Metal extrusion

Process

Extrusion is a compression process in which work metal is forced to flow through a die opening
to produce a desired cross-sectional shape. The process is like squeezing toothpaste out of a
toothpaste tube. Lubricant is provided to ease the passage of the metal through the die. Extrusion
process is usually classified based on the physical configuration and working temperature.

Based on physical configuration it is classified as: direct extrusion and indirect extrusion.
Direct extrusion is also called forward extrusion. In the direct extrusion process the metal
billet is loaded into the container and the ram compresses the metal billet. The flow of
material occurs in the direction of application of force through the opposite end as shown
in the Figure M4.1.1. Hollow sections are possible to create by this process setup as
shown in Figure M4.1.2. Indirect extrusion is also called backward extrusion process. In
the backward extrusion process, the die is mounted on the ram. As the ram penetrates into
the work, the metal is forced to flow through the die in the opposite direction of motion
of the ram as shown in the Figure M4.1.3.

Figure M4.1.1: Direct Extrusion

 Figure M4.1.2: Direct Extrusion to produce hollow cross-section

Figure M4.1.3: Indirect Extrusion

Based on working temperature, classification of extrusion is as: hot extrusion and cold
extrusion. Hot extrusion involves prior heating of billet to a temperature above its
crystallization temperature. Cold extrusion is usually used to produce parts at room
temperature.
Typical parts and applications

Any part with constant cross-section can be produced by this method. Cross-section that cant be
produced by normal machining process are often more economical by the extrusion process. A
standard method of measuring capacity is used called circumscribingcircle-diameter (CCD).
This is the size of circle into which the cross section will fit. For aluminum, the minimum CCD
is 6.3mm and maximum CCD is 1.02m. For steel the diameter is small. Maximum CCD for steel
is 150mm. In fact, extrusion over 30m in length and 1 Ton in weight can be made. Wall
thickness for aluminum ranges from 1mm upward. For carbon steel, the minimum is 3.2 mm and
for stainless alloys 4.8mm.

Suitable material for extrusion

Two factors affect the ease with which the metal can be extruded namely, required temperature
and the temperature range. If the required temperature for extrusion is low and available
temperature range is wide the extrusion will be better. The most common metals used for the
extrusion are the following (listed in order of extrudability):

Aluminum and aluminum alloys

Copper and copper alloys

Magnesium

Low-carbon and medium-carbon steels

Modified-carbon steels

Low-alloy steels

Stainless steels

General design recommendation

Though complicated shapes are possible to create, it is advisable to use standard cross-section
whenever possible as shown in Figure M4.1.4.
 Figure M4.1.4: Standard extruded shapes available.

The problem with complicated shapers are: metal flows less readily into narrow and irregular die
section, distortion and other quality problems, price of the customized dies are higher.

Detail design recommendation

The various design recommendations are as follows:

Sharp corners are avoided for both internal and external corner of extruded part. If
sharp corners are used various problems encountered are: less smooth flow of
material through the die, increase tool wear, increased possibility of tool breakage,
less strength in the part due to stress concentration. Recommended minimum radii for
various metals and alloys are summarized in Table M4.1.1 for guidance. Figure
M4.1.5 shows the good and bad practice in the design of cross-section of component
to be extruded.
 Figure M4.1.5: Good and bad practice in the design of cross-sections to be extruded
Table M4.1.1: Recommended minimum corner and fillet radii. (Source: Design for
Manufacturability Handbook by James G Bralla, 2nd Ed)

Material Corners, mm Fillets, mm

Aluminum, magnesium, and copper alloys
As extruded 0.75 0.75
After cold drawing 0.4 0.4
Ferrous metals, titanium, and nickel alloys
As extruded 1.5 3
After cold drawing 0.75 1.5

Section walls should be balanced as much as the design function permits as shown in
Figure M4.1.5.

Ribs are added in order to avoid the variation of flatness of a long thin section those
having critical flatness requirement as shown in Figure M4.1.6.

Figure M4.1.6: Ribs are added to the sections for long sections.
 Knife like edge part is avoided because it affects smooth flow of material through die.
Holes in nonsymmetrical shapes should be avoided in less extrudable material as
shown in Figure M4.1.7.

Figure M4.1.7: Knife edge should be avoided.

Abrupt changes in section thickness are avoided for less extrudable materials like
steel as shown in Figure M4.1.8.

Cant be extruded in steel Can be extruded in steel

Figure M4.1.8: Avoid abrupt changes in section thickness for less extrudable
materials

Recommendations for depth of indentation has been shown in the Figure M4.1.9.
 Figure M4.1.9: Design rules for indentations.

The ratio of length to thickness of any segment should not exceed 14:1. For
magnesium it is 20:1 as shown in Figure M4.1.10.

Figure M4.1.10: The length-to-thickness ratio of any section of an extrusion of steel

or other difficult-to-extrude material should not exceed14.
 Symmetrical cross sections are preferable to non-symmetrical designs to avoid
unbalanced stresses and warpage. Design recommendation has been shown in the
Figure M4.1.11.

Possible Sometimes preferable

Figure M4.1.11: Nonsymmetrical shape by extruding asymmetrical section and

dividing it in two.

Dimensional factor

Extrusion is a hot process and temperature and cooling rate variation affect the final dimension
of the extruded parts. Hence, extruded parts are more inherent to piece-to-piece and drawing-to-
piece dimensional variation than parts made with other processes.
Recommended tolerances

Table M4.1.2 summarizes the recommended tolerances for extruded parts for ferrous metal.

Table M4.1.2: Recommended Dimensional Tolerances for Ferrous-Metal Extrusions. (Source:

Design for Manufacturability Handbook by James G Bralla, 2nd Ed)

Dimension Tolerance
Cross-sectional dimensions
040 mm 0.5 mm
41120 mm 0.8 mm
121160 mm 1.2 mm
Over 160 mm 1.6 mm
Cross-sectional dimensions if cold-drawn after extrusion (all dimensions)
Angles 2
Surface finish 6.2 m
Flatness (transverse)
Dimensions to 25 mm 0.25 mm
Dimensions over 25 mm 0.1 mm/cm
Twist
Widest dimension, 60 mm 2 mm/m
Widest dimension, 61160 mm 3 mm/m
Widest dimension, 161 mm up 4 mm/m
Camber Maximum, 2 mm/m
Table M4.1.3: Recommended Dimensional Tolerances for Ferrous-Metal Extrusions. (Source:
Design for Manufacturability Handbook by James G Bralla, 2nd Ed)

Dimension Tolerance
Cross-sectional dimensions*
013 mm 0.25 mm
1438 mm 0.30 mm
39100 mm 0.50 mm
101200 mm 1 mm
201300 mm 1.6 mm
301500 mm 2.5 mm
Angles
Wall thickness, 05 mm 2
Wall thickness, 519 mm 112
Wall thickness, 19 mm or more 1
Surface finish (depth of surface defects)
Specified section thickness Maximum depth
To 1.5 mm 0.04 mm
1.56 mm 0.06 mm
612 mm 0.1 mm
12 mm and over 0.2 mm
Twist
Widest dimension Twist Per length Twist maximum
To 40 mm 3/m 7
4075 mm 112/m 7
75 mm and over 34/m 3
Camber (deviation from straightness)
Wall thickness Camber
To 2.5 mm 4 mm/m
Over 2.5 mm 1 mm/m
*Add 50% to these values if more than 25% of the dimension is over open space.