Ain Shams University Faculty of Engineering Design & Prod. Dept.

Metal Extrusion
Definition

Production Engineering st 1 Year Mechanical

Dr. tayseer

Extrusion is the conversion of an ingot or billet into lengths of uniform cross section by forcing metal to flow plastically through a die.

Classification of Extrusion Processes

Direct Extrusion [Forward Extrusion]: The metal billet is placed in a container and driven through the die by the ram (extrusion ram and metal flow are in the same direction); high forces are required to overcome the metal deformation and the friction between the billet and container [Stationary container & die and moving ram] during process.

Indirect Extrusion [Backward Extrusion]: The extrusion die is fixed to a hollow ram (extrusion ram and metal flow are in opposite direction); the required extrusion forces are lower because of no relative movement between billet and container. [Stationary ram & die and moving container]

Lecture Notes

Metal Extrusion

Ain Shams University Faculty of Engineering Design & Prod. Dept.

1. Direct Extrusion 2. Indirect Extrusion A. The billet is upset to fill the container. B. further compression until the beginning of metal flow through the die.

Production Engineering st 1 Year Mechanical

Dr. tayseer

C. Extrusion proceeds. D. Piping defect occurs. E. Formation of dead metal zone.

Lecture Notes

Metal Extrusion

Ain Shams University Faculty of Engineering Design & Prod. Dept.

Impact extrusion: Impact extrusion is a special process to form hollow shapes with short lengths. Typical product is collapsible toothpaste aluminum tube. As shown in figure, the die has an accurate outside diameter of the tube and a punch having an accurate inside diameter of the tube strike the billet at high velocity. It is a restricted process to soft metals such as aluminum, copper, tin and lead.

Production Engineering st 1 Year Mechanical

Dr. tayseer

Extrusion Forging: Extrusion forging is a combined process of forging and extrusion. A common example is the production of engine valves, where the billet is partially extruded to form the valve shank, and the rest of the billet is forged to form the valve head.

Lecture Notes

Metal Extrusion

Ain Shams University Faculty of Engineering Design & Prod. Dept.

Hydrostatic Extrusion: In hydrostatic extrusion, a pressurized fluid is used instead of extrusion ram to act on the billet sides and back face, the advantages of this process are no frictional forces, and the billet need not to be of the same shape as the container. Typical products are stepped shafts.

Production Engineering st 1 Year Mechanical

Dr. tayseer

Lecture Notes

Metal Extrusion

Ain Shams University Faculty of Engineering Design & Prod. Dept.

Production of Hollow Shapes and Tubes:
Tube Extrusion:

Production Engineering st 1 Year Mechanical

Dr. tayseer

Tubes and hollow sections can be produced by extrusion by attaching a mandrel, the clearance between the mandrel and die wall determines the wall thickness of the tube. Fixed Mandrel:

Moving Mandrel:

Lecture Notes

Metal Extrusion

Ain Shams University Faculty of Engineering Design & Prod. Dept.

Porthole or Spider Die: Porthole dies are suitable for very long section of different hollow shapes, and for thin wall thickness or small dimensions. The metal (Aluminum) flow through the holes and then pressure welded during deformation at die outlet.

Production Engineering st 1 Year Mechanical

Dr. tayseer

Lecture Notes

Metal Extrusion

Ain Shams University Faculty of Engineering Design & Prod. Dept.

Extrusion Die

Production Engineering st 1 Year Mechanical

Dr. tayseer

Extrusion dies are made from different types of hot working tool steels. The figure below shows schematic sketches for (a) Taper die for hot extrusion of steels with molten glass as a lubricant, and (b) flat die commonly used for non-ferrous materials. The cross section explains the entrance angle, die land and relief angle.

Lecture Notes

Metal Extrusion

Ain Shams University Faculty of Engineering Design & Prod. Dept.

Production Engineering st 1 Year Mechanical

Dr. tayseer

Lecture Notes

Metal Extrusion

Ain Shams University Faculty of Engineering Design & Prod. Dept.

Metal Flow in Extrusion:

Production Engineering st 1 Year Mechanical

Dr. tayseer

The flow pattern in extrusion is important because of its effect on the quality and mechanical properties of the final product, where the improper metal flow during extrusion can produce various defects. In extrusion metal flow longitudinally like a fluid flow, so the extruded products have an elongated grain structure.

A common technique for investigating the flow pattern is to section the billet into two longitudinal halves and mark the sectional face with a square grid pattern, the two halves are placed in the chamber together and partially extruded, and then they are taken apart and studied.

Low friction

High Friction

Dead Metal zone

Lecture Notes

Metal Extrusion

Ain Shams University Faculty of Engineering Design & Prod. Dept.

Extrusion Defects:

Production Engineering st 1 Year Mechanical

Dr. tayseer

Due to improper material conditions and process variables, several types of defects can be developed in extruded products. There are three principle extrusion defects: Surface cracks (also called speed cracks) Cause: high speed or high speed and friction. These cracks are intergranular (along the grain boundaries) and are usually caused by hot shortness. Hot shortness is the tendency for some alloys to separate along grain boundaries when stresses of deformed at high temperatures due to the low melting point constituents segregated at grain boundaries. Solution: Reduce billet temperature and extrusion speed. Piping (also called fish tailing) Cause: Surface oxides and impurities. According to the metal flow pattern, surface oxides and impurities are drawn towards the center during deformation, as much as one third of the extruded product length may contain this type of defect, and have to be cut off as scrap. Solution: Piping can be minimized by modifying the flow pattern and controlling friction, or by machining the billet outer surface before extrusion to remove surface scales. Internal cracks Cause: high internal stresses at the centerline. Internal cracks are due to high internal stresses near the centerline in the deformation zone of the extrusion die. The tendency y for center cracking: Increases with the increase of die angle and amount of impurities. Decreases with the increase of extrusion ratio and friction. Solution: Select proper die geometry and extrusion variables.

Lecture Notes

10

Metal Extrusion

Ain Shams University Faculty of Engineering Design & Prod. Dept.

Production Engineering st 1 Year Mechanical

Dr. tayseer

Lecture Notes

11

Metal Extrusion

Ain Shams University Faculty of Engineering Design & Prod. Dept.

Hot Extrusion & Cold Extrusion
HOT EXTRUSION is the process of forcing a heated billet to flow through a shaped die opening. The temperature at which extrusion is performed depends on the material being extruded. Hot extrusion is used to produce long, straight metal products of constant cross section, such as bars, solid and hollow sections, tubes, wires, and strips, from materials that cannot be formed by cold extrusion.

Production Engineering st 1 Year Mechanical

Dr. tayseer

Typical billet temperatures for hot extrusion

Material Lead alloys Magnesium alloys Aluminum alloys Copper alloys Titanium alloys Nickel alloys Steels

Billet Temp. C 90-260 340-430 340-510 650-1100 870-1040 1100-1260 1100-1260

Cold Extrusion Cold extrusion is a general term often denoting a combination of operations, such as direct or indirect extrusion and forging to produce short solid or hollow shaped products. Workpieces are often cup-shaped and have wall thicknesses equal to the clearance between the punch and die. Ductility must be restored between operations by annealing, and any scale formed during annealing must be removed by blasting or pickling before COLD EXTRUSION is so called because the slug or subsequent extrusion. preform enters the extrusion die at room temperature. Cold-Extruded Metals in the order Any subsequent increase in temperature, which may of decreasing extrudability are amount to several hundred degrees, is caused by the Aluminum and aluminum alloys, conversion of deformation work into heat. Cold copper and copper alloys, low- extrusion involves backward (indirect), forward carbon and medium-carbon (direct), or combined backward and forward (indirectsteels, modified carbon steels,

Lecture Notes

12

Metal Extrusion

Ain Shams University Faculty of Engineering Design & Prod. Dept.

low-alloy steels, and stainless direct). steels.

Production Engineering st 1 Year Mechanical

Dr. tayseer

Lecture Notes

13

Metal Extrusion

Ain Shams University Faculty of Engineering Design & Prod. Dept.

Metal Drawing

Production Engineering st 1 Year Mechanical

Dr. tayseer

This lecture is concerned with the plastic deformation of metals through conical tapered and circular dies. The forming process is called Drawing when the metal is forced through the die by tensile force applied to metal at the exit of the die, and it is called Extrusion when a compressive force is applied at the entry of the die. Rod and shape Drawing: In rod drawing operations, one end of the a bar is reduced or pointed, inserted through a die (with smaller cross sectional area than the original bar), gripped and pulled in tension, and drawing the remainder of bar through the die. The reduction in area per pass is usually restricted to (20% - 50%) to avoid tensile fracture. Therefore, multiple draws through a series of dies may be required to produce a desired final size. Intermediate annealing may be required to restore ductility and enable further working. Tube Drawing: Tube drawing is a reduction process in which one end of a tube is grasped and pulled through a die that is smaller than the tube diameter. To obtain the desired size, a series of successive reductions, or passes, may be necessary. Because of its versatility, tube drawing is suited for both small and large production runs.

With floating Mandrel

Fixed Mandrel Without mandrel

Lecture Notes

14

Metal Extrusion

Ain Shams University Faculty of Engineering Design & Prod. Dept.

Production Engineering st 1 Year Mechanical

Dr. tayseer

Wire Drawing: Wire drawing is a metal-reducing process in which a wire rod is pulled or drawn through a single die or a series of continuous dies, thereby reducing its diameter. Because the volume of the wire remains the same, the length of the wire changes according to its new diameter. Various wire tempers (hardness) can be produced by a series of drawing and annealing operations. A wire drawing die is a tool that consists of a highly polished, shaped hole through which wire is drawn to reduce its diameter. The choice of die material, viz. natural or synthetic single crystal diamond, polycrystalline diamond, carbide etc. depends on the material of the wire to be drawn and the operating parameters.

Extrusion Stresses & Drawing Stresses

Extrusion ratio R is determined by dividing the original area undergoing deformation by the final deformed area of the workpiece: [R= AO/AF]. Because volume remains constant during extrusion, the extrusion ratio can also be estimated by increase in length. An extrusion ratio of 4 to 1 indicates that the length has increased by approximately a factor of four. The metal being extruded has a large effect on the maximum ratio that is practical. Some typical approximate maximum extrusion ratios are 40 for (aluminum alloy 1100), 5 for (1018 steel) and 3.5 for (type 305 stainless steel) and similar austenitic grades.

Extrusion

Drawing

Reduction Ratio = (AO-AF)/AO True Strain = Ln (LO/LF) = Ln (AF/AO)

AO = Original Billet Area AF = Final Extruded Bar Area

Reduction Ratio = (AO-AF)/AO True Strain = Ln (LF/LO) = Ln (AO/AF)

AO = Original Billet Area AF = Final Extruded Bar Area

Axial Stress Lecture Notes

= yield Ln (AF/AO)

Axial Stress 15

= yield Ln (AO/AF) Metal Extrusion

Ain Shams University Faculty of Engineering Design & Prod. Dept.

= yield Ln (dF/dO)2 =2 yield Ln (dF/dO) Axial Force = Axial Stress * AO

Production Engineering st 1 Year Mechanical

Dr. tayseer

= yield Ln (dO/dF)2 =2 yield Ln (dO/dF) Axial Force = Axial Stress * AF

Lecture Notes

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Metal Extrusion