Extrusion

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 Types of extrusion processes
• Direct extrusion process
• Indirect/Reverse extrusion process

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THE ALUMINIUM EXTRUSION PROCESS

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Continuous Production Line for Aluminum Tube
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Products of
Dajcor Aluminum Ltd,
155 Irwin St.
Chatham, Ontario
Canada N7M 5J5

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Extruded Aluminum 11
Samples of extruded-aluminum heat sinks
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 Parameter used in extrusion process
• Extrusion ratio = R

Ai
R=
–
A
Where A is initial area f
i
– Af is the final area
• Shape factor. It is the ratio of the perimeter of the part to its cross-
sectional area
• True strain = Ɛ
 Ai   Lf 
ε = ln  = ln  = ln (R )
 Af   Li 
• Where Lf and Li are final and initial lengths
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Analysis for extrusion force

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 For perfectly plastic material with yield stress, Y,
energy dissipated/unit volume, u, is
u = Yε
Workdone = A i L i u
Let F is the ram force and Li is the distance travelled
by the ram. Then
Wokdone = FLi = pA i L i
A  L 
∴ Extrusion _ pressure = p = u = Yε = Y ln i  = Y ln f  = Y ln (R )
 Af   Li 
& Ideal − force = F = pA i
Where:
Ai, Af, Li & Lf = area and length of billet (i) and extruded (f) products
p = extrusion pressure
Note: For strain-hardening material Y should replaced by the average flow
stress, Ȳ. 16
 True stress - true strain curves
A relationship between true stress - true strain
can be typically approximated by the equation:
σ = Kε n
• If σ = Y, is known as flow stress and defined as
true stress to continue deformation at a
particular true strain, Ɛ. For strain hardening
materials the flow stress increases with an
increase in strain. Hence, value of Y can be
calculated.
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Values of K and n at room temperature

For strain hardening

materials:

σ = Kε n

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 Forces in hot extrusion
• In hot extrusion
• p = KelnR
• Where, Ke = extrusion constant and is a
function of material and temperature.

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 Problem 1
• Calculate the force required in direct extrusion of 1100-
O aluminium from a diameter of 152.4 mm to 50.8
mm. Assume that the redundant work is 30% of the
ideal work of deformation, and friction work is 25% of
the total work of deformation.
(utotal= uideal+ ufriction + uredundant )
u = specific energy
uideal = actual energy
ufriction = energy due to frictional forces
uredundant = energy required additional plastic
deformation

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Values of K and n at room temperature

For strain hardening

materials:

σ = Kε n

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 Problem 2
• Estimate the force required in extruding 70-30
brass at 973 K if the billet diameter is 125 mm
and extrusion ratio is 20. Also compute its true
strain.

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Drawing

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 Drawing
• Similar to extrusion process
• In drawing process the work is under tension
whereas in extrusion it is under compression
• Generally finishing process

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The Cold Drawing Process for Steel Bars
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Cold drawn Seamless tubes
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Sizes from small diameter hypodermic medical tubing
.009" OD (.23mm) to .375"OD (9.35mm). Fabrication
processes include welding, drawing, straightening, .. 32
 Drawing force
For ideal deformation:
 Ai 
Drawing _ stress = σ d = Y ln 
 Af 
For strain hardening materials , Y is replaced by an average flow stress, Ȳ.
For a material that exhibits true-stress-true-strain behaviour of
σ = Kεn
Where
K = strength coefficient
n = strain hardening exponent
Hence, for strain hardening material, Ȳ can be given as
Kε n
Y=
n +1
 Ai 
& Drawing − force = F = YA f ln 
 Af 

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 Maximum reduction per pass
• As reduction increases
– The drawing stress increases
– It may reach the material yield stress, Y, at
the exit
• Hence, at this stress, the work continues
to yield and fail
– Therefore, the limiting condition is σd = Y

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  Ai 
∴ σ d = Y ln  = Y
 Af 
 Ai 
ln  = 1
 Af 
Ai
=e
Af
Ai − Af 1
∴ Maximum − reduction / pass = = 1 − = 0.63 = 63%
Ai e

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 Drawing of flat strip
• Assuming no change in the width of the strip
− t 
σ d = Y ln i 
 tf 

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 Maximum reduction per pass for a
strip
• In this case the drawing stress is equated with
uni-directional yield stress
• Because the strip is only subjected to tension
−t 
∴ σ d = Y ln i  = Y
 tf 
t  Y  3
ln i  = − =  
 2 
 tf  Y  
 3
 
ti  2 
=e  
tf
ti − tf 1
Maximum − reduction / pass = = 1−  3
= 0.58 = 58%
ti  
 2 
 
e

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 Problem
• If an annealed 85-15 brass work-piece is drawn
from an initial diameter of 8 mm to a final
diameter of 6 mm at a speed of 0.6 m/s, calculate
a. The power required and
b. The die pressure at the exit.
Assume a value of 40% of the ideal work for the
total of both the redundancy and the friction
work.
(For yield strength, see Table 3.10,
Manufacturing processes for engineering
materials by Kalpakjian &Schmid)
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Thanks

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