EXTRUSION

EXTRUSION

 Extrusion is defined as process of pushing the heated

metal through an orifice provided in die thus
forming an elongated pan of uniform cross section
corresponding to the shape of the orifices. It is also
elaborated as the process of confining the heated
metal in a closed cavity and then allowing it to flow
from only one opening so that the metal will take the
shape of the opening. The pressure is applied
hydraulically of mechanically This operation is
identical to the squeezing of tooth paste out of the
tooth paste tune opening .
 EXTRUSION PRINCIPLE

 The extrusion equipment consists of a cylinder or

container into which the heated metal t loaded. On
one end of the container, the die plate with the
necessary shaped opening is fixed From the other
end, al plunger or ram compressed the metal against
the container walls and the die plate, thus forcing it
to flow through the die opening Acquiring the shape
of the die opening. The extruded metal is then
carried by the metal handling system as it come out
of the die
EXTRUSION PROCESS
 CHARACTERSTICS OF EXTRUSION

 By the extrusion process, it is possible to make components which

have a constant cross section over all in the length .
 Extrusion is Single pass process unlike Rolling.
 Metals like Aluminum, Nickel and their alloys are commonly used
for extrusion at elevated temperature although steel and its alloys
and also be extruded. Even brittle metals .
 extrusion Dies are made of either Heat resistance alloy steels or
Tungsten Carbide.
 It is possible to make sharp corners, angles, and complicate shapes
by extrusion.
 Thin walled tubular products with excellent concentricity and
tolerance cane be produced.
 The temperature range for extrusion varied from 500 to 1200
degree c depending upon the material.
 The Pressure range varies from 35 to 1000 mpa depends upon the
various metals, extrusion temperature, reduction in area and
extrusion speed.
 CLASSIFICATION OF EXTRUSION
PROCESSES

EXTRUSION

Hot Extrusion Cold Extrusion

Forward Backward Forward Backward

Hydrostatic Impact
extrusion Cold extrusion extrusion
 ADVNTAGES OF EXTRUSION PROCESS

 Extrusion is a faster process

 The products have good tolerances
 Mechanical properties are superior than rolling
 Complex shapes can be easily extruded.
 Products have good surface finish
 Small lots can be produces economically.
 Set up cost is low.
 Suitable for production of seamless tubing specially or
steels
 Complicate shapes can be produced with sharp angles
and corners.
 VARIABES IN EXTRUSION

The various variable involved in extrusion process are

 Extrusion Ratio is defined as the ratio of cross sectional

area of billet to that of the ratio of cross section of the
extruded part.
 Extrusion Temperature extrusion the temperature range
varies from 500 to 1200 degree C depending upon the work
material to be extruded, Cylinder and Ram size.
 Extrusion Pressure The pressure range from 35 to 1000
mpa depending material to be extruded, temperature,
extrusion speed, reduction in area.
 Extrusion SPEED Depends on the work material. Light
alloys can be extruded with0.05 m/s where as copper alloys
can be extruded at 4.50m/s .
 DFECTS IN EXTRUSION

The defects in extrusion can be classified into three categories:

 Centre Burst Defect is an internal crack that develops as a
result of tensile stresses along the centre line of the part
during the extrusion process. Other names of centre burst is
Arrow head fracture, centre cracking and chevron cracking.
 Piping is a defect associated with a direct extrusion. It is the
formation of sink hole at the end o the billet. Other name of
piping is tailpipe and fishtailing.
 Surface cracking effect result from high work temperature
that causes cracks on the surface when extrusion speed is very
high. Other factors contributing to surface cracking are high
friction and surface chilling of high temperature bullets.
 TYPES OF EXTRUSION DIES

Normally three types of dies are used for extrusion Flat

face dies
 Pocket dies
 Feeder dies
MATERIAL FOR EXTRUSION DIES
 The material used for extrusion are:
 Hot die steel H 13
 Tungston carbide
 HSS hot work tool steel such as DAC DAC3 D 10
DAC 40
 TYPES OF EXTRUSION PROCESES

 The different types of Extrusion Processes are classified as under

 HOT EXTRUSION PROCESS
 Forward Hot Extrusion This process signifies the flow of the material in
forward direction Le. the same as that of the ram. In forward extrusion the
problem of friction is prevalent because of the relative motion between the
heated metal billet and the cylinder walls. This is particularly severe in the
case of steels because of their higher extrusion temperature. To prevent this
lubricants are used. At lower temperatures mixture of oil an graphite is
generally used. At high temperatures molten glass is used .
 Backward Hot Extrusion In order to completely overcome the friction, he
backward hot extrusion is used in this the metal is confined fully by
cylinder. The ram which houses the die, also compresses the metal against
the container, forcing it to flow backwards through the die in the hollow
plunger or cat is termed backwards because of the opposite direction of the
flow of metal to that of ram movement. The disadvantage of backward
extrusion is that the surface defects of the billet would end up in the final
product. This process is not extensively used because of the problem of
handling extruded material coming though the ram.
 COLD EXTRUSION

Forward Cold Extrusion.

 This process is similar to that of forward hot extrusion except for
the fact that the extrusion ratio possible are lower that of extrusion
pressures higher than that of the hot extrusion. Normally used for
simpler shapes requiring better surface finish and Improves
mechanical properties such as cans, various aluminium bracket,
shocker absorber cylinder etc
IMPACT EXTRUSION
 Backward cold extrusion is called Impact extrusion, the set up
consists of a die and a punch. The slug for making the component is
kept on the die and the punch strikes the slug against the die. The
metal is then extruded thought the gap between the punch and die
opposite to the punch movement Because of the impact force the
side walls go straight along he punch. This process is used for
making the collapsible pipes for making housing.
COLD EXTRUSION FORGING
 Cold extrusion forgings is similar to Impact extrusion but with the main
difference that the side walls are much thicker and their height is smaller.
This also contains die and punch As the punch slowly descends over the
slug kept on the die, thus forging some metal between the punch and die
and the rest being extruded through the clearance between the punch and
die. The side walls thus generated are short and thick with and with any
profile in the end unlike the impact extrusion. Afterwards the component is
ejected by means of the ejector pin provided in .
HYDROSTATIC EXTRUSION
 In this process the metal billet is compressed from all side by a liquid
rather than the ram. Presence of liquid inside the container eliminates the
need for any lubricant and also the material is more uniformly compressed
from all sided throughout the deformation zone. Bof this highly brittle
material such as grey cast iron can also be extruded
 EXTRUSION OF TUBES

 Hollows objects like tubes and other shapes can also be obtained by
forwards hot extrusion. One way of obtaining a tube is by means of
a solid ram in a double action as in fig. First the solid ram moves
through the heated metal billet creating a hole at the centre . Later
the hollow plunger moves the metal billet through the die. Because
of the presence of the solid ram very close to the die, the necessary
hole is made in the extruded metal.
 Another way of obtaining hollow shapes is by the use of a spider
extruding die. The spider die is essentially an extrusion die with a
mandrel., for the hollow portion to be generated. It is held to the die
by means of It thin ribs simulating the spider legs. The material
when extrude, flow through the opening between the legs and forms
as the central opening because of the stub mandrel. The Metal
flowing out is actually divided but get welded together since it is still
in plastic state.
Extruding tubes in a double action press
Spider die for hollow shapes
Cold extrusion forging
Cold extrusion pressures
Backward hot extrusion process
Typical extrusion setup
Typical extrusion shapes