Extrusion, Shearing and Drawing

Extrusion
Compression forming process in which work
metal is forced to flow through a die opening
to produce a desired cross-sectional shape.
In general, extrusion is used to produce long
parts of uniform cross sections

Two basic types:

Direct extrusion
Indirect extrusion

Direct Extrusion
Also called forward extrusion
As ram approaches die opening, a small
portion of billet remains that cannot be
forced through die opening
This extra portion, called the butt, must be
separated from extrudate by cutting it just
beyond the die exit
Starting billet cross section usually round
Final shape of extrudate is determined by die
opening

Indirect Extrusion
Also called backward extrusion and
reverse extrusion
Limitations of indirect extrusion are
imposed by
Lower rigidity of hollow ram
Difficulty in supporting extruded product
as it exits die

Advantages of Extrusion
Variety of shapes possible, especially
hot extrusion
Grain structure and strength enhanced
cold and warm extrusion
Close tolerances possible, especially
cold extrusion
In some operations, little or no waste
material

in
in
in
of

Extrusion Defects

Hot vs. Cold Extrusion

Hot extrusion - prior heating of billet to
above its recrystallization temperature
Reduces strength and increases ductility of
the metal, permitting more size reductions
and more complex shapes
Cold extrusion - generally used to produce
discrete parts
The term impact extrusion is used to
indicate high speed cold extrusion

Shearing
Shearing in continuum mechanics refers to the
occurrence of a shear strain, which is
a deformation of a material substance in which
parallel internal surfaces slide past one
another. It is induced by a shear stress in the
material. Shear strain is distinguished from

volumetric strain, the change in a material's

volume in response to stress.

Shearing of sheet metal between two cutting edges:

(1) Just before the punch contacts work;
(2) Punch begins to push into work, causing plastic
deformation;
Shearing of sheet metal between two cutting edges:
(3) Punch compresses and penetrates into work
causing a smooth cut surface;
(4) Fracture is initiated at the opposing cutting
edges which separates the sheet.

Shearing operation: (a) side view of the shearing

operation; (b) front view of power shears equipped
with inclined upper cutting blade.

Deep drawing
Sheet metal forming to make cup-shaped, boxshaped, or other complex-curved, hollow-shaped
parts
Sheet metal blank is positioned over die cavity
and then punch pushes metal into opening
Products: beverage cans, automobile body
panels

Applications: bar, tube and wire drawing