Introduction to Extrusion

Process

is similar to
squeezing
toothpaste
out of a toothpaste tube

Material is compressed in a chamber

Figure 19.31 - Direct extrusion
and the
deformed material is forced to flow through a
shaped opening in a die.
The die opening corresponds to the cross section
of the required product.
It is basically a hot working process, however, for
softer materials cold extrusion is also performed.
In general, extrusion is used to produce long parts
of uniform cross-sections
ME477

Lecture 13

Extruded Items
Railings for sliding doors
Window frames
Tubing having various cross-sections
Aluminum ladders
Numerous structural and architectural shapes

Extruded Metals
Common metals used in extraction process:
Aluminum
Copper
Steels
Stainless steels
Magnesium
Lead
Other metal alloys can be extruded with
various levels of difficulty

Extrusion Ratio
It is the ratio of area of cross-section of the billet
(A0) to the area of cross-section of the extrude
(Af).

A0
R
Af

About 40: 1 for hot extrusion of steel, 400: 1 for

aluminum

Extrusion Dies
Simplest cross section shape = circular die orifice
This process allows designers and engineers
freedom to create products in complex and
intricate shapes, since the end product can be
extruded as a final piece instead of requiring
multiple ones that must be assembled.
Shape of die orifice affects ram pressure
As cross-section becomes more complex, higher
pressure and greater force are required.
A solid die, as shown here,
produces shapes without any
enclosed voids and/or semihollow conditions

Extrusion
Features
Extrusion
DieDie
Features

(a) Definition of die

(a)
Definition of die angle;
angle

(b) Effect of die angle on ram

force.

(b) Effect of die angle on ram force.

35

Process parameters
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 crosssectional 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

Types of Extrusion
1. Direct extrusion
2. Indirect extrusion
3. Impact extrusion and
4. hydrostatic extrusion.

Forming Processes

Direct Extrusion

- Extrusion -

Extrusion is a metal

forming
process
Also called forward
extrusion
involving shaping a
metal
billet (hot
or
Metal flows in the
same
direction
cold) by forcing it
as that of the ram.
through a die with
opening.
Because of theanrelative
motion
between the heated
billet
and the
The two
possible
schemes is
of severe.
chamber walls, friction
extrusion are
Friction is reduced
presentedby
in the using
molten glass aspicture:
a lubricant in
case
of
steels
at
higher
temperatures.
At lower temperatures, oils with
graphite powder is used for
lubrication.
Starting billet cross section is
usually round, but final shape is
determined by die opening

Forming Processes

29

- Direct Extrusion -

g Processes

- Extrusion -

Indirect Extrusion

n is a metal

Also called backward extrusion and reverse

process
extrusion
g shaping a
Metal
let (hot
or flows in the opposite direction of the ram.
forcingItitis more efficient since it reduces friction losses
considerably.
a die with
ng.
The process, however, is not used extensively
because it restricts the length of the extruded
possible
component.
of
n are Lower rigidity of hollow ram and difficulty in
supporting extruded product as it exits die
d in the

It is similar to indirect
extrusion. Here the punch
descends rapidly on to the
blank which gets indirectly
extruded on to the punch and
to give a tubular section. The
Similar to indirect extrusion.
length of the tube formed is
The punch is madecontrolled
to strike
the ofslug
by the amount
metal in theload.
slug or by the
at high speed by impact
blank thickness. Collapsible
The slug gets indirectly
extruded
tubes for pastes
are extruded on
to the punch and byto
this give
method. a tubular

Impact Extrusion

section.
The length of the tube formed is
controlled by the amount of metal in
the slug or by the blank thickness.
Hollow sections such as cups,
toothpaste containers are made by
impact extrusion.
Usually
metals
like
copper,
aluminium,
lead
are
impact
extruded.

Hydrostatic Extrusion

Container is filled with a fluid.

Extrusion pressure is transmitted through the
fluid to the billet.
Friction is eliminated in this process because of
no contact between billet and container wall.
Hydrostatic
Extrusion
Brittle
materials
can be extruded by this process.
Greater reductions are possible by this method.
n this process the
Pressure involved in the process may be as high
iction between
riction
asand1700
ontainer wall
billet Mpa.

s eliminated, however,
his process has got
mited applications in
ndustry due to
pecialized equipment &

Hydrostatic Extrusion
Pressure is limited by the strength of the container,
punch and die materials.
Vegetable oils such as castor oil are used.
Normally this process is carried out at room
temperature.
A couple of disadvantages of the process are:
leakage of pressurized oil and uncontrolled speed of
extrusion at exit, due to release of stored energy by
the oil.
This may result in shock in the machinery. This
problem is overcome by making the punch come
into contact with the billet and reducing the
quantity of oil through less clearance between billet
and container.

Cold Extrusion
Cold extrusion could produce parts with

good surface finish,

high strength due to strain hardening,
improved accuracy,
high rate of production.

However, the process requires

higher pressure and

tools are subjected to higher stresses.

Used with lowstrength metals such as lead, tin, zinc,

and aluminum
Proper lubrication is necessary for preventing seizure
of tool and workpiece.
To produce collapsible tubes for toothpaste,
medications, and other creams; small "cans" for
shielding electronic components and larger cans for
food and beverages.

Hot Extrusion
Hot extrusion can be employed for higher
extrusion ratios.
Difficult to work metals are usually hot extruded
or warm extruded
Inhomogeneous deformation can occur due to die
wall chilling of the billet.
Metal may get oxidized. The oxide layer can
increase friction as well as the material flow.
Glass is used as lubricant for hot extrusion.
Molybdenum disulfide or graphite are the solid
lubricants used in hot extrusion.
Canned extrusion using thin walled cans made of
copper or tin is usually used for extruding highly
reactive metals and metal powders.

Extrusion Presses
1. Horizontal presses
2. Vertical presses

Horizontal
Extrusion
Horizontal extrusion
presses
(
(15
50 MN capacity
i or upto
Presses
140 MN)
Horizontal presses up to 50
MN Used
capacity
being
used.
for are
most
commercial

extrusion of bars and shapes.

Used for most commercial
Disadvantages:
extrusion
of bars and shapes.
Deformation is nonuniform
Disadvantages:
due to different temperatures
p
Deformation
nonuniform
between top is
and bottomparts
dueoftothe
different
temperatures
billet
between top and bottom
parts of the billet

 Uniform deformation, due to uniform cooling of the b

container.
Requirements:
Need considerable headroom to make extrusions of
length.
Vertical presses
are of capacity
Afloorpitisnecessary
ranging from 3 to 20 MN.
Tubular extrusions are mostly
done in vertical presses

Vertical Extrusion Presses

Advantages:
Easier alignment between the press ram and tools.
Higher rate of production.
Require less floor space than horizontal presses.
Uniform deformation, due to uniform cooling of the
billet in the container.
Requirements:
Need considerable headroom to make extrusions of
appreciable length.
A floor pit is necessary

General Advantages of
Extrusion

Variety of shapes possible, especially in hot

extrusion
Large deformations can take place without fracture
Extrusion results in better grain structure, accuracy
and surface finish of the components.
Close tolerances possible, especially in cold
extrusion
In some operations, little or no wastage of material
Many shapes (than rolling)
Since the die geometry remains constant
throughout the process extruded products have a
constant cross-section