Extrusion

Mechanism
For analysing, Extrusion process can be
divided into two parts:
Conical Section
Cylindrical Section

For Conical Section, analysis is same as that for drawing except

(a ) to find constant of integration , theend condition is ,

at r r f , x 0
(b) b xi
(c) x is compressive instead of tensile

xi

ri 2
y r 1
f

R 1 A

y R 1

Fxi

where , R

ri
rf

Ai
Af

extrusion ratio

Force required to overcomefrictionin cylindrical zone,

F f pd i l
kd i l

y
3

d i l

Therefore,totalload required

ri 2

y r 1 Ai
y dil
3
f

Determination of frictional power loss:

Cylindrical Zone :
Pf i

y
3

d i l VBB

Conocal Zone :
Frictional Force on elemental strip :
p 2r sindr
Frictional Power loss on elemental strip :
V
p 2r sindr cos

2kr

dr
sin . cos

ri 2
VBB . r

Frictional Power loss in Conical Zone :

ri

Pf i

2k
sin . cos

.VBB .ri 2

dr
r

rf

Pf i 2

VBB
3 sin . cos

r
.ri 2 ln r i
f

Extrusion Process

Examples of Extruded Parts

Types of Extrusion
Hot
Direct Extrusion
Indirect Extrusion

Cold
Direct Extrusion
Hydrostatic Extrusion

Indirect Extrusion
Impact Extrusion
Cold Extrusion Forging

Coaxial Extrusion
Lateral Extrusion

Direct Extrusion

Types of Extrusion

(a) indirect; (b) hydrostatic; (c) lateral.

Cold Extrusion

Examples of cold extrusion.

Thin arrows indicate the direction of metal flow during extrusion.

Impact Extrusion

Extrusion Defects
Surface Cracking
Fir-tree cracking or Speed Cracking
Bamboo Defects

Pipe/tailpipe/fishtailing
Internal Cracking/Chevron Cracking/
centre-burst/arrowhead fracture

Chevron Cracking
(b)
(a)

(a) Chevron cracking (central burst) in extruded round steel bars. Unless the
products are inspected, such internal defects may remain undetected, and
later cause failure of the part in service. This defect can also develop in the
drawing of rod, of wire, and of tubes.
(b) Schematic illustration of rigid and plastic zones in extrusion. The tendency
toward chevron cracking increases if the two plastic zones do not meet. Note
that the plastic zone can be made larger either by decreasing the die angel or
by increasing the reduction in cross-section (or both).

Types of Metal Flow in Extrusion

(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 defect.

Thanks