EXTRUSION
Extrusion is defined as a process in which a block of metals placed in
a chamber is reduced in cross-section by forcing through a die
opening either in hot or in cold state by using compressive force.
The process may be viewed a squeezing toothpaste out of a
toothpaste tube.
CLASSIFICATION OF EXTRUSION
According to the movement of the ram and the extruded product:
Direct (Forward) and indirect (Backward) extrusion
According to the working temperature:
Hot and Cold extrusion
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Direct extrusion (Simpler than indirect extrusion)
A small portion of the billet cannot be extruded through the die opening
as the ram approaches the die. This extra portion, called the butt, is
separated from the product by cutting it just beyond the exit of the die.
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DISADVANTAGES:
# High Friction between the work surface and the wall of the
chamber
# Results in the significant frictional loss
# Substantial increase in the extrusion load
To avoid this problem, a dummy block is often used between the ram
and the billet. The diameter of the dummy block is slightly smaller
than the billet diameter, so that a narrow ring of metal (mostly the
oxide layer) is left in the container, leaving the final product free of
oxides.
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Direct extrusion for production of hollow shapes
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Indirect Extrusion
Comparison:
± no friction at the container walls,
± the ram force is lower than in direct extrusion and the power
required is lower than the direct extrusion by 25 to 30%.
± limitations of indirect extrusion are imposed by the lower
rigidity of the hollow ram and the difficulty in material handling
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ANALYSIS OF EXTRUSION PROCESS
Variables in extrusion process
One important parameter in extrusion
process is Extrusion Ratio (also called
reduction ratio) “r” is defined as
The true strain is given by
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Under the assumption of ideal deformation (no friction and no
redundant work), the pressure (p) applied by the ram to compress the
billet through the die opening can be determined as:
p∝ 𝜺
𝑨𝒐 𝑫𝒐
𝒑 = 𝑪𝜺 = 𝟐𝒍𝒏(𝒓) = 𝑪𝒍𝒏 = 𝟐𝑪𝒍𝒏
𝑨𝒇 𝑫𝒇
C = extrusion constant (MPa)
= Yield stress (o)
= Mean flow stress
The above equation determines pressure in an ideal condition in
frictionless condition.
𝑬𝒙𝒕𝒓𝒖𝒔𝒊𝒏 𝒍𝒐𝒂𝒅, 𝑭𝒆 = 𝒑 × 𝑨𝒐 (Straight Extrusion)
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The following empirical equation proposed by Johnson for estimating
extrusion is generally used
Is extrusion strain; and a and b are empirical constants for a
given die angle
Typical values of these constants are: a = 0.8 and b= 1.2 to 1.5.
Values of a and b tend to increase with increasing die angle
The ram pressure to perform indirect extrusion can be
estimated based on Johnson’s extrusion strain formula
as follows:
𝒑 = 𝑪𝜺𝒙 for indirect extrusion
𝑭𝒐𝒓𝒄𝒆, 𝑭𝒆 = 𝒑𝑨𝒐
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In direct extrusion, the effect of friction between the container walls
and the billet is high resulting in the higher ram pressure than for
indirect extrusion. The expression which isolates the friction force in
the direct extrusion container is given by
Eqn. 1
pf = the additional pressure required to overcome friction
A0 = billet original cross-sectional area is given by
D0= original diameter of the billet
=coefficient if friction
pc= pressure of the billet against the container wall
= coefficient of friction at the container wall
DoL = area of the interface between billet and container wall
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If sticking occurs at the container wall then the friction stress equals
shear yield strength of the work metal. In that case we have
where, o = shear yield strength of the material, We can assume
average flow stress during deformation. Then pf is given by
Additional pressure required
Applying the above reasoning, the ram pressure in direct extrusion
is given by
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Ram pressure as a function of ram stroke
Power require (P)
𝑷 = 𝑭𝒆 𝒗
Fe = Extrusion force
V = ram velocity
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The shape of the die orifice affects the ram pressure required to
perform an extrusion operation. A complex cross section requires
a higher pressure and greater force than a circular shape. The
effect of the die orifice shape can be assessed by the die shape
factor, defined as the ratio of the pressure required to extrude a
cross section of a given shape relative to the extrusion pressure
for a round cross section of the same area.
𝟐.𝟐𝟓
𝑪𝒙
𝑲𝒙 = 𝟎. 𝟗𝟖 + 𝟎. 𝟐
𝑪𝒄
Kx = die shape factor in extrusion
Cx = Perimeter of the extruded section, mm
Cc = Perimeter of a circle of the same area as the extruded shape, mm
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For shapes other than round, the corresponding expression for
indirect extrusion is
𝒑 = 𝑲𝒙 𝑪𝜺𝒙
For direct extrusion,
𝟐𝑳
𝑷 = 𝑲𝒙 𝑪 𝜺 𝒙 +
𝑫𝒐
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OTHER EXTRUSION PROCESSES
Impact Extrusion (Cold working Process)
Extruded Part
Forward impact extrusion
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Backward impact extrusion
Backward impact extrusion is most common. Products made by this
process include toothpaste tubes and battery cases. Very thin walls are
possible on impact extruded parts. The high-speed characteristics of
impacting permit large reductions and high production rates, making this
an important commercial process.
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Hydrostatic Extrusion
Hydrostatic pressure on the work increases the material’s
ductility. Hence the process can be used on metals that would be
too brittle for conventional extrusion operations.
One of the disadvantages of the process is the required
preparation of the starting work billet. The billet must be formed
with a taper at one end to fit closely into the die entry angle.
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The absence of billet and container interface friction increases the tendency of
formation of internal cracks in the extruded products. This problem can be
overcome by receiving the extruded product in chamber at the die end maintained
approximately at a pressure half of that used in extrusion.
DEFECTS IN EXTRUDED PRODUCTS
Centre-burst This defect is an internal crack that develops as a result
of tensile stresses along the centreline of the work piece
during extrusion.
Conditions that promote centre-burst are high die
angles, low extrusion ratios, and impurities in the
work metal that serve as starting points for crack
defects.
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Piping (tailpipe and fishtailing
Piping is a defect associated with direct
extrusion. It is the formation of a sink hole in
the end of the billet. The use of a dummy block
whose diameter is slightly less than that of the
billet helps to avoid piping.
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Surface cracking
This defect results from high work piece
temperatures that cause cracks to develop at
the surface. They often occur when extrusion
speed is too high, leading to high strain rates
and associated heat generation. Other factors
contributing to surface cracking are high
friction and surface chilling of high temperature
billets in hot extrusion.
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EX: A cylindrical billet that is 100 mm long and 40 mm in diameter is reduced by
indirect (backward) extrusion to a 15 mm diameter. Die angle = 90°. If the Johnson
equation has a = 0.8 and b = 1.5, and the flow curve for the work metal has K = 750
MPa and n = 0.15, determine: (a) extrusion ratio, (b) true strain (homogeneous
deformation), (c) extrusion strain, (d) ram pressure, and (e) ram force
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Q. A heated billet of steel at 700 C is to be extruded from an initial
diameter of 100 mm to a final diameter of 50 mm. Determine the force
required for extrusion if the extrusion constant is given as 250 MPa.
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