Extrusion Technology Guide

Prepared by -- Clifford L. Lotzenhiser, Extrusion Consultant

ABSTRACT --- A primer-handbook toward training and problem solving is offered. It is

written with the apprentice and the extrusion specialist in mind to furnish a broad view,
yet detailed and specific. The framework of the primer with a sampling of a few
particulars is presented. Prevalent empirical knowledge is to be available free on the
Internet; specific data and practices offered by subscription and a complete monograph
available by purchase.

INTRODUCTION COMMON KNOWLEDGE SECTIONS

I have been in the extrusion industry for over 45
years, a time that has been both interesting and
rewarding to me. For this reason I want to pass back
to the industry some of the knowledge I have gained
while performing my jobs in die design, operations,
marketing and general management.
It occurred to me, the best way of doing this was
to put together a comprehensive training guide.
Although there is now a great body of technical
information available, those beginning to learn this
process have no place to start. Also there are some
that only have a partial view of the operation and
would like to peer into other areas.
The Extrusion Technology Guide is a primer with
supplements. The primer is presented in four parts:
1) Introduction to the basic process, 2) details about
Products, 3) Process Principles, and 4) Operating
Strategies.
There are seven supplements, which are:
1) Operation Benchmarks, 2) Die Design Techniques,
3) Costing and Pricing, 4) Training Agenda, 5)
Quality, 6) Plant Checklists, and 7) Management
Guideposts.
My intention is to offer this information on the
Internet and as a monograph. The primer will be
offered free on the Internet. The supplements will be
made available by subscription or purchase of the
complete treatise.
Because of the scope and detail of this work, I
offer here only an outline with a few representative
details.
An introduction to the basic operations and the
direct extrusion process elements are first defined and
then described. A brief, one-page, industry profile and
operating process flow is first described in part one.
It continues with an explanation of the direct
extrusion process. The process elements of the
billet, force of extrusion, extrusion press tooling, die
and support tooling, and the product are precisely
brought about and illustrated. Other extrusion
processes are noted.
A verbal and illustrated tour through a plant
operation is depicted. Pertinent information about
each operation from the material storage and press
areas through packaging is covered. It is explained
at the beginner’s level, but with sufficient detail to
spell out its applicability and interest to visitors.
The second part deals with the product. While
most of the information is from standard industry
terminology, a few items should be of particular
interest, such as:
• An Aspect Description Chart is given to assist
in picturing many of the multitudes of profile
idiosyncrasies. The profile aspect or
appearance is somewhat described, coded,
and portrayed. [See Appendix A at end of
article]
• A section devoted to extrudability covers the
elements that measure difficulty and the
design of profiles.

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 The third part presents principles of the extrusion
process. The temperature history and mechanical
forming work are most important to understand.

Recognizing that the total extrusion pressure and

the pressure at the die are significantly different is
basic in operating practice. Yet, it is particularly
helpful to see diagrams that illustrate the
relationships of billet length, alloy, temperature, and
extrusion ratio on the extrusion pressure

All the primary elements that affect extrusion

parameters are specified. Diagrams, notes and/or
charts illustrate operation elements. They are:

• Typical extrusion and deformation curves

show the near constant pressure on the die
and varying extrusion pressure. (Figure 1)

px – pd is due to container friction Figure 2. Extrusion pressure curve and extrusion

Figure 1. Typical extrusion and deformation curves. cycle diagrams.
• Extrusion pressure curve with extrusion cycle Soft Alloy Hard Alloy
diagrams note 1) pre-crushed billet; 2) the
shorter crushed billet; 3) extrudate
breakthrough; 4) extrude phase; and
pressure build-up phase. (Figure 2)
• Extrusion pressure curves for soft and hard
alloys of the same extrusion ratio, noting the
effect of billet length on pressure. (Figure 3)
• Note on temperature lineal affect of yield
strength of material.

From the text: Temperature change affects

pressure in relation to the yield strength
of the material. The yield strength of 6063
o o
at 1000 F is 1400 psi and at 800 F 1700
psi. This is typical for this alloy. The
lower temperature will require is 21%
more to extrude.
Figure 3. Extrusion pressure curves.
• Extrusion pressure curves for soft and hard
alloys noting effect of extrusion ratio; and
note chart showing the true ratio relationship
of natural logarithm values for select
extrusion ratios. (Figure 4.)

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 Soft Alloy Hard Alloy Application #1: R = 40; L/D = 4.0
Alloy = soft; kf = 10,500 psi.
From charts: ln R = 3.69; q = 1.50
Estimated pressure: px = pd × q
pd = kf • ln R = 10,500 x 3.69 = 38,745 psi.
px = 38,745 x 1.50 = 58,118 psi.

Application #2: R = 40; L/D = 2.5

Alloy = hard; kf = 14,000 psi.
From charts: ln R = 3.69; q = 2.23
THE TRUE EXTRUSION PRESSURE INDEX – ln R *
Estimated pressure: px = pd × q
pd = kf • ln R = 14,000 x 3.69 = 51,660 psi.
R ln R R ln R
10 2.30 60 4.09
px = 51,660 x 2.23 = 115,202 psi.
20 3.00 70 4.25
The “k” value used in the estimating formula is
the product of the material yield stress times a
30 3.40 80 4.38
design/speed factor.
40 3.69 90 4.50
50 3.91 100 4.61
Limit diagrams and isothermal vs. conventional
* Natural logarithm of extrusion ratio pressure curves are used to help visualize the major
Figure 4. Extrusion pressure curves, showing effect limiting factors in extrusion.
of extrusion ratio.
In addition, the fundamental basis for die and tool
• Note (rule of thumb) for speed effect on design is summarized. Tool strength, metal flow, die-
pressure. working surface and die distortion corrections are
discussed.
From the text: Ram speed increases
pressure in the magnitude of one-sixth Some of the handling principles are also
(17%) for doubling the speed. discussed, that is, extrudate-control, stretching,
cutting lengths, and aging.
A method for estimating extrusion pressured is
provided. (Exhibit 1) With a clear grasp of the extrusion principles, the
operating practices that follow can then be better
Exhibit 1. Estimating Extrusion Pressure understood.
Pressure formulas
pd ≈ kf • ln R where: pd = deformation pressure Part four deals with various strategies applied in
kf = Β Y (10,500 psi for the industry. Production schemes (or operation
soft alloy and 14,000 sequence), utilization, productivity, product mix and
psi for hard alloy.) training are noted.
Β = design/speed factor
Y = yield stress
px ≈ pd × q where: px = total extrusion pressure DATA AND APPLICATION SECTIONS
q = friction quotient
(determined by the billet
Significant to understanding data and application
length/diameter ratio
and alloy type taken is the valuation of the profile or profile mix. In part
from friction quotient four, Operating Strategies, a means of judging profile
chart.) value is presented. It is summarized in the following
FRICTION QUOTIENT CHART table.
L/D qs (soft alloy) qh (hard alloy)
1.5 1.16 1.62
2.0 1.22 1.90
2.5 1.28 2.23
3.0 1.35 2.62
3.5 1.42 3.06
4.0 1.50 3.60

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Table 1. Difficulty Guide.
Difficulty Simple Average Irregular Complex
factor * 1 2 3 4
Sym Balance Compact N/A N/A
Wall 2 x Std Std 80% Std Under
minimum 80% Std
Wall chg 1.25:1 2:1 4:1 Over
maximum 4:1
Tongue 1:2 2:1 4:1 Over
Ratio 4:1
Rect. 5:1 10:1 25:1 Over
Ratio maximum 25:1
Tolerance Std or 80% Std 60% Std Less than
more minimum minimum 60% Std
Surface Com Com 30-60 Less than 30
microinch microinch

*Sym = symmetry
Wall = wall thickness
Wall chg = change in wall thickness
Tongue ratio = area of tongue / gap2
Rect Ratio = width of profile / height
Std = standard manufacturing practice
Com = commercial surface (60-100 microinch)
One of the supplements to the primer is on
Operation Benchmarks. It covers press selection to
standard manufacturing limits; product-production-
billet planning and the planning aspects of die design.
• Press selection charts showing typical
pressure requirements for select extrusion
ratios (R) by alloy type and maximum
pressure available by press and cylinder are
provided. (Table 2) The soft alloy estimated
extrusion pressure for R=150 with and billet
L/D of 4.0 is 80 kips (i.e., 80,000 psi). From
the press chart a 1750T—7″ press would be
adequate at 82 kips.
• Extrusion practices illustrated for soft alloy.
(Table 3)
• The die design planning and billet plan
elements are thoroughly detailed with data
charts and illustrations. An example is
shown in the illustration for a cost graph to
help determine the number of die openings.
(Figure 5)
Figure 5. Cost graph for die openings.
One supplement is devoted to pricing, cost
estimating and engineered costing. Some specifics
are:
• Unit cost comparisons of one and two-press
operations (Table 4)
• Sample costing spreadsheet
• Price worktables and price schedules.
Besides other supplements on training,
checklists, and management guideposts, there is also
an appendix with a glossary of terms and subject
index for the primer.
INTERNET DYNAMIC
Should the subscription of Data and Application
develop enough interest, a number of possible
extensions to the guide may develop.
• A problem-solving exchange or service could
be set up to assist subscribers.
• Further updating data and applications
sections.
• A periodic extrusion newsletter.

The Die Design supplement furnishes detail for: CONCLUSION

• Die Layout
• Tool Strength
• Die opening and die distortion correction
• Die Bearing and Flow control Techniques.
The information presented illustrates facts, data,
and graphics that will assist the student of extrusion.
Both newcomer and department specialist can grasp
a larger view of the extrusion process and its major
operations through the illustrations and data
comparisons.

The fundamentals will be offered free on the

Internet. Subscription for the Data and Application
sections or purchase of the monograph will provide
great detail for training and problem solving.

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 APPENDIX A

Product Aspect Description and Code

Description Code - Scheme Code - Scheme

Angle, acute AA E (double channel) EP

Angle, obtuse AO F (single winged FP

channel)
Angle. right AR Fork (channel with tail) FX

Bar, belted BB H or I HI

Bar, symmetrical BS Multiple Tongues MT

Bar, tapered BT Tee, right TR

Channel, constricted CC Tee, tilted TT

Channel, flanged CF Unsymmetrical, general UG

Channel, plain CP Zee, right ZR

Channel, winged CW X XX

Profiles that have small projection or detail that does not alter the scheme can have an M or O placed in the third
character to designate modification(s) or not. The fourth and fifth characters can designate the wall thickness in
tenths or other designate: serrated (SE), tapered (TA) or irregular (IR).

A projection should be four times as long as its wall thickness to be considered part of the scheme if there is a
question of its applicability.

Examples:
Double track with nail fin, typical 0.050 Heat sink, taper fins: MTMTA
wall: EPM.05 for serrated fins: MTMSE

Glass frame surround, no constriction or Special categories can be made up:

irregularities, 0.078 typical wall: CPO.08 hollow screen frame: HSR.04 or SCN.04

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Table 2. Press Selection According to Pressure Requirements.
SOFT ALLOY - ESTIMATED PRESSURES FOR FLAT DIES (IN 1000 PSI.)
BILLET AT R=20 R=40 R=60 R=80 R=100 R=120 R=150
pd (L/D=0) 32 39 43 46 48 51 53
L/D=2.0 38 48 52 56 59 62 65
L/D=2.5 40 50 55 59 62 65 68
L/D=3.0 43 53 58 62 65 68 72
L/D=3.5 45 55 61 65 69 72 75
L/D=4.0 47 59 65 69 73 76 80
Notes: Feederplate and Porthole Dies may require up to 25% more pressure than flat dies.
The L/D ratio is for the crushed billet.

HARD ALLOY - ESTIMATED PRESSURES FOR FLAT DIES (IN 1000 PSI.)
Billet at R=10 R=20 R=30 R=40 R=50 R=60 R=70 R=80 R=100
pd (L/D = 0) 32 42 48 52 55 58 60 62 65
L/D=1.5 52 68 78 84 89 93 96 100 104
L/D=2.0 61 80 91 99 105 109 113 117 123
L/D=2.5 72 94 107 116 123 128 133 137 144
L/D=3.0 84 110 126 136 144 151 156 161 *
L/D=3.5 99 129 147 159 * * * * *
Note: The L/D ratio is for the crushed billet
* Pressure over 165,000 psi is near the yield strength of the hot work steel and will deteriorate the tool life greatly.

M AXIMUM EXTRUSION PRESSURE AVAILABLE FOR SELECTED PRESSES (IN 1000 PSI.).
Container Billet 1000T 1500T 1750T 2000T 2250 T 2500T 3000T 3500T 4000T 4500T 5000T
Dia. Dia.
Bore Area
5.375 22.69 5 88 132 154
6.375 31.92 6 63 94 110 125 141 157
7.375 42.72 7 47 70 82 94 105 117 140 164
8.375 55.09 8 36 54 64 73 82 90 109 127 145 163
9.375 69.03 9 43 51 58 65 72 87 101 116 130 145
10.375 84.54 10 41 47 53 59 71 83 95 106 118
11.375 101.62 11 39 44 49 59 69 79 89 98
12.375 120.28 12 37 42 50 58 67 75 83
13.375 140.50 13 36 43 50 57 64 71
14.375 162.30 14 37 43 49 55, 62
15.375 185.66 15 43 48 54
16.375 210.60 16 43 47

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Table 3.
SOFT ALLOY STANDARD TEMPERATURE PRACTICE, REGULAR DIES
Alloy & Container Die Preheat Reheat Emerging Cooling Rate
Temper Temperature Temperature Temperature Temperature
1100- All 650 -- 700o F 775 -- 825o F 700 -- 850o F 1000o F max. N/A
3003- All 650 -- 700o F 775 -- 825o F 700 -- 850o F 1000o F max. N/A
6063-F 650 -- 700o F 775 -- 825o F 750 -- 950o F 1050o F max. N/A
6063-T 1, -T5 650 -- 700o F 775 -- 825o F 800-- 930o F 900 ---1050o F 200o F/minute
6063-T 4, -T6 650 -- 700o F 775 -- 825o F 930 -- 960o F 950 -- 1050o F 250o F/minute
6061-F 650 -- 700o F 775 -- 825o F 750 -- 950o F 1050o F max. N/A
6061-T1, -T5 650 -- 700o F 775 -- 825o F 800-- 930o F 900 ---1050o F N/A
6061-T4, -T6 650 -- 700o F 775 -- 825o F 950 -- 980o F 950 -- 1050o F 1000o F/minute

SOFT ALLOY STANDARD RUNOUT SPEED, PRACTICE FOR REGULAR DIES

Alloy Extrudate Average Runout Speed (fpm)
Simple Standard Irregular Complex
1100 180 165 150 **
6063 EZ * 150 135 120 **
6063 GP * 135 120 100 **
6063 XS * 110 95 80 **
6061 90 75 60 **
* EZ = Easy Squeeze (dilute variation of 6063 or 6060); GP = General Purpose; XS = High Strength ** ** requires special instructions.
To Exhibit ram speed divided the extrudate ft per min. by 12 times the extrusion ratio (Vr = Vx /[12 x R] ).
Table 4. Cost comparisons for one- and two- press operations.
LABOR & BURDEN RATE COMPARISON CHART
ONE - 7″″ PRESS OPERATION TWO - 7″″ PRESS OPERATION
one shift two shifts three shifts one shift two shifts three shifts
LABOR

Personnel 12 24 34 23 46 68

Ave. hr. rate * $139/hr. $131/hr. $130/hr. $129/hr. $127/hr. $126/hr.

BURDEN
Mgmt and
Adm. Staff
9 10 11 9 13 15
Salary
Expense
$55900 $65000 $70200 $55900 $76050 $83850
Operating
Expense
$54000 $79000 $105000 $108000 $160000 $210000
Overhead
Expense.
$109900 $144000 $175200 $163900 $236050 $293850

Hr. of oper 160 320 480 320 640 960

Ave. hr. rate * $689/hr $450/hr. $365/hr. $512/hr. $369/hr. $306/hr

LBR & BRDN
Personnel 21 34 46 32 59 83

Ave Unit Cost $828/hr. $581/hr. $495/hr. $641/hr. $496/hr $432/hr.

* Ave. hr. rate is the cost of one hour of press operating time.

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