Manufacturing Process Lab

Report 2

EXTRUSION

Name: Ömercan
Surname: Limli
Number: 190505084
INTRODUCTION
Extrusion is one of the most common metal casting proccesses. It is a proccess that which the material,
most probabbly metal is forced in to a smaller cross-section area for flow in it amd take the required
shape (Jhonson, Kudo, 1962). The products which is manufactured by the extrusion procces could be
cut to the neccessary dimensions to make parts like gears, brackets etc. There is a round billet in the
cell and ram that compresses the metal into the die opening (Yadav, Dewang, Raghuvanshi, 2015).
There is two types of extrusion procces when the temperature is not considered. These types are “Direct
Extrusion” and “Indirect Extrusion”. In the direct extrusion there is a frictional force between the
surface of the material and chamber that
increases the power need to extrude to
material because the ram pushes the
uniform shaped material into the steady
die, there is also a piece that the ram
cannot push anymore which iscalled
“butt” the butt of the metal will be cutted
after the extrusion proccess. (Wiley, Sons,
2007).
Figure 1. Direct Extrusion
When the topic is indirect extrusion
actually the friction effects are much
lower than the direct extrusion. In the
indirect extrusion there is a hollow ram
which pushes the die reverse along the
steady billet (Yadav, Dewang,
Raghuvanshi, 2015).

Figure 2. Indirect Extrusion.

If it is neccessary to compare hot and cool extrusion the most important difference between them is
speed. Because when the material is hot it is easy to flow it into the chamber by the ram [4]. But in the
other hand it has lower strength and surface quality compared to cold extrusion. In cold extrusion the
neccessary force applied by the ram is much more higher but the strength of the material gets high
because there is a strain hardening occurs during the proccess [5]. The effect of die shape in the
extrusion proccess will be investigated in this experiment.

EXPERIMENT
The alluminium alloy 2024 at the hot extrusion proccess is used as a test material in the experiment.
The curve of the straing hardening is related to given equation below;
(Askeland, Phule, 2006)
Working conditions during the hot extrusion is;

• T = 293K
• Length = 75mm
• Billet D = 45mm
• Final D = 10mm, 20mm
• Extrusion Ratio (R) = 5, 20
•
Angles of the die = 450, 600, 900, 1050,1200, 1350
• Radius of the fillet = 0mm, 1.5mm, 3mm, 4.5mm
To see the effect of the fillet radius on the 2024 series alluminium with the straight die, the material is
deformed by the following conditions; (Solomon, Solomon, 2010)

• T = 724K
• R = 8.5
•
Angle of the Die = 900
• Radius of the fillet = 3mm
By using this conditions the material is compressed directly to the chamber to get the experimental data.

RESULTS

Figure 3. Metal Flow (1) (2) (3)

1- Fillet radius with 0mm

2- Fillet radius with 3mm
3- Fillet radius with 4.5mm
For the next figures below the first one is the fillet radius with 3mm and the second one is fillet radius
with 0mm for the flat die.

Figure 4. Equivalent strain.

Figure 5. Hydrostatic Pressure.

CONCLUSION
It could be concluded that the fillet radius of the die effects the mechanical properties of the material.
As seen in the Figure 4 and the Figure 5 when the radius of fillet is 0mm there is much more hydrostatic
pressure on the material which causes more strain. But on the other hand this strain value shows that
when the fillet radius is 0mm the strain hardening effect on the alluminium 2024 much more than the
3mm fillet. This concludes that if the power of the ram is enough to apply neccessary hydrostatic
pressure the 0mm fillet radius die can be choosen to increase the mechanical properties of the extruded
material.
REFERENCES
[1] William Johnson and Hideaki Kudo, “The Mechanics of Metal Extrusion”,1962.
[2] Rahul Ranjan Yadav, Yogesh Dewang, Jitendra Raghuvanshi, “A study on metal extrusion process”,
2015.
[3] Groover MP. Fundamentals of modern manufacturing: materials processes, and systems. John Wiley
& Sons; 2007.
[4] Parvizian F, Schneidt A, Svendsen B, Mahnken R. Thermo‐mechanically coupled modeling and
simulation of hot metal‐forming processes using adaptive remeshing method. GAMM‐Mitteilungen.
2010; 33(1):95-115.
[5] Ghaemi F, Ebrahimi R, Hosseinifar R. Optimization of die profile for cold forward extrusion using
an improved slab method analysis. Iranian Journal of Science and Technology. Transactions of
Mechanical Engineering. 2013; 37(M2):189.
[6] D.R. Askeland, P.P. Phulé, The science and engineering of materials, 5th ed., Cengage Learning,
2006.
[7] N. Solomon and I. Solomon, “Effect of die shape on the metal flow pattern during direct extrusion
process”, 2010.
[8] N. Solomon, PhD Thesis, University of Galati, 1997.
[9] Joun MS, Hwang SM. Die shape optimal design in three‐dimensional shape metal extrusion by the
finite element method. International Journal for numerical methods in engineering. 1998; 41(2):311-35.