Date-26/03/2024

NATIONAL INSTITUTE OF TECHNOLOGY

RAIPUR

METAL FORMING PROCESSES

EXTRUSION
- Types, Equipment, Defects and deformation,
Analysis

Name – Nikhil Nagpure

Roll no. – 21120073
Branch – Metallurgical And Materials Engineering
 What is Extrusion ?
Extrusion is the process by which a block/billet of metal is reduced in cross
section by forcing it to flow through a die orifice under high pressure.
The products obtained are also called extrusion.
 CLASSIFICATION OF EXTRUSION
Extrusion can ve classified on the basis of :

Extrusion

A. Direction B. Operating
temperature

Direct/ Forward/
Indirect Backward Hot Cold
extrusion extrusion extrusion extrusion
A. ON THE BASIS OF DIRECTION

DIRECT INDIRECT
EXTRUSION EXTRUSION
➢ The hollow ram Containing the die is kept ➢ The metal billet is placed in a container and
stationary and the container with the billet is driven through the die by the ram.
caused to move.
➢ The dummy block or pressure plate, is placed at
➢ Friction at the die only (no relative movement the end of the ram in contact with the billet.
at the container wall) → requires roughly
constant pressure. ➢ Friction is at the die and container wall requires
higher pressure than indirect extrusion.
➢ Hollow ram limits the applied load.
A. ON THE BASIS OF DIRECTION

FORWARD BACKWARD
EXTRUSION EXTRUSION
➢ Metal is forced to flow in the same ➢ Metal is forced to flow in the
direction as the punch. direction opposite to the punch
movement.
➢ The punch closely fits the die cavity
to prevent backward flow of the ➢ Metal can also be forced to flow into
material recesses in the punch
B. ON THE BASIS OF OPERATING TEMPERATURE

COLD EXTRUSION HOT EXTRUSION

➢ Cold extrusion is the process done at room temperature ➢ Hot extrusion is done at fairly high temperatures,
or slightly elevated temperatures. This process can be approximately 50 to 75% of the melting point of the
used for most materials-subject to designing robust metal.
enough tooling that can withstand the stresses created
by extrusion. Cold extrusion ➢ The most commonly used extrusion process is the
hot direct process. The cross-sectional shape of the
➢ Examples of the metals that can be extruded are lead, extrusion is defined by the shape of the die.Due to
tin, aluminium alloys, copper, titanium, molybdenum, the high temperatures and pressures and its
vanadium, steel. detrimental effect on the die life as well as other
components, good lubrication is necessary.
➢ Examples of parts that are cold extruded are
collapsible tubes, aluminium cans, cylinders, gear
blanks.
 Hot Extrusion Cold Extrusion
Advantages Advantages
1. Low force required. 1. High mechanical properties.

2. Easy to work in hot form. 2. High surface finish

3. Product is free from stain hardening 3. No oxidation at metal surface

Disadvantages Disadvantages
1. Low surface finish due to scale 1. High force required.
formation on extruded part.
2. Increase die wear 2. Product is accomplished with strain
hardening.
EXTRUSION EQUIPMENTS
Extrusion equipment mainly includes presses, dies and tooling.

1. PRESSES
Most extrusions are made with hydraulic presses classified based on the
direction of travel of the ram.
a) Horizontal presses
b) Vertical presses

2. EXTRUSION DIES
Die design, Die materials

3. TOOLS
Typical arrangement of extrusion tools.
1. PRESSES
HORIZONTAL VERTICAL
PRESSES PRESSES
➢ Used for most commercial extrusion of bars and ➢ Chiefly used in the production of thin-wall
shapes. tubing.
➢ Deformation is non-uniform due to different ➢ Easier alignment between the press ram and
temperatures between top and bottom parts of tools.
the billet. ➢ Higher rate of production.
➢ Proper alignment is needed ➢ Require less floor space than horizontal
➢ Floor space is needed presses.
➢ Uniform deformation.
2. a) DIE DESIGN

➢ Die design is at the heart of efficient extrusion production.

➢ Dies must withstand considerable amount of stresses, thermal
shock, and oxidation.

➢ Die design consideration

1. Wall thickness: different wall thicknesses in one section should be avoided.

2. Simple shapes: the more simple shape the more cost effective.
3. Symmetrical: more accurate.
4. Sharp or rounded corners: sharp corners should be avoided.
5. Size to weight ratio
6. Tolerances: tolerances are added to allow some distortions.
b) DIE MATERIALS

➢ Dies are made from highly alloy tools steels or ceramics

➢ Wall thickness as small as 0.5 mm (on flat dies) or 0.7 mm

(on hollow dies) can be made for aluminium extrusion.

➢ Heat treatments such as nitriding increases hardness

improving die life. → avoiding unscheduled press shutdown.

There are two general types of extrusion dies:

1) Flat-faced dies
2) Dies with conical entrance
TYPES OF EXTRUSION DIES

FLAT FACED DIES CONICAL DIES

➢ It is used when metal entering the die forms a ➢ The entrance side has conical shape and
dead zone and shears internally to form its own taper.
die angle. ➢ They are used in extrusion with good
➢ A parallel land on the exit side of the die lubrication.
strengthens the die. ➢ Die angle is decreased and this increases
➢ It also allows reworking of the flat face on the homogeneity of deformation and also
entrance side without increasing the exit reduces extrusion pressure.
diameter. ➢ If the angle is too small, it leads too high
friction in die surface. Hence an optimal angle
is necessary.
DEFORMATION IN EXTRUSION
a) Homogeneous Deformation
• The deformation is more uniform until close to the die
entrance where metal flow is restricted.

a) Deformation with more friction between billet and

container wall
• producing a dead zone of stagnant metal at corners which
undergoes little deformation.
• Essentially pure elongation in the centre and extensive shear
along the sides of the billet.
• The latter leads to redundant work

c) Deformation with very high friction

• For high friction at the container-billet interface, metal flow is
concentrated toward the centre and an internal shear plane
develops - due to cold container.

d) Homogeneous deformation in indirect extrusion

DEFECTS IN EXTRUSION
a) Inhomogeneous deformation
In direct extrusion provide the dead zone along the outer
surface of the billet due to the movement of the metal in the
center being higher than the periphery.
Cause : Non-uniform temperature distribution
Remedy: Optimise heating and preheating

b) Surface cracking
Cracks appear on the surface of extrude products
Cause : Rapid cooling Surface cracking
Remedy: Improve cooling control and lubrication

c) Chevron cracking
V-shape cracks along the surface
Cause : High extrusion speed
Remedy: Reduce extrusion speed
Chevron cracking
c) Variation in structural properties
Inconsistent grain structure
Cause : Inconsistent material flow
Remedy: enhance material homogenization

Variation in structural properties

d) Hot- shortness
Cracking and fracturing of material during hot working
Cause : High sulphur content
Remedy: Reduce sulphur content

Hot-shortness
EXTRUSION OF TUBING
a) Extrusion of tubing from a solid billet
To produce tubing by extrusion from a solid billet,
the ram may also be fitted with a piercing mandrel.
As the ram moves forward, the metal is forced over
the mandrel and through the hole in the die,
causing a long hollow tube. Just like toothpaste,
only hollow.

b) Extrusion of tubing from a solid billet

If the billets are hollow, a rod that matches the
diameter of the cast hole in the billet, but slightly
smaller than the hole in the die at the opposite
end of the chamber are used.
PRODUCTION OF SEAMLESS PIPING
➢ Extrusion is suited for producing seamless pipe and tubing, especially for metals which are difficult to
work.

➢ The red-hot billet is rotated and drawn by rolls over a piercing rod, or mandrel. The action of the rolls
causes the metal to flow over and about the mandrel to create a hollow pipe shell.

➢ After reheating, the shell is moved forward over a support bar and is hot- rolled in several reducing/sizing
stands to the desired wall thickness and diameter.

a) The Mannesmann mill b) The plug rolling mills c) The three-roll piercing d) The reeling mill burnishes
uses two barrel-shape drive the tube over a machine produces more the outside and inside
driven rolls, which are set at long mandrel containing concentric tubes with surfaces and removes the
an angle to each other a plug. smoother inside and outside slight oval shape.
surface.
THANK YOU