Bulk Forming Processes

Extrusion
16.6 Extrusion
 Metal is squeezed
and forced to flow
through a shaped Pressing ram

die to form a
product with a
constant cross
section
 A ram advances
from one end of the
die and causes the
Figure 16-25 Direct extrusion schematic showing
metal to flow the various equipment components. (Courtesy of
plastically through Danieli Wean United, Cranberry Township, PA.)

the die
 Extrusion

 Metal is forced to flow through a shaped die to

form a product with a constant cross section
 A ram advances from one end of the die and
causes the metal to flow plastically through
the die
Extrusion
Definition:
◦ Process of forcing a billet through a die above its
elastic limit, taking shape of the opening.

Purpose:
◦ To reduce its cross-section or to produce a
solid or hollow cross section.

Analogy: “Like squeezing toothpaste out of

a tube”.
Extrusion
 Extruded products always have a constant cross-
section.

 It can be a semi-continuous or a batch process.

 Extrusions can be cut into lengths to become

discrete parts like gears, brackets, etc.

A billet can also extruded individually in a chamber,

and produces discrete parts.

 Typical
products: railings, tubing, structural
shapes, etc.
 Extrusion
 Can be performed at elevated temperatures or
room temperatures, depending on material
ductility.
 Commonly extruded materials include aluminum,
magnesium (low yield strength materials),
copper, and lead.

 Steels and nickel based alloys are far more

difficult to extrude (high yield strength materials).

 Lubricants are essential to extrude high

strength alloys to avoid tendency of material to
weld to die walls.
 Extruded items

 Railings for sliding doors

 Window frames
 Tubing having various cross-sections
 Aluminum ladders
 Numerous structural and architectural shapes
Advantages of Extrusion
Many shapes can be produced that are
not possible with rolling
No draft is required
Amount of reduction in a single step is
only limited by the equipment, not the
material or the design
Dies are relatively inexpensive
Small quantities of a desired shape can
be produced economically
 Extrusion Methods
Methods of extrusion:
◦ Hot extrusion is usually done by either the direct or
indirect methods.

◦ Direct extrusion
 Solid ram drives the entire billet to and through a
stationary die
 Must provide additional power to overcome friction
between billet surface and die walls
Extrusion Methods
◦ Indirect extrusion
 A hollow ram pushes the die back through a
stationary, confined billet
 No relative motion and no friction
between billet and die walls.
 Lower forces required, can extrude longer
billets.
 More complex process, more expensive
equipment required.
Extrusion Methods

Figure 16-27 Direct and indirect extrusion. In direct extrusion, the ram and billet both
move and friction between the billet and the chamber opposes forward motion. For
indirect extrusion, the billet is stationary. There is no billet-chamber friction, since
there is no relative motion.
Extrusion dies
Typical arrangement of extrusion
tooling
1-wedge
2-die head
3-container
4-liner
5-die
holder
6-die
7-bolster
Extrusion dies
Extrusion Dies
Example of an Extrusion Die
Extruded Metals
Typical extruded metals (hot or cold)
Aluminum, copper, magnesium, zinc,
tin and alloys of these

Steel alloys are usually extruded hot;

softer steels may be extruded cold

Others such as titanium and refractory

metals may be extruded, but with
difficulty
 Variables in Extrusion
Die Angle
Extrusion Ratio R (A0 / Af): where A0 and

Af are billet and extruded product areas.

Billet Temperature
Ram Velocity
Type of Lubricant used.
Extrusion
 Ram pressure or extrusion pressure is the
extrusion force divided by c/s area of the billet.
The rapid rise in the pressure during the initial
ram travel is due to initial compression of the
billet to fill the extrusion container.

 Fordirect extrusion the metal begins to flow

through the die at the max value of pressure. as
the billet extrudes through the die the pressure
required to maintain the flow progressively
decreases with decreasing length of the billet in
the container
 Forindirect extrusion there is no relative motion
b/w the billet and the container wall. Therefore
the extrusion pressure is approximately constant
with increasing ram travel

 Atthe end of the stroke the pressure buildsup

rapidly and it is usual to stop the ram travel so
as to leave a small discard in the container.this
discard often contains defects which are
unwanted in the product
 Extrusion Force
 Factors for determining extrusion force:
billet strength, extrusion ratio,
friction between billet and die surfaces,
temperature, extrusion speed.

Estimation of Force required:

F = A0 k ln (A0/Af)
◦ k = extrusion constant
◦ Ao, Af billet and extruded product cross section areas
 Example for calculation
Extrusion Force
 Given: a 70-30 brass round billet is
extruded at 1250 deg. F. Billet diam. = 5”.
Extrusion Diam. = 2”.
 Find: Required force.
 Assumptions: friction is negligible.
 Solution: Find k from Fig. 15.6 for 70-30
brass : 30,000 psi at 1250 deg. F.

F =  (2.5) 2 (30,000) ln [( (2.5) 2) / ( (1.0) 2)]

= 1.08 x 106 lb = 490 tons.

Lubrication
Essential in drawing to improve die life,
reduce drawing forces/temperature,
improve surface finish, particularly in
hot extrusion.
Difficult to maintain a constant lubricant
film constant between the die and the
workpiece.
Can coat with zirconia to add life to die.
 Metal Flow
 Quite complex.
 Impact quality and mechanical properties of
product: must not overlook to prevent defects.
 Extruded products have elongated grain
structure.
◦ Metal at center passes through die w/little
distortion
◦ Metal near surface undergoes considerable
shearing.
◦ Friction between moving billet and stationary
chamber walls impedes surface flow.
◦ Result is deformation pattern
  Extrusion process
actually increases the
properties of metals,
Properties because it allows the
creation of a final end
product that is stronger
and more resilient than
components that must be
assembled. It allows for
the fabrication of products
to various specifications
and sizes, while being
flexible enough to allow
for design alterations.
Furnace

 The extrusion process starts with the furnace, where

aluminum billets are heated to the necessary point of
malleability. The aluminum or aluminum alloy is heated
to temperatures ranging 750 to 900 degrees
Fahrenheit, at which temperatures it acts as a
malleable solid.
  Common metals used
in extraction process:
 Aluminum
 Copper

Metals  Steels
 Stainless steels
 Magnesium
 Lead

 Other metal alloys can

be extruded with
various levels of
difficulty
Extrusion Principles
The force required for extrusion
depends on:
 The strength of the billet material
 The extrusion ratio Ao/Af
 Friction between the billet and the
chamber and die surface
The geometric variables in extrusion are:
 The die angle
 The ratio of the cross-sectional area of the
billet to that of the extruded product, Ao/Af
 The temperature of the billet
 The speed at which the ram travels
 The type of lubrication

Flow through a die

Benifits

A benefit to extrusions and Drawing process would

be that large deformations can take place without
fracture, because the material is under high triaxial
compression during the process.
Since the die geometry remains constant
throughout the process extruded products have a
constant cross-section
Extrusion Processes
Hot extrusion
Keeping the processing temperature to above
the re-crystalline temperature. Reducing the
ram force, increasing the ram speed, and
reduction of grain flow characteristics.
Controlling the cooling is a problem. Glass may
be used as a lubricant.
Cold extrusion
Often used to produce discrete parts. Increase
strength due to strain hardening, close
tolerances, improved surface finish, absence of
oxide layer and high production rates.
 Extrusion can be Hot or Cold
 Hot Extrusion
◦ Takes place at elevated temperatures.
◦ Used in metals that have low ductility at room temperature.
◦ Need to pre-heat dies to prolong die life and reduce billet
cooling.
◦ Hot working tends to develop an oxide film on the outside of
the work unless done in an inert environment.
◦ Solution:
 place smaller-diameter dummy block ahead of ram before
the billet. A layer of oxidized material is then left in the
chamber, and is later removed and final part is free of
oxides.
 Extrusion can be Hot or Cold
Cold Extrusion (also know as Impact
Extrusion)
◦ Designated as cold when combined with other
forging operations.
◦ Key variables:
 Slug dimensions
 Material property, and
 lubrication
◦ Diameters up to 6” and thin walls can be made.
◦ Collapsible tubes can be made this way (toothpaste
tubes).
 Advantages Cold vs. Hot
Extrusion
Cold:
◦ Better mechanical properties due to work-
hardening.
◦ Good dimensional tolerances & surface finish.
◦ No need to heat billet.
◦ Competitive production rates & costs.
Hot:
◦ Larger variety of materials.
◦ Less forces required.
◦ Better material flow.
Cold extrusion advantages:
- Improved mechanical properties from
work-hardening
- Good control of dimensional tolerances
- Improved surface finish (no oxide film)
- No heating required
- Competitive production rates and costs
 Guidelines for Die Design
Avoid sharp corners
Have similarly sized voids if possible.
Have even thickness in walls if possible.
General idea is to favor even flow.
 Defects in Extrusions
Surface Cracking / Tearing
◦ Occurs with high friction or speed.
◦ Can also occur with sticking of billet material on die
land.
◦ Material sticks, pressure increases, product stops
and starts to move again.
◦ This produces circumferential cracks on surface.
Extrusion Defects
 Hot shortness in extrusion
It is a tendency of alloys to separate along
grain boundaries when stressed and
deformed at temperatures near the
melting point ( ex steel due to high
sulphur content)