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Extrusion
Extrusion
For the process that creates volcanic rock, see Extrusive 1 History
(geology).
Extrusion is a process used to create objects of a xed In 1797, Joseph Bramah patented the rst extrusion process for making pipe out of soft metals. It involved preheating the metal and then forcing it through a die via a
hand-driven plunger. In 1820 Thomas Burr implemented
that process for lead pipe, with a hydraulic press (also invented by Joseph Bramah). At that time the process was
called squirting. In 1894, Alexander Dick expanded
the extrusion process to copper and brass alloys.[2]
2 Process
2 PROCESS
the press. A dummy block is placed behind it where the Examples of products produced by this process are: colram then presses on the material to push it out of the die. lapsible tubes, re extinguisher cases, shock absorber
Afterward the extrusion is stretched in order to straighten cylinders and gear blanks.
it. If better properties are required then it may be heat
treated or cold worked.[2]
The extrusion ratio is dened as the starting crosssectional area divided by the cross-sectional area of the
Warm extrusion is done above room temperature, but benal extrusion. One of the main advantages of the extrulow the recrystallization temperature of the material the
sion process is that this ratio can be very large while still
temperatures ranges from 800 to 1800 F (424 to 975
producing quality parts.
C). It is usually used to achieve the proper balance of required forces, ductility and nal extrusion properties.[3]
2.1
Hot extrusion
2.2
Cold extrusion
2.4 Microextrusion
Main article: Microextrusion
Microextrusion is a microforming extrusion process performed at the submillimeter range. Like extrusion, metal
is pushed through a die orice, but the resulting products cross section can t through a 1mm square. Several
microextrusion processes have been developed since microforming was envisioned in 1990.[4][5][6] Forward (ram
and billet move in the same direction) and backward (ram
and billet move in the opposite direction) microextrusion
were rst introduced, with forward rod-backward cup and
double cup extrusion methods developing later.[5][7] Regardless of method, one of the greatest challenges of creating a successful microextrusion machine is the manufacture of the die and ram. The small size of the die and
ram, along with the stringent accuracy requirement, needs
suitable manufacturing processes.[5] Additionally, as Fu
and Chan pointed out in a 2013 state-of-the-art technology review, several issues must still be resolved before microextrusion and other microforming technologies
can be implemented more widely, including deformation
load and defects, forming system stability, mechanical
properties, and other size-related eects on the crystallite
(grain) structure and boundaries.[5][6]
3.1
Equipment
There are many dierent variations of extrusion equipment. They vary by four major characteristics:[1]
3 EQUIPMENT
dummy block between the ram and the billet to keep them
1. Constant-rate extrusion: A ram or plunger is used to
separated. The major disadvantage of this process is that
pressurize the uid inside the container.
the force required to extrude the billet is greater than that
2. Constant-pressure extrusion: A pump is used, possineeded in the indirect extrusion process because of the
bly with a pressure intensier, to pressurize the uid,
frictional forces introduced by the need for the billet to
which is then pumped to the container.
travel the entire length of the container. Because of this
the greatest force required is at the beginning of process
and slowly decreases as the billet is used up. At the end The advantages of this process include:[10]
of the billet the force greatly increases because the billet
is thin and the material must ow radially to exit the die.
No friction between the container and the billet reThe end of the billet (called the butt end) is not used for
duces force requirements. This ultimately allows for
this reason.[9]
faster speeds, higher reduction ratios, and lower billet temperatures.
3.3
Indirect extrusion
Impurities and defects on the surface of the billet affect the surface of the extrusion. These defects ruin
3.5 Drives
the piece if it needs to be anodized or the aesthetics
are important. In order to get around this the bilMost modern direct or indirect extrusion presses are hylets may be wire brushed, machined or chemically
draulically driven, but there are some small mechanical
cleaned before being used.
presses still used. Of the hydraulic presses there are
This process isn't as versatile as direct extrusions be- two types: direct-drive oil presses and accumulator wacause the cross-sectional area is limited by the max- ter drives.
imum size of the stem.
Direct-drive oil presses are the most common because
they are reliable and robust. They can deliver over
35 MPa (5000 psi). They supply a constant pressure
3.4 Hydrostatic extrusion
throughout the whole billet. The disadvantage is that they
[11]
In the hydrostatic extrusion process the billet is com- are slow, between 50 and 200 mm/s (28 ips).
pletely surrounded by a pressurized liquid, except where Accumulator water drives are more expensive and larger
the billet contacts the die. This process can be done hot, than direct-drive oil presses, and they lose about 10% of
warm, or cold, however the temperature is limited by the their pressure over the stroke, but they are much faster, up
stability of the uid used. The process must be carried out to 380 mm/s (15 ips). Because of this they are used when
in a sealed cylinder to contain the hydrostatic medium. extruding steel. They are also used on materials that must
The uid can be pressurized two ways:[10]
be heated to very hot temperatures for safety reasons.[11]
5.2
Plastic
Die design
5
also be used in place of billets on vertical extrusion
presses.
Magnesium (575 to 1100 F (300 to 600 C)) aircraft parts and nuclear industry parts. Magnesium is
about as extrudable as aluminum.
Zinc (400 to 650 F (200 to 350 C)) rods, bar,
tubes, hardware components, tting, and handrails.
5.1
Metal
Another breakthrough in lubrication is the use of phosphate coatings. With this process, in conjunction with
Metals that are commonly extruded include:[14]
glass lubrication, steel can be cold extruded. The phosphate coat absorbs the liquid glass to oer even better
[3]
Aluminium is the most commonly extruded mate- lubricating properties.
rial. Aluminium can be hot or cold extruded. If it is
hot extruded it is heated to 575 to 1100 F (300 to
600 C). Examples of products include proles for 5.2 Plastic
tracks, frames, rails, mullions, and heat sinks.
Main article: Plastics extrusion
Brass is used to extrude corrosion free rods, automobile parts, pipe ttings, engineering parts.
Plastics extrusion commonly uses plastic chips or pellets,
Copper (1100 to 1825 F (600 to 1000 C)) pipe, which are usually dried, to drive out moisture, in a hopwire, rods, bars, tubes, and welding electrodes. Of- per before going to the feed screw. The polymer resin is
ten more than 100 ksi (690 MPa) is required to ex- heated to molten state by a combination of heating elements and shear heating from the extrusion screw. The
trude copper.
screw, or screws as the case with twin screw extrusion,
Lead and tin (maximum 575 F (300 C)) pipes, forces the resin through a die, forming the resin into the
wire, tubes, and cable sheathing. Molten lead may desired shape. The extrudate is cooled and solidied as
6 APPLICATIONS
6.1 Food
Main article: Food extrusion
With the advent of industrial manufacturing, extrusion
5.3
Ceramic
Applications
8.2
Bibliography
6.3
Biomass briquettes
See also
Equal channel angular extrusion
Impact extrusion
Extrusion coating
Fused deposition modeling
3D printer extruder
8
8.1
References
Notes
8.2 Bibliography
Backus, Robert G.; Boshold, R. F.; Johannisson,
Thomas G.; Noble, Paul D.; Pfeer, Jerome B.;
Schiebold, Ted A.; Spearman, J. E. (1998) [1984].
Drawing, extruding, and upsetting. In Wick,
Charles; Benedict, John T.; Veilleux, Raymond F.
Tool and manufacturing engineers handbook. vol. 2
(4th ed.). SME. ISBN 0-87263-135-4.
Oberg, Erik; Jones, Franklin D.; Horton, Holbrook
L.; Ryel, Henry H. (2000), Machinerys Handbook
(26th ed.), New York: Industrial Press, ISBN 08311-2635-3.
10
See also
Forming (metalworking)
10
External links
EXTERNAL LINKS
11
11.1
11.2
Images
11.3
Content license