Exp9: Extrusion

Extrusion
Compression forming process in which work metal is forced to flow through a
die opening to produce a desired cross-sectional shape
• Process is similar to squeezing toothpaste out of a toothpaste tube
• In general, extrusion is used to produce long parts of uniform cross
sections
• Two basic types:
– Direct extrusion
– Indirect extrusion

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Introduction
• There are several advantages of the modern process:
• (1) A variety of shapes are possible, especially with hot extrusion
• (2) Grain structure and strength properties are enhanced in cold and warm extrusion
• (3) Fairly close tolerances are possible, especially in cold extrusion
• (4) In some extrusion operations, little or no wasted material is created
• However, a limitation is that the cross section of the extruded part must be uniform
• throughout its length
• (Food industry, structural architectural shapes (door and window
• slides), tubes and pipes.

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Direct Extrusion
• Also called forward extrusion
• Starting billet cross section
usually round
• Final shape of extrudate is
determined by die
opening
• Extruded rod and ingot
moved in one and the same
direction
• pushing the ingot forward
demands high friction force
and work
• As ram approaches die opening, a small portion of billet remains that
cannot be forced through die opening
• This extra portion, called the butt, must be separated from extrudate by cutting
it just beyond the die exit
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Indirect Extrusion

a solid cross section a hollow cross section.

• Also called backward extrusion and reverse extrusion
• no relative movement between the ingot and the
container
• friction forces between ingot and container are
negligible
• Limitations of indirect extrusion are imposed by
– Lower rigidity of hollow ram
– Difficulty in supporting extruded product as it exits die
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Hydrostatic extrusion
• Pressure applied by fluid
medium
• Reduces friction

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Hot Extrusion
• Extrusion is carried out at elevated temperatures – for metals and
alloys that do not have sufficient ductility at room temperature, or in
order to reduce the forces required.

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Extrusion Processes
• Cold Extrusion
– Room temperature or a few hundred degrees
– Advantages
• Close control of tolerance
• Improved surface finish
• Strain hardening can give some desirable properties
• No oxide layer formation
– High stresses on dies
– Lubrication is very critical (phosphate, wax, etc.)

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Extrusion Ratio
Also called the reduction ratio, it is defined as

A
r x  Ao
f

where rx = extrusion ratio; Ao = cross-sectional area of the starting

billet; and Af = final cross-sectional area of the extruded section
• Applies to both direct and indirect extrusion

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Extrusion Analysis
Ao
Extrusion ratio, rx 
Af

Assuming all sections

are circular, ideal

deformation, no friction,

no redundant work:
  ln rx
Ram pressure
p  Yf ln rx
Taking into account friction,
p  Y f (a  b ln
where a =0.8 and b =1.2 to 1.5.
rx )
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