Extrusion process Extrusionprocess

Theprocessofextrusionissimplyforcingabilletofmetalthrough
ashapeddietoproduceacontinuouslengthofconstantsection
similartothedieprofile.
Pb,AlandCuextensivelyextruded.
Generallyhydraulicallyoperated.
Generallycompletedinahorizontaldirection.
Capacitiesofover200MN arealsoused.
Hotmetalextrusioninvolvespreheatingthebilletpriorto
extrusiontoreducetheworkrequiredtoextrudethesection.
T i l C f t i t l f TypicalCurvesofextrusionpressurevs ramtravelfor
directandindirectextrusion.
There are three basic extrusion processes ,
i i Direct extrusion,
indirect extrusion, and
h d i i hydrostatic extrusion.
The most widely used process The most widely used process.
The metal is placed in container and driven through the
die by the ram.
d bl k l l h d f A dummy block or pressure plate is place at the end of
the ram in contact with the billet.
In direct extrusion, the frictional forces are the highest g
among all the extrusion process due to the direct contact
of the billet and container walls.
Indirectextrusion
a hollow ram carries the die, while the other end of the container is
closed with a plate closed with a plate.
Normally the ram containing the die is kept stationary and the container
with the billet is used to move.
Since there is no relative motion between the wall of the container and Since there is no relative motion between the wall of the container and
the billet in indirect extrusion the friction forces are lower and the power
required for extrusion is less than for direct extrusion.
Th li it ti i th t th li it ti f th l th f th d th t b The limitation is that the limitation of the length of the rod that can be
extruded as well as limitation of loads which can be applied. Indirect
extrusion more efficient and produced higher quality products.
Hydrostaticextrusion y
Process in which the billet is completely circumscribed by a pressurized
liquid in all the sides except the region where billet is in the contact with
die. d e
This process can be carried out in many ways including warm, cold or
hot but due to the stability of the used fluid, the temperature is limited.
Hydrostatic extrusion has to be carried out in a completely sealed Hydrostatic extrusion has to be carried out in a completely sealed
cylinder for containing the hydrostatic medium.
AdvantagesofHydrostaticExtrusion
No friction amidst the container and billet. This minimizes the
force requirements, allowing higher reduction ratios, faster
speeds, & lower billet temperatures.
Friction of the die can be largely reduced by a film of pressurized
lubricant amidst the die surface and deforming metal. g
On applying high pressures, the ductility of material increases.
Even flow of material.
Large billets & large cross sections are extruded Large billets & large crosssections are extruded.
Uniform hydrostatic pressure inside the container eliminates the
requirement of billets being straightened.
No billet residue is left on the walls of container
DisadvantagesofHydrostaticExtrusion
The billets have to be prepared by tapering one end so that it matches The billets have to be prepared by tapering one end so that it matches
the die entry angle. This is essential for forming a seal at the starting
of the cycle. Generally, the complete billet is required to be machined
for the removal of surface defects for the removal of surface defects.
It can be difficult to contain the fluid, under the effects of high
pressures (up to 2 GPa, or 290 ksi).
LimitationsofHydrostaticExtrusion
Increasedhandlingfortheinjectionandremovalofthefluidfor
every extrusion cycle everyextrusioncycle.
Decreasedcontrolofspeedofthebillet&stoppingbecauseof
potentialstickslipandenormousstoredenergyinthecompressed
fl id fluid
Decreasedprocessefficiencyintermsofbillettocontainervolume
ratio
h d li i h i i d l d Enhancedcomplications,whenextrusionisdoneatelevated
temperatures.
Impact extrusion:
Process used to produce short lengths of hollow pipes like collapsible Process used to produce short lengths of hollow pipes like collapsible
tooth paste tubes. It may be either indirect or direct extrusion and is
usually performed on a high speed mechanical Press. Though the
process is done in cold condition large amount of heat is generated process is done in cold condition, large amount of heat is generated
due to the high speed deformation.
Extrusion ratio is the ratio of initial cross sectional area of the billet
to the final cross sectional area after extrusion.
R = Ao/Af. Extrusion ratios o reach from about 40:1 for hot extrusion
of steel and may be as high as 400:1 for aluminum. The distinction
between extrusion ratio (R) and Fractional reduction in area( r). between extrusion ratio (R) and Fractional reduction in area( r).
The change in fractional reduction from 0.95 to 0.98 appears relatively
small, yet it corresponds to a change in area ration from R = 20:1 to R =
50:1.
The velocity of the extrude product is the ram velocity x R so that high y p y g
sliding velocities can be achieved along the die land. The extrusion
pressure is directly related to the natural logarithm of the extrusion ratio,
so that extrusion force may be expressed as y p
Mostmetalsareextrudedhotsoastotakeadvantageofthedecreaseinflow
stresswithincreaseintemperature.
Steelbilletsareheatedintherange1100to1200C.whilethetoolingis
preheatedto350C.
The combination of high stress and tmepeature necessitates use of galss Thecombinationofhighstressandtmepeature necessitatesuseofgalss
lubrication.
Aluminium isextrudedwithoutanylubrication.
Increaseinramspeedresultsinincreaseinextrusionpressure.
A t f ld i i d lt i b t 50 % i i Atenfoldincreaseinspeedresultsinabout50%increaseinpressure.
Atlowerspeeds,billetcooingwillbedominatingresultinginincreaseinextrusion
pressure.
(a) Low container friction with well lubricated billet Nearly homogeneous (a) Lowcontainerfrictionwithwelllubricatedbillet.Nearlyhomogeneous
deformation.Deformationisuniformuntilclosetothedieentrance.
(b) Increasedcontainerwallfrictionshownbyseveredistortionofgridpatternin
the corner to produce a dead metal zone. The elements at thee centre of then thecornertoproduceadeadmetalzone.Theelementsattheecentreofthen
billetundergopureelongationwhileneartothesidesofthebilletundergo
sheardeformation
(c) Highfrictionattheinterface,flowisconcentratedtowardsthecentreandan g
internalplanedevelops.Thiscanalsooccurwhenthebilletischilledby
container.
(d) Indirectextrusion