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MANUFACTURING PROCESS
i.rajkumar@klu.ac.in
Presented By I.Rajkumar
Kalasalinagm
university
KALASALINGAM
UNIVERSITY
CONTENTS
Introduction
The Extrusion Process
Hot & Cold Extrusion
Impact Extrusion
Hydrostatic Extrusion
Extrusion Defects
The Drawing Process
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INTRODUCTION
Extrusion:-
Extrusion
By
Direction
Direct Indirec
/
t/
Forwa Backw
rd i.rajkumar@klu.ac.in
ard
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By
Operating
Temperatur
e
Hot
Col
d
By
Equipme
nt
Horizon
tal
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Vertic
al
CLASSIFICATION BY DIRECTION
1. Direct Extrusion: It is a process in which the metal billet, placed in a
container is forced by a ram to pass through a die.
In this type the direction
of flow of metal is, in same
as that of movement of ram.
The punch closely fits the die cavity to prevent
backward flow of the material.
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CLASSIFICATION BY DIRECTION
2. In-direct Extrusion: It is a process in which a hollow ram containing the
die is forced into the container, containing metal.
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Hot
Extrusion
Lubricate
d
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NonLubricated
Hydrosta
tic
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and
lubrication.
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using
typically used.
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HYDROSTATIC EXTRUSION
In the hydrostatic extrusion process the billet is
completely
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Pressure
= 1400 Mpa (approx.)
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Contd..
Advantages:
Elimination of large friction force between the
billet and the container wall.
Possible to use dies with a very low semi cone
angle (-200).
This process can be done hot, warm, or cold,
however the
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Contd..
Limitations:
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process
for
metals
is
at
very
high
temperatures.
Die is preheated to increase its life, so there are chances
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DISADVANTAGES OF COLD
EXTRUSION
Tooling cost is high, therefore large production
lot size is required.
Special coating is required to reduce friction
and to maintain a lubricant film throughout.
Limited deformation can be obtained.
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IMPACT EXTRUSION
Impact extrusion
A manufacturing process in
which a small shot of solid
material is placed in the die
and is impacted by a ram,
which causes cold
flow in
the material.
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usually
performed on a highi.rajkumar@klu.ac.in
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contd..
Applications
short
lengths
of
hollow
shapes,
such
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as
CLASSIFICATION BY EQUIPMENT
15-50 MN capacity.
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CLASSIFICATION BY EQUIPMENT
3-20 MN capacity.
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DIE MATERIALS
Commonly used materials are Tool Steels and
Carbides
Diamond dies are used for fine wire.
For improved wear resistance, steel dies may be
chromium plated, and carbide dies may be coated
with titanium nitride
For Hot drawing, cast-steel dies are used .
Dies are made from highly alloy tools steels or
ceramics (Si3N4).
Heat treatments such as nitriding are required
(several times) to increase hardness (1000-1100
Hvor 65-70 HRC). This improves die life.
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LUBRICATION
NEED Proper lubrication is essential in extruding, in order
to improve die life, reduce drawing forces and
temperature, and improve surface finish.
a)
b)
c)
d)
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container wall
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MATHEMATICAL RELATIONS
1. Extrusion ratio, R It is defined as the ratio of the initial crosssectional area , Ao, of the billet to the final
cross-sectional area , Af, after extrusion.
A0
R
Af
2.Fractional
area, r -
r 1
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reduction
Af
A0
in
1
R
1 r
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Contd..
3. Velocity Velocity of extruded product = (Ram velocity) x
(R)
4. Extrusion force -
A0
P kA0 ln
Af
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EXTRUSION DEFECT
1) Inhomogeneous deformation
In direct extrusion, a dead zone along
the outer surface of the billet due to the
movement of metal in the centre being
higher than the periphery.
After 2/3 of the billet is extruded, the
outer surface of the billet (normally with
oxidised skin) moves toward the centre and
extrudes to the through the die, resulting in
internal oxide stringers.
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Contd..
2) Surface cracking
It is the ranging from a badly roughened
surface to repetitive transverse cracking
called fir-tree cracking.
It is due to longitudinal tensile stresses
generated as the extrusion passes through
the die.
In hot extrusion, this form of cracking
usually is intergranular and is associated
with hot shortness.
The most common case is too high ram
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speed for the extrusion temperature.
Contd..
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Contd..
4) Variations in structure and properties
Structure
Grain
grain growth, due to high Grow
th
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Contd..
5) Hot shortness (in aluminium extrusion)
High
temperatures
generated
cause
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DRAWING PROCESS
Drawing
It is an operation in which the cross-section
of solid rod, wire or tubing is reduced or
changed in shape by pulling it through a
die.
stock (bar)
die
wire
F (pulling force)
Working Principle
The principle of this procedure consist of
reducing the thickness of a pointed ,tapered
wire by drawing it through KALASALINGAM
a conical
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opening
in a tool made of
a hard
Various
variables
Contd..
affecting
the
Drawing Process
1.Work Material
2.Reduction in curve section
3.Die angle
4.Drawing speed
5.Lubrication
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Note:KALASALINGAM
It is almost similar to extrusion,
except
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REFERENCES
Kalpakjian
Seope,
Schmid
Steven
R.:
Manufacturing Engineering & Technology
Pearson Education India, 2009, pp 395-402.
Sharma,
P.C.A
textbook
of
production
engineering. 11. New DELHI: S.Chand & Company
Ltd, 2009, 504-515. Print.
Sharma,
P.C.A
textbook
of
production
Technology. 7. New Delhi: S.Chand & Company
Ltd, 2011, 265-280. Print.
Todd
H.
Robert,
Allen
K.
Dell,
Alting
Leo.Manufacturing
processes
reference
guide.1. New york: Industrial Press Inc, 1994, pp.
295-299.
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Rajput, R. K.A textbook of Manufacturing
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Email ID :- bkdeepamgoyal@gmail.com
&
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