Lecture 6 Extrusion and Drawing

Extrusion
Outline
• Extrusion process
- Direct extrusion
- Indirect extrusion
- Impact extrusion
Direct extrusion Indirect extrusion
• Extrusion analysis
• Bar drawing • Compression forming process in which the work metal is
forced to flow through a die opening to produce a desired
• Wire drawing
cross-sectional shape
• Drawing analysis • In general, extrusion is used to produce long parts of ………….
cross-sections
• Two basic types of extrusion:
– ……….. extrusion
– ……….. extrusion
Dr. M. Medraj Mech. Eng. Dept. - Concordia University Mech 421/6511 lecture 6/1 Dr. M. Medraj Mech. Eng. Dept. - Concordia University Mech 421/6511 lecture 6/2
Direct Extrusion Indirect Extrusion

• Also called backward extrusion
• Also called ………….. extrusion and reverse extrusion
• As ram approaches die opening, • Limitations of indirect
a small portion of billet remains extrusion are imposed by the
that cannot be forced through die lower rigidity of hollow ram
opening
and difficulty in supporting
• This extra portion, called the extruded product as it exits die
butt, must be separated from
extruded product by cutting it
just beyond the die exit
• Starting billet cross section
usually round, but final shape is
determined by die opening
solid cross-section Hollow cross-section
General Advantages of Extrusion Impact Extrusion
• Variety of shapes possible, especially in hot extrusion • Similar to indirect extrusion

– Limitation: part cross-section must be uniform throughout length • Cold extrusion
• Grain structure and strength …………. in cold and warm extrusion • Most nonferrous metals at rates of two parts/second
• Thin walled tubular sections possible
• Close tolerances possible, especially in cold extrusion
• In some operations, little or no waste of material
Hot vs. Cold Extrusion

• Hot extrusion - prior heating of billet to above its recrystallization
temperature
– This reduces strength and increases ductility of the metal,
permitting more size reductions and more ………….. shapes
• Cold extrusion - generally used to produce discrete parts
– The term impact extrusion is used to indicate high speed cold The extruded parts are stripped by the use of a stripper plate, because
extrusion they tend to stick to the punch.
Comments on Die Angle Comments on Orifice Shape of Extrusion Die

• Simplest cross section shape = circular die orifice
• Shape of die orifice affects ram pressure
• As cross-section becomes more complex, ………… pressure
and greater force are required
• Low die angle - surface area is large, leading to increased

friction at die-billet interface
– Higher friction results in larger ram force
• Large die angle - more turbulence in metal flow during
reduction
– Turbulence increases ram force required
• Optimum angle depends on ………………, …….……………..,
and ……………………… A complex extruded cross-section for a heat sink
Extrusion Presses Extrusion Analysis
• Either horizontal or vertical • Reduction (extrusion) ratio
– Horizontal is more common A
rx = o
• Extrusion presses - usually hydraulically driven, which is especially Af
suited to semi-continuous direct extrusion of long sections • Extrusion pressure can be calculated from:
• Mechanical drives - often used for cold extrusion of individual parts
pe = Qe × Y f Assuming no friction Direct extrusion
Where Qe is the multiplying factor for extrusion
• Qe is related to the extrusion ratio according to:

General view of a 9-MN Qe = ε x = a + b ln rx where a (~0.8) and b (~1.2-1.5) increase with dies angle
(900-ton) hydraulic-
extrusion press
Friction is significant in extrusion and should be considered, so;
p p = pe + p f where: pp is the punch pressure pe is extrusion

pressure and pf is the friction pressure
Extrusion Analysis Extrusion Dies and Press

Where:
τt is the shear flow strength
F f = τ tπDl D is the diameter of the deformed billet Shape factor Direct
Ram pressure
l is the length of the frictional resistance …… formation
(taking into account the dead metal zone)
2.25
C  Indirect
Tresca’s failure Criterion says: τ t = 0.5Y f K x = 0.98 + 0.02 x 
Actual extrusion begins
  Cc 
2L  Ram Force, Fp=ppAp
p p = Y f  ε x +  L is the billet length
Do  ⇒ Ram stroke
 Power P=Fpv
Cx=perimeter of the extruded cross-section
For indirect extrusion friction can be assumed insignificant Cc=Perimeter of a circle with the same area
Note that in direct extrusion the
Hot extrusion → strain rate effects become important ram pressure decreases as the
p = K xY f ε x For Indirect billet is extruded further because
Where: ε•m is the mean strain rate L decreases, whereas in indirect
. 6vDo2 ln rx v is the punch velocity  2L  extrusion the ram pressure is not
ε• m = p = K xY f  ε x +  For Direct a function of the billet length.
3 Do is the diameter of the deformed billet  D
Do − D 3 D is the extruded product diameter
Wire and Bar Drawing Wire Drawing vs. Bar Drawing
• Difference between bar drawing and wire drawing is …………
– Bar drawing - large diameter bar and rod stock
– Wire drawing - small diameter stock - wire sizes down to 0.03
mm (0.001 in.) are possible
• Although the mechanics are the same, the methods, equipment,
and even terminology are different
• Cross-section of a bar, rod, or wire is reduced by pulling it • Drawing practice:

through a die opening – Usually performed as cold working
– Most frequently used for round cross-sections
• Similar to extrusion except work is ……….. through die in
• Products:
drawing (it is …………. through in extrusion) – Wire: electrical wire; wire stock for fences, coat hangers,
• Although drawing applies tensile stress, compression also and shopping carts
plays a significant role since metal is squeezed as it passes – Rod stock for nails, screws, rivets, and springs
through die opening – Bar stock: metal bars for machining, forging, and other
processes
Bar Drawing Wire Drawing

…………….
Hydraulically operated draw Continuous drawing of wire

bench for drawing metal bars
• Continuous drawing machines consisting of multiple draw
dies (typically 4 to 12) separated by accumulating drums
• Accomplished as a single-draft operation - the stock is – Each drum (capstan) provides proper force to draw wire
pulled through one die opening stock through upstream die
• Beginning stock has large diameter and is a straight cylinder – Each die provides a small reduction, so desired total
reduction is achieved by the series
• This necessitates a batch type operation
– Annealing sometimes required between dies
Features of a Draw Die Drawing Analysis
Area Reduction: Df F
Ao − A f Do
r=
Ao
Draft: α Lc
d = Do − D f
Mechanics of Drawing: Where:
D
A 1 φ = 0.88 + 0.12
• Entry region - funnels lubricant into the die to prevent scoring ε = ln o = ln Lc
of work and die Af 1− r Do + D f Do − D f
D= and Lc =
• Approach - cone-shaped region where drawing occurs Ao 2 2 sin α
σ = Y f ε = Y f ln Ideal
• Bearing surface - determines final stock size Af
• Back relief - exit zone - provided with a back relief angle
Draw Force:
 µ  A  µ  A
(half-angle) of about 30° σ = Y f 1 + φ ln o Actual F = A f σ = A f Y f 1 + φ ln o
• Die materials: tool steels or cemented carbides  tan α  Af  tan α  Af
Maximum Reduction per pass

Example
• For a perfect plastic material
Ao A 1
σ = Y f ln = Y ln o = Y ln =Y
Af Af 1− r
Next time
A 
ln o  = ln 1  = 1 ⇒ ε max = 1 Review of Bulk Deformation: Examples
A  1− r 
 f 
Ao
= ...... = ..........
Af
e −1
rmax = = ..........
e

Lecture 6 Extrusion and Drawing

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Extrusion

Direct Extrusion Indirect Extrusion

• Variety of shapes possible, especially in hot extrusion • Similar to indirect extrusion

Hot vs. Cold Extrusion

Comments on Die Angle Comments on Orifice Shape of Extrusion Die

• Low die angle - surface area is large, leading to increased

• Qe is related to the extrusion ratio according to:

p p = pe + p f where: pp is the punch pressure pe is extrusion

Extrusion Analysis Extrusion Dies and Press

• Cross-section of a bar, rod, or wire is reduced by pulling it • Drawing practice:

Bar Drawing Wire Drawing

Hydraulically operated draw Continuous drawing of wire

Maximum Reduction per pass

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