UNIT-III

Extrusion

Extrusion: Extrusion principle Hot extrusion and

cold extrusion - Forward extrusion and backward
extrusion, Impact extrusion, Hydrostatic extrusion
 PRINCIPLE
Extrusion is a compression process in which the work metal is
forced to flow through a die opening to produce a desired cross-
sectional shape.

The metal is confined in a closed cavity and then allowed to flow

from only one opening so that the metal will take the shape of the die
opening
 This process is used to produced long work pieces with uniform
cross section
The process can be likened to squeezing toothpaste out of a
toothpaste tube
Extrusions and Products Made from
Extrusions

Extrusions and examples of

products made by sectioning off
extrusions.
 EXTRUDED PRODUCTS
Typical products made by extrusion are:
Railings for sliding doors, tubing having carious cross-sections, structural and
architectural shapes, and door and windows frames
Typical extrusion shapes
 PRINCIPLE

The Basic extrusion equipment consists of:

1) Cylinder or container
2) Plunger or Ram
3) Die plate
4) Dummy block
5) Heated metal billet

Dummy
block
 PRINCIPLE
 Heated metal billet is loaded into the container

 One end of the container the die plate with necessary

opening is fixed

 From the other end the ram compresses the metal billet
against the die plate thus forcing the it to flow through the
die opening acquiring the shape of the opening

 The extruded metal is then carried away by the material

handling system as it comes out of the die.

 A dummy block which is a steel disc of about 40mm thick

with diameter slightly less than the container is kept
between the hot billet and the ram to protect it from the
heat and pressure
 Extrusion Component
Extrusion Die

Extruded Component Extruded Die

Important characteristics of the process:

Long Components with constant cross-section

Complexity of parts obtained are better than rolling
Single pass process
Amount of reduction possible is large
Brittle materials can also be extruded
Possible to produce parts with sharp corners and re-entrant
angles
Large dia-Thin walled tubes with excellent concentricity can
be produced
 CLASSIFICATION OF EXTRUSION PROCESS

Extrusion

Hot Extrusion Cold Extrusion

Forward Backward Forward Backward

Or Or
Direct Indirect

Impact Cold Extrusion

Extrusion forging
Hydrostatic
Extrusion
 Hot Extrusion
 Extrusion process carried out above recrystallization temperature
 The heated metal billet is placed in the extrusion container. The
extrusion force is applied thru the ram.
 Lot of friction is prevalent in hot extrusion due to relative motion
between metal billet and container walls
 This friction will be higher specially in case of metals and alloys having
high extrusion temperature
 Hence lubricants such as molten glass is used to reduce friction at high
temperatures such as steel extrusions
 At lower extrusion temps mixture of mineral oil and graphite
 To reduce damage to equipment extrusion are finished quickly and
container is cooled before further extrusion
 Cold Extrusion

 Extrusion process carried out below recrystallization

temperature
 Friction is overcome in this process compared to hot extrusion
 This process is used to obtain simple shapes requiring better
surface finish and to improve mechanical properties
 Surface quality achieved is good since no heat cracking is
involved
Ex:- Cans, Aluminium brackets
Direct Extrusion (Forward Extrusion)

Dummy block

Metal flows in forward

direction ie., same
direction as the
movement of ram
Indirect-Extrusion (Backward Extrusion)

Metal flows in opposite direction

to the movement of ram
The advantages of indirect extrusion are partly related to the lower load
needed and partly to the more uniform flow pattern developed because
of the absence of relative motion between the billet and the container
i.e. heat induced by friction.
The main advantages are:
A 25 to 30% reduction in load compared with direct extrusion.

The resultant higher extrusion load available can be used either to

extrude more complicated cross sections or to decrease the billet
temperatures, permitting the use of higher speeds.

No heat is produced by friction between the billet and the container,
and consequently no temperature increase occurs at the billet surface
towards the end of extrusion, as is typical in the direct extrusion of
aluminum alloys. Therefore, there is less sensitive to tear on surfaces
and edges to crack in the indirect process.

There is more uniform deformation of the complete billet cross

section with no tendency to form extrusion defect or a coarse-grained
peripheral zone.
Extrusion Temperature Ranges
 Extrusion Force

Butt end
scrap

Actual extrusion
begins
The major disadvantage of direct extrusion process is that the force
required to extrude the billet is greater than that needed in the indirect
extrusion process because of the frictional forces introduced by the
need for the billet to 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 of the billet the force greatly increases because the billet
is thin and the material must flow radially to exit the die. The end of the
billet (called the butt end) is not used for this reason
Extrusion ratio
Hydrostatic Extrusion
 Hydrostatic extrusion is an extrusion process in which the required
pressure is applied through a fluid medium sorrounding the billet
 The work piece is held in a sealed chamber surrounded by
pressurized liquid.
 Hydrostatic extrusion is actually a form of direct extrusion.
 The force delivered through the ram is what pressurizes the liquid.
 The liquid applies pressure to all surfaces of the work billet.
 When the ram moves forward, it is the force from the incompressible
fluid that pushes the work through the die, extruding the metal part.

Process Parameters:
Hydraulic pressure – 1000MPa to 3500MPa
Pressure transmitting Oil – Castor Oil with 10% alcohol, SAE30 Mineral
oils, ethylene glycol

A critical aspect of manufacturing by this process is setup. The metal

work billet must first be tapered to fit through the die opening, thus
creating a seal. This is done before adding the liquid, in order to prevent
leaking. Since the liquid is under great pressure, this taper must be
precise to create a robust bond.
Applications:
Cladding of metals
Extrusion of brittle materials like Molybdenum, Tungsten
Nuclear Fuel rods
Advantages:

1) No friction between the container and the billet reduces force

requirements. This ultimately allows for faster speeds, higher
reduction ratios, and lower billet temperatures.
2) Usually the ductility of the material increases when high
pressures are applied.
3) An even flow of material.
4) Large billets and large cross-sections can be extruded.
5) No billet residue is left on the container walls.

Disadvantages:

1) Specialized equipment and tooling

2) Containing the fluid under high pressures can be difficult
3) Low production rate – High set-up time
 Impact Extrusion
Commonly used to make collapsible tubes such as toothpaste tubes,
cans usually using soft materials such as aluminum, lead, tin.
Usually a small shot of solid material is placed in the die and is
impacted by a ram, which causes cold flow in the material.