extrusion

Forward extrusion
Combined extrusion

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Cold Extrusion
BACKWARD EXTRUSION

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Cold Extrusion
BACKWARD EXTRUSION

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Cold Extrusion
BACKWARD EXTRUSION

a) Slug insertion b) Compression


School of Postgraduate Studies, NTTF 2001-2002

c) Impact extrusion d) Ejection


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Cold Extrusion

a) Preform insertion b) Compression


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c) Impact extrusion d) Ejection


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Cold Extrusion
FORWARD EXTRUSION

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Cold Extrusion
FORWARD EXTRUSION

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Cold Extrusion
FORWARD EXTRUSION

a) Slug insertion b) Compression


School of Postgraduate Studies, NTTF 2001-2002

c) Impact extrusion d) Ejection


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Cold Extrusion
FORWARD EXTRUSION

a) Preform insertion b) Compression


School of Postgraduate Studies, NTTF 2001-2002

c) Impact extrusion d) Ejection


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Cold Extrusion
COMBINATION EXTRUSION

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Cold Extrusion
COMBINATION EXTRUSION

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Cold Extrusion
PRESSES

Mechanical

Hydraulic

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Cold Extrusion
MECHANICAL PRESSES Short stroke

High speed requirements


Production is high

small to medium size

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Cold Extrusion
HYDRAULIC PRESSES Long stroke High and uniform force Slower speed requirements Production is small Long size
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Cold Extrusion
TOOLING

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Cold Extrusion
TOOLING

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Cold Extrusion
TOOLING

Punch
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Die
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Cold Extrusion
SLUG PREPARATION Blanking Sawing

Cutoff
Shearing

Coining

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Cold Extrusion
SLUG TREATMENT Annealing Cleaning Coating Lubricating

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Cold Extrusion
DESIGN RECOMMENDATION
Symmetry: Avoids lateral movement of tooling punches Unequal wall thickness.

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Cold Extrusion
DESIGN RECOMMENDATION

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Cold Extrusion
DESIGN RECOMMENDATION

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Cold Extrusion
DESIGN RECOMMENDATION

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Cold Extrusion
DESIGN RECOMMENDATION

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Cold Extrusion
DESIGN RECOMMENDATION

More difficult

Easier

Inclined interior surfaces and rounded outside corners assist metal flow in backward extrusion
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Cold Extrusion
DESIGN RECOMMENDATION

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Cold Extrusion
DESIGN RECOMMENDATION

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Cold Extrusion
DESIGN RECOMMENDATION

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Cold Extrusion
DESIGN RECOMMENDATION for forward extrusion

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Cold Extrusion
DESIGN RECOMMENDATION

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Flanges should be atleast as thick as the sidewall (a) Located at or near the end (b)
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DESIGN RECOMMENDATION

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Cold Extrusion
Recommended wall thickness

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Cold Extrusion
Tolerance

Diameter, Small parts: Large parts:


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mm + 0.05 + 0.13

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Cold Extrusion
Automotive Industry: Airbag components, gear shift assemblies .... Electronics Industry: Capacitor cans,relay housings Textile Industry:

Defence
Candle Molds
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Cold Extrusion

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Cold Extrusion

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Cold Extrusion

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Cold Extrusion

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Cold Extrusion
Economic Production Quantity
Aluminum parts : 50,000

Steels

10,000 for parts weighing 1 to 2 g 5000 for parts weighing 2 to 500 g 3000 for parts weighing over 500 g
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Cold Extrusion

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