EXTRUSION

pp 1
Extrusion
 Extrusion process
• Push an ingot through
an orifice with the
desired shape
• Like toothpaste out of
the tube
• Both hot and cold
extrusion are possible
– Depends on the
material

pp 2
Extrusion
 Schematic of Extrusion

Process variables in direct extrusion. The die angle, reduction in cross-section, extrusion speed, billet
temperature, and lubrication all affect the extrusion pressure.
pp 3
Extrusion
 Extrusion Independent Variables
• Die angle
• Extrusion ratio (ratio of input to output cross-
sectional areas)
• Circumscribing circle diameter CCD
• Shape factor
– ratio of perimeter of shape to cross-sectional
area
– a circular shape has the minimum
– a measure of the complexity of the extrusion
• Temperature of billet
• Ram speed
• Lubricant
• Product design
pp 4
Extrusion
 Circumscribing Diameter and
Shape Factor

pp 5
Extrusion
 Direct Extrusion Processes
• Direct or forward extrusion
– Billet pushed through die from behind

pp 6
Extrusion
 Extrusion Processes
• Indirect
– Die pushed into billet (advantageous for materials with
high billet-container friction)

pp 7
Extrusion
 Extrusion Processes
• Hydrostatic
– Ram compresses fluid surrounding billet
which is pushed out through the die (the fluid
transmits pressure to the billet)

pp 8
Extrusion
 Hydrostatic Extrusion
• More recent development (1950's)
• Advantages
– No friction at walls
– Can successful extrude brittle materials
– Yield stress reduced by hydrostatic pressure
– Room temperature operation
• Disadvantages
– Limited industrial applications
– Complex tooling
– High pressure experience required

pp 9
Extrusion
 Extrusion Processes

• Lateral
– Like direct, but
material comes out of
the die at right angles
to the direction in
which the billet is
pushed

pp 10
Extrusion
 Impact Extrusion
• Similar to indirect extrusion
• Can be considered a subset of cold extrusion
• Tends to look very similar to forging Used to
make short parts with thin walls (hollow shapes)

pp 11
Extrusion
 Examples of Impact Extrusion and
Dies

FIGURE 6.57 (a) Impact extrusion of a collapsible tube

(Hooker process).(b) Two examples of products made by
impact extrusion, these parts may also be made by casting,
forging, and machining, depending on the dimensions and
materials involved and the properties desired. Economic
considerations are also important in final process selection.

pp 12
Extrusion
 Material Flow

• Easy to extrude metals and alloys

– Aluminum
– Copper
– Magnesium
– Steels
– Stainless steels
• Difficult to extrude metals and alloys
– Titanium
– Refractory metals

pp 13
Extrusion
 Material Flow in Extrusion

Types of metal flow in extruding with square dies. (a) Flow pattern obtained at low friction, or in indirect
extrusion. (b) Pattern obtained with high friction at the billet-chamber interfaces. (c) Pattern obtained at
high friction, or with cooling of the outer regions of the billet in the chamber. This type of pattern, observed
in metals whose strength increases rapidly with decreasing temperature, leads to a defect known as pipe, or
extrusion defect.

1. Frictional conditions at billet-container-die interfaces

2. Thermal gradients in the billet

pp 14
Extrusion
 Ideal Extrusion Force

F = k Aoln(Ao/Af)

Where
– k is the extrusion constant
– related to stress-strain behavior
– A0 and Af are the initial and final cross-
sectional areas
– A0/Af is the extrusion ratio

pp 15
Extrusion
 Extrusion Pressure
FIGURE 6.52 Schematic
illustration of typical extrusion
pressure as a function of ram
travel: (a) direct extrusion and
(b) indirect extrusion. The
pressure in direct extrusion is
higher because of frictional
resistance in the chamber as
the billet moves toward the die.
Extrusion
FIGURE 6.53 Schematic illustration of
extrusion force as a function of die angle: (a)
total force; (b) ideal force; (c) force required for
redundant deformation; (d) force required to
overcome friction. Note that there is an
optimum die angle where the total extrusion
force is a minimum.
pp 16
 Hot Extrusion

• Advantages
– Lower stresses
– Sometimes the only way to extrude certain
metals
• e.g. Titanium, refractory alloys, high strength alloys
• Disadvantages
– Higher die wear
– Oxide film buildup results in non-uniform flow,
inclusions and poor surface finish
– Cooling of billet in container results in non-
uniform flow
– Distorted parts

pp 17
Extrusion
 Hot Extrusion

Process temperature ranges

Material Temp
Range (oC)
Lead 200-250
Aluminum and alloys 375-475
Copper and alloys 650-975
Steels 875-1300
Refractory alloys 975-2200

pp 18
Extrusion
 Different types of dies

pp 19
Extrusion