Extrusion Press

Extrusion press is a sophisticated machinery in the extrusion process that is available in a huge variety of sizes ranging from 400 tonnes to 1600 tonnes. From the common large extruded profiles to thin- all extruded profiles! extrusion presses are geared to meet virtually any demand of the extrusion industry. "odern extrusion presses are e#uipped ith all the latest technology and innovative features! for example the infinitely variable extrusion speeds! $%& control! reducing an operator's need etc. (t is the press size that determines the size of an extrusion! and therefore the selection of a proper extrusion press is of critical importance in the extrusion process. discussed. Aluminium Extrusion Press

)o be in a position understand an aluminium extrusion press completely and thoroughly! e need a basic understanding of hat are the main parts of an extrusion press! hat do they loo* li*e! hat functions do they perform! etc! etc. +oing through the diagram belo ould be helpful in understanding the extrusion process step by step in detail. ,n extrusion press is comprised of a front platen and bac* platen hich is held together by four tie rods. )he parts of the extrusion press are as follo sParts "ain &ylinder .ydraulic $ressure /am 1ummy 2loc* &ontainer )ool stac* Function hydraulic fluid is pumped here for generating ram pressure and movement. $ressure applied to move the ram for ard. 0teel rod that is attached to main cylinder ith dummy bloc* on the end. )ight fitting steel bloc* connected to the ram! seals the billet. &hamber in an extrusion press needed for holding the billet. 0olid-

.ollo -

$ress leadout table $laten $ressure /ing /un 3ut )able )ie rods &anister &radle 1ie oven 1ie loc* 1ie holder

)able hich supports extrusion .ardened tool steel ring that is inserted into platen for supporting die stac* )able at immediate exit of press leadout device
Connects

the front and bac* press platen

4sed in guiding the aluminum extrusions from the die 2ears the billet hile it gets pushed into extrusion press ith the pressure from the ram. .ere dies are heated up to 5607 - 8007 F for min of 4-6 hours before it is used. 4sed for loc*ing die into the die holder. &ontainer for tool stac*.

Selecting an Extrusion Press 0electing the correct size of the extrusion press is very important for successfully carrying out the extrusion process! as the press size 9as mentioned above: is critical. )he factors that you should pay special attention to! hile selecting an extrusion press are )he re#uired tolerance level hich ill vary as per your need. )he thic*ness of the all &ircle size for each shape

1iameter of the billet 3rdered #uantity

Low Dead Cycle Time Improves Productivity of Extrusion Press 1ead cycle time on an extrusion press can be defined as the period of time hich remains non-productive during the automatic mode of the extrusion press. )herefore a challenge to the extrusion process lies in minimising dead cycle time. )hough speed is fundamental! but this must be got ithout inducing shoc*s. 0hoc*s can result in an excessive strain to the machine! causing all sorts of problems and an excessive do n time. )here is need for a compromise as moving the press #uic*ly is re#uired along ith having a full control. )he challenge here is to balance the conflicting re#uirements. 3nly a detailed and broad understanding of all aspects of the machine can result in the perfect solution.

(ndal has the latest technology for machining and fabrication! such as cutting! drilling! counter-sin*ing! punching and piercing! reaming! milling! boring! shearing! notching! turning! coining! tapping and perforating to produce value added products. (ndal also offers the possibility of producing profiles ith special cuts and polished edges according to customer;s specifications. 2eing an integrated aluminium manufacturer! (ndal fabrication division is able to offer several advantages such as lo er price at reasonable rate and effective turnaround time to the customers through vendor consolidation ith extrusion division. (ndal;s fabricated products #uality has been ac*no ledged by many premier customers. 3ur production capacities for this mar*et are supported by modern and integrated facilities such as

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Die manufacturing!
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, die is a specialized tool used in manufacturing industries to cut or shape material using a press. %i*e molds! dies are generally customized to the item they are used to create. $roducts made ith dies range from simple paper clips to complex pieces used in advanced technology.

Contents
hide!

" #ie forming o "." #ie components

o o o

".$ #ie operations and types ".% &teel'rule die ".( )otary die

$ Wire pulling % )eferences

o

%." *ibliography

( Further reading

[edit] Die forming

Progressive die +ith scrap strip and stampings

Forming dies are typically made by tool and die ma*ers and put into production after mounting into a press. )he die is a metal bloc* that is used for forming materials li*e sheet metal and plastic. For the vacuum forming of plastic sheet only a single form is used! typically to form transparent plastic containers 9called blister pac*s: for merchandise. >acuum forming is considered a simple molding thermoforming process but uses the same principles as die forming. For the forming of sheet metal! such as automobile body parts! t o parts may be used! one! called the punch! performs the stretching! bending! andBor blan*ing operation! hile another part! called the die block! securely clamps the or*piece and provides similar! stretching! bending! andBor blan*ing operation. )he or*piece may pass through several stages using different tools or operations to obtain the final form. (n the case of an automotive component there ill usually be a shearing operation after the main forming is done and then additional crimping or rolling operations to ensure that all sharp edges are hidden and to add rigidity to the panel.

[edit] Die components

#ie block Punch plate *lank punch Pierce punch &tripper plate Pilot #o+el Pin *ack gage Finger stop &etting *lock

[edit] Die operations and types

1ie operations are often named after the specific type of die that performs the operation. For example a bending operation is performed by a bending die. 3perations are not limited to one specific die as some dies may incorporate multiple operation types-

Press +ith bending die.

Bending: The bending operation is the act of bending blanks at a predetermined angle. ,n e-ample +ould be an ./. bracket +hich is a straight piece of metal bent at a 012 angle. The main difference bet+een a forming operation and a bending operation is the bending operation creates a straight line bend 3such as a corner in a bo-4 as +here a form operation may create a curved bend 3such as the bottom of a drinks can4. Blanking: , blanking die produces a flat piece of material by cutting the desired shape in one operation. The finish part is referred to as a blank. 5enerally a blanking die may only cut the outside contour of a part, often used for parts +ith no internal features. Three benefits to die blanking are:

". Accuracy. , properly sharpened die, +ith the correct amount of clearance bet+een the punch and die, +ill produce a part that holds close dimensional tolerances in relationship to the parts edges. $. Appearance. &ince the part is blanked in one operation, the finish edges of the part produces a uniform appearance as opposed to varying degrees of burnishing from multiple operations. %. Flatness. #ue to the even compression of the blanking process, the end result is a flat part that may retain a specific level of flatness for additional manufacturing operations.

Broaching: The process of removing material through the use of multiple cutting teeth, +ith each tooth cutting behind the other. , broaching die is often used to remove material from parts that are too thick for shaving. Bulging: , bulging die e-pands the closed end of tube through the use of t+o types of bulging dies. &imilar to the +ay a chefs hat bulges out at the top from the cylindrical band around the chefs head.

". Bulging fluid dies: Uses +ater or oil as a vehicle to e-pand the part. $. Bulging rubber dies: Uses a rubber pad or block under pressure to move the +all of a +orkpiece.

Coining: is similar to forming +ith the main difference being that a coining die may form completely different features on either face of the blank, these features being transferred from the face of the punch or die respectively. The coining die and punch flo+ the metal by s6uee7ing the blank +ithin a confined area, instead of bending the blank. For e-ample: an 8lympic medal that +as formed from a coining die may have a flat surface on the back and a raised feature on the front. 9f the medal +as formed 3or embossed4, the surface on the back +ould be the reverse image of the front. Compound operations: :ompound dies perform multiple operations on the part. The compound operation is the act of implementing more than one operation during the press cycle. Compound die: , type of die that has the die block 3matri-4 mounted on a punch plate +ith perforators in the upper die +ith the inner punch mounted in the lo+er die set. ,n inverted type of blanking die that punches up+ards, leaving the part sitting on the lo+er punch 3after being shed from the upper matri- on the press return stroke4 instead of blanking the part through. , compound die allo+s the cutting of internal and e-ternal part features on a single press stroke. Curling: The curling operation is used to roll the material into a curved shape. , door hinge is an e-ample of a part created by a curling die. Cut off: :ut off dies are used to cut off e-cess material from a finished end of a part or to cut off a predetermined length of material strip for additional operations.

Drawing: The dra+ing operation is very similar to the forming operation e-cept that the dra+ing operation undergoes severe plastic deformation and the material of the part e-tends around the sides. , metal cup +ith a detailed feature at the bottom is an e-ample of the difference bet+een formed and dra+n. The bottom of the cup +as formed +hile the sides +ere dra+n. Extruding: ;-truding is the act of severely deforming blanks of metal called slugs into finished parts such as an aluminum 9'beam. ;-trusion dies use e-tremely high pressure from the punch to s6uee7e the metal out into the desired form. The difference bet+een cold forming and e-trusion is e-truded parts do not take shape of the punch. orming: Forming dies bend the blank along a curved surface. ,n e-ample of a part that has been formed +ould be the positive end3<4 of a ,, battery. Cold forming !cold heading": :old forming is similar to e-truding in that it s6uee7es the blank material but cold forming uses the punch and the die to create the desired form, e-truding does not.

)oll Forming &tand

#oll forming: a continuous bending operation in +hich sheet or strip metal is gradually formed in tandem sets of rollers until the desired cross' sectional configuration is obtained. )oll forming is ideal for producing parts +ith long lengths or in large 6uantities. $orning: , horning die provides an arbor or horn +hich the parts are place for secondary operations. $ydroforming: Forming of tubular part from simpler tubes +ith high +ater pressure. %ancake die: , Pancake die is a simple type of manufacturing die that performs blanking and=or piercing. While many dies perform compleprocedures simultaneously, a pancake die may only perform one simple procedure +ith the finished product being removed by hand. %iercing: The piercing operation is used to pierce holes in stampings. %rogressive die: Progressive dies provide different stations for operations to be performed. , common practice is to move the material

through the die so it is progressively modified at each station until the final operation e>ects a finished part.

&having: The shaving operation removes a small amount of material from the edges of the part to improve the edges finish or part accuracy. 3:ompare to 'rimming4. &ide cam die: &ide cams transform vertical motion from the press ram into hori7ontal or angular motion. &ub press operation: &ub'press dies blank and=or form small +atch, clock, and instrument parts. &waging: &+aging 3necking4 is the process of .necking do+n. a feature on a part. &+aging is the opposite of bulging as it reduces the si7e of the part. The end of a shell casing that captures the bullet is an e-ample of s+aging. 'rimming: Trimming dies cut a+ay e-cess or un+anted irregular features from a part, they are usually the last operation performed.

[edit] &teel(rule die

Steel-rule dies! also *no n as cookie-cutter dies! are used to cut sheet metal and softer ebs! such as plastics! ood! cor*! felt! fabrics! and cardboard. )he cutting surface of the die is the edge of hardened steel strips! *no n as steel rule. )hese steel rules are usually located using sa -cut grooves in ply ood. )he mating die can be a flat pieces of hard ood or steel! a male shape that matches the or*piece profile! or it can have a matching groove that allo s the rule to nest into. /ubber strips are edged in ith the steel rule to act as the stripper plateC the rubber compresses on the do n-stro*e and on the up-stro*e it pushes the or*piece out of the die. )he main advantage of steel-rule dies is the lo cost to ma*e them! as compared to solid diesC ho ever! they are not as robust as solid dies! so they usually only used for short production runs.D1E

, steel-rule die

, steel-rule die

0teel-rule die in a press

[edit] #otary die

(n the broadest sense! a rotary die is a circular shaped die that may be used in any manufacturing field. .o ever! it most commonly refers to circular shaped dies used to process soft ebs! such as paper and cardboard. ) o dies are used! one has cutting and creasing rules! hile the other acts as the anvil. /otary dies are faster than flat dies! but not as accurate.D?ED<E )he term also refers to dies used in the roll forming process.D4E

[edit] Wire pulling

?ain article: #ra+ plate

Fire-ma*ing dies have a hole through the middle of them. , ire or rod of steel! copper! other metals! or alloy enters into one side and is lubricated and reduced in size. )he leading tip of the ire is usually pointed in the process. )he tip of the ire is then guided into the die and rolled onto a bloc* on the opposite side. )he bloc* provides the po er to pull the ire through the die. )he die is divided into several different sections. First is an entrance angle that guides the ire into the die. =ext is the approach angle! hich brings the ire to the nib! hich facilitates the reduction. =ext is the bearing and the bac* relief. %ubrication is added at the entrance angle. )he lube can be in po dered soap form. (f the lubricant is soap! the friction of the dra ing of ire heats the soap to li#uid form and coats the ire. )he ire should never actually come in contact ith the die. , thin coat of lubricant should prevent the metal to metal contact. For pulling a substantial rod do n to a fine ire a series of several dies is used to obtain progressive reduction of diameter in stages. 0tandard ire gauges used to refer to the number of dies through hich the ire had been pulled. )hus! a higher-numbered ire gauge meant a thinner ire. )ypical telephone ires ere ??-gauge! hile main po er cables might be <- or 4-gauge.

[edit] References
". ) #egarmo, *lack @ Aohser $11%, pp. (%1B(%". $. ) T+ede, #ianaC &elke, &usan ;. ?. 3$11D4, Cartons, crates and corrugated board: handbook of paper and wood packag ng technology , #;&tech, p. (%E, 9&*F 0GH"0%$1GH($H, http:==books.google.com=booksI idJkc1?&7FvrKH:@pgJP,(%E. %. ) &oroka, Walter 3$11H4, !llustrated "lossary of #ackag ng $er% nology 3$nd ed.4, #;&tech, p. E(, 9&*F 0GH"0%1$EH$G$, http:==books.google.com=booksIidJ/$8tF0ea1g1:@pgJP,E(. (. ) Kalmos, 5eorge T. 3$11E4, &oll for% ng handbook, :): Press, p. ('(E, 9&*F 0GH1H$(G0DE%(, http:==books.google.com=booksI idJ#6cD6E,9oLs:@pgJ&,('P,(E.

[edit] Bibliography

#egarmo, ;. PaulC *lack, J T.C Aohser, )onald ,. 3$11%4, 'ater als and #rocesses n 'anufactur ng 30th ed.4, Wiley, 9&*F 1'(G"'EDED%'(.

[edit] Further reading

J. ). Pa6uin and ). ;. :ro+ley 3"0HG4. ( e (es gn Funda%entals. Fe+ Mork, Fe+ Mork: 9ndustrial Press 9nc. 9&*F 1'H%""'""G$'1 #avid T. )eid 3"00"4. Funda%entals of $ool (es gn. #earborn, ?ichigan: &ociety of ?anufacturing ;ngineers. 9&*F 1'HG$E%'("$'(

[show]
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*etalwor king

t enty-inch billet and every size in bet een.

Taper Seal Hollow Die

36" Diameter Hollow Die

Taper Seal Hollow Die

5" Diameter Hollow Die

15" Diameter Multi-void Hollow with Internal Feed

5" Diameter Multi-void Hollow with Internal Feed

"Zerostep" Solid Die

" Dia! Multi-void Hollow Die

"Zerostep" Solid Die "rossse#tion

Solid Die with "avit$ and Formpo#%et

Multi-void Mandrel& Taper Seal Hollow Die

$rocess 3vervie -- $rinter-Friendly >ersion

5" Hollow Die and 1'!5" Sel("ontained )orthole

)he aluminum extrusion process really begins ith the design process! for it is the design of the product--based on its intended use--that determines many of the ultimate production parameters. Guestions regarding machinability! finishing! and environment of use ill lead to the choice of alloy to be extruded. )he function of the profile ill determine the design of its form and! hence! the design of the die that shapes it. 3nce the design #uestions have been ans ered! the actual extrusion process begins ith billet! the aluminum material from hich profiles are extruded. )he billet must be softened by heat prior to extrusion. )he heated billet is placed into the extrusion press! a po erful hydraulic device herein a ram pushes a dummy bloc* that forces the softened metal through a precision opening! *no n as a die! to produce the desired shape.

)his is a simple diagram of a typical horizontal hydraulic extrusion pressC the direction of extrusion here is from left to right. )hat is a simplified description of the process *no n as direct extrusion! hich is the most common method in use today. (ndirect extrusion is a similar process! but ith some important differences. (n the direct extrusion process! the die is stationary and the ram forces the alloy through the opening in the die. (n the indirect process! the die is contained ithin the hollo ram! hich moves into the stationary billet from one end! forcing the metal to flo into the ram! ac#uiring the shape of the die as it does so. )he extrusion process has been li*ened to s#ueezing toothpaste out of a tube. Fhen pressure is applied at the closed end! the paste is forced to flo through the open end! accepting the round shape of the opening as it emerges. (f the opening is flattened! the paste ill emerge as a flat ribbon. &omplex shapes can be produced by complex openings. 2a*ers! for example! use a collection of shaped nozzles to decorate ca*es ith fancy bands of icing. )hey;re producing extruded shapes. As suggested by these toothpaste tubes, the shape of the extrusion (profile) is determined by the shape of the opening (die).

2ut you can;t ma*e very many useful products out of toothpaste or icing and you can;t s#ueeze aluminum out of a tube ith your fingers. Hou can s#ueeze aluminum through a shaped opening! ho ever! ith the aid of a po erful hydraulic press! producing an incredible variety of useful products ith almost any shape imaginable. These photos show a new length

of extrudate, ust emerging from the press (left) and the production of a profile in progress (right).

2illet 2illet is the starting stoc* for the extrusion operation. Extrusion billet may be a solid or hollo form! commonly cylindrical! and is the length charged into the extrusion press container. (t is usually a cast product but may be a rought product or po der compact. 3ften it is cut from a longer length of alloyed aluminum! *no n as a log. ,lloys are metals composed of more than one metallic element. ,luminum extrusion alloys contain small amounts 9usually less than five percent: of elements such as copper! manganese! silicon! magnesium! or zinc. )hese alloying elements enhance the natural properties of aluminum and influence the extrusion process. 2illet length varies according to a number of factors! including the desired length of the finished profile! the extrusion ratio! the length of the runout! and the re#uirements of the extrusion press. 0tandard lengths may run from about ?6 inches 9660 mm: up to 5? inches 91!@<0 mm:. )he outside diameter may range from < inches 956 mm: to << inches 9@<@ mm:C 6-inch 9166 mm: to 8-inch 9??@ mm: diameters are the most common. )op 1irect Extrusion 3peration

This diagram shows the basic steps in!ol!ed in extruding an aluminum profile. 3nce the shape of the final product has been identified! the proper alloy selected! and the die prepared! to ma*e ready for the actual extrusion process! the billet and extrusion tools are preheated. 1uring extrusion! the billet is still solid! but has been softened in a heating furnace. )he melting point of aluminum varies ith the purity of the metal! but is approximately 1!??07 Fahrenheit 96607 &entigrade:. Extrusion operations typically ta*e place ith billet heated to temperatures in excess of 5007F 9<567&:! and--depending upon the alloy being extruded--as high as 8<07F 96007&:. )he actual extrusion process begins hen the ram starts applying pressure to the billet ithin the container. >arious hydraulic press designs are capable of exerting any here from 100

tons to 16!000 tons of pressure. )his pressure capacity of a press determines ho large an extrusion it can produce. )he extrusion size is measured by its longest cross-sectional dimension! sometimes referred to as its fit ithin a circumscribing circle diameter 9&&1:. ,s pressure is first applied! the billet is crushed against the die! becoming shorter and ider until its expansion is restricted by full contact ith the container alls. )hen! as the pressure increases! the soft 9but still solid: metal has no place else to go and begins to s#ueeze out through the shaped orifice of the die to emerge on the other side as a fully formed profile. ,bout 10 percent of the billet! including its outer s*in! is left behind in the container. )he completed extrusion is cut off at the die and the remainder of the metal is removed to be recycled. ,fter it leaves the die! the still-hot extrusion may be #uenched! mechanically treated! and aged. As heated aluminum is forced out of the container and through the die, the core of the billet flows more rapidly than the periphery, as illustrated by the dark banding in this photograph. The periphery, which is left behind as residue, is recycled for future use. Extrusion rates vary! depending on the alloy used and the shape of the die. , hard alloy! given a complex shape! may emerge from the press as slo ly as one or t o feet per minuteC a soft alloy ta*ing on a simple shape may be extruded at a rate of 1@0 feet per minute! or even faster. 1epending on billet size and die opening! a continuous extrusion as much as ?00 feet long may be produced ith each stro*e of the press. )he ne ly-formed extrusion is supported on a runout conveyor as it leaves the press. 1epending on the alloy! the extrusion is cooled after emerging from the die! either naturally or through the use of air or ater #uenches. )his is a critical step to ensure sufficient metallurgical properties after aging. )he extrusion is then transferred to a cooling table. 0tretching , stretcher andBor straightener may be employed! after the profile has been #uenched 9cooled: to straighten the extrusion and correct any t isting that may have occurred subse#uent to extrusion. 9)he stretcher may also be used to impart cold or* to the extrusion.: &onveyors feed the or* to the sa . &utting )ypically! a finish cut sa is used to cut the profile to the specified commercial length. &ircular sa s are the most common in use today and are generally similar to a radial arm sa that cuts across the profile at a perpendicular angle to the length of the extrusion. 3ther sa s may s ing do n onto the profile 9li*e a po er miter sa :! or may operate more li*e a table sa ! ith the circular blade rising up to ma*e the cut! then dropping do n belo the table for the return pass.

, typical! circular! finish cut sa may be 16 - ?0 inches in diameter! ith more than a hundred carbide-tipped teeth. %arger sa s are used for larger-diameter presses. %ubricated sa s are e#uipped ith delivery systems that feed the lubricant through the teeth of the sa for optimal efficiency and cut surface. ,utomatic devices clamp profiles in place for sa ing. 0a chips are collected for later recycling. ,ging 0ome extrusion alloys reach their optimal strength through the process of aging! sometimes *no n as age-hardening. =atural aging occurs at room temperature. ,rtificial aging ta*es place through controlled heating in an aging oven and is sometimes referred to as precipitation heat-treating. Fhen the profile emerges from the press it is in a semi-solid state! but rapidly solidifies as it cools or is #uenched 9 hether by air or ater:. =on-heat-treatable aluminum alloys 9such as those utilizing manganese or magnesium: derive their strength through natural aging and cold or*ing. .eat-treatable alloys 9such as those utilizing copper! zinc! and magnesium ith silicon: are further strengthened or hardened through controlled thermal treatments that affect the metallurgical structure of the alloys. Either ay! the aging process ensures the uniform precipitation of fine particles through the metal! yielding maximum strength! hardness! and elasticity for the specific extrusion alloy. $ac*aging ,fter sufficient aging! hether in an aging oven or at room temperature! the profiles are moved to other areas of the plant for finishing or fabricating! or to be pac*ed and prepared for shipment to the customer. "ost extrusion plants are e#uipped to accommodate any li*ely pac*aging re#uirement. $rofiles are palletized in such a ay as to be protected from surface damage! t isting! or other hazards. &ustomers may specify their o n pac*aging re#uirements! or the Aluminum profiles can type of extruded product may suggest a particular method of pac*aging for ease of storage or delivery. be packaged in a !ariety of ways.

$ress &omponents )he front and rear platens are held parallel ith one another by the tie rods and nuts. )he diagram belo sho s a press ith four tie rods. (t is possible to have presses ith only t o or three tie rods.

)he ram pistonBcylinder pushes the ram stem for ard! hich in turn pushes the billet through the container and then through the die 9held in position by the die carrier: that ultimately forms the profile. 0ee labeled illustration belo that identifies the component parts involved in this process.

)he diagram belo sho s a cross-sectional vie of the die! bac*er! and bolster in the tool carrier.