Lecture 10 - Bulk Forming - Reduction & Extrusion

Miskolci Egyetem Mechanikai Technológiai Tanszék
Metal Forming
Bulk metal forming
Extrusion and reduction processes
Prof. Dr. Miklós Tisza

Miskolci Egyetem
Képlékenyalakítás 1 12. előadás

Reduction processes
• Definition of reduction in bulk Schematic view of bulk reduction

forming
• Reduction is regarded as a bulk 

forming process where the main
aim of the process is to reduce the
billet diameter usually in a conical Fred
converging die as shown in the
figure
• An important pre-condition in
reduction that the billet cannot be
deformed outside the die.

Main application fields

• If only the diameter reduction of Some typical parts produced by
shaft-like component occurs bulk bulk reduction
reduction is the primary process.
• Reduction is often combined with
other bulk forming processes like
upsetting and extrusion.
• Reduction is also often used to
produce stepped shafts with
multiple reduction processes, e.g.
– shafts for electro-motors,
– pedals for bicycles, etc.
• as billet material usually drawn
bars are used.

Combined reduction and upsetting processes
• Combined application of reduction and

upsetting is often used in screw manufacturing. Combined application of reduction
and upsetting
• The d shaft diameter where the screw-thread
will be rolled is reduced to the mean thread
diameter.
redukálókúp
• Process steps fejező
α redukált
– The billet is pushed into the die by the szárrész
h a
forward movement of the header. d H7/h10
– When the end of the billet arrives to the d r

reduction die starting edge the reduction d
process starts with further movement of the 3
header.
– When the reduced part is stopped by the
ejector pin reduction is finished followed by kilökő matrica
the heading process.

The stress state in reduction
• The general solution of differential equation

m 1 m
z , ált zh zp
Ce k fk .
m
• The stress boundary condition
z z1 1
és z 1
0
• The final solution together with the additional stress component due to the
torsion in the cone
z ,teljes z ,id z , súrl z ,torz

k fk 1 0.77 .
• The stress condition of reducibility

 z ,max  k f 0
The forming force and die pressure
• The force of reduction
D2 D2 The pressure distribution

Fred z ,teljes
k fk max
1 0.77 . in the die
4 4 max
• Since the force of reduction is

calculated by the initial rod
diameter (initial billet cross
section), therefore, it is valid
Freduction > Fdrawing
• The pressure in the die may be
calculated by applying the yield
condition, i.e.
pb  k f   z

Extrusion
• Definition of extrusion
– extrusion is a bulk forming process when
» the billet is deformed by a compressive force exerted by the
punch,
» the material is deformed in a die which is closed in all direction
except the die orifice.
– The cross section of the component is always reduced in the
process.

Classification of extrusion processes
1. According to the material flow

– Forward (direct) extrusion: the material flows in the same direction as
the punch moves
– Backward (indirect) extrusion: the material flows in the reverse
direction of the punch movement.
– Forward/backward extrusion: the material flows in both directions.
2. According to the shape of the parts

– Extrusion of solid extrusion of hollow parts: parts should have hollow
sections, too.
– Mixed extrusion: parts have both solid and hollow sections.

Direct ()forward) extrusion of solid bars
punch
The most often applied billet

extrusion process to
produce parts with solid
cross-section extruded
die component
Main application fields
• Shaft-like components,
• Screw manufacturing,
• Production of solid
bolts, rivets, pins.
ejector

Forward (direct) extrusion of hollow parts
• It may be done applying

– tube preforms, or punch
– cup-like preforms
tube-like die
preform
• Main application fields component
– thin-walled cartridge-cases,
ejector

Direct (forward) extrusion of hollow parts from solid

preform applying a piercing counter punch
punch
• It is less often used than the

former process
• Typical application field

– production of wheel-nuts
for vehichles die
counter-punch
ejector

Backward (indirect) extrusion of hollow parts
• The most widely applied backward extrusion process

– Preform: thick disc-like billet
– Characteristic feature: different thickness along the wall and in the
bottom
punch
stripper component
preform
die

Direct/indirect extrusion of hollow parts
• It may be done
– both from solid and hollow preforms,
– with or without counter puncht
a) b)
Direct/indirect mixed extrusion
During the extrusion

• material flows
– partly in forward, punch
– partly in backward direction,
i.e. it is a double direction process.
• the component has
die
– both solid
– and hollow sections
This is why it is called as mixed
extrusion. ejector
• Tipical application field
– Production of telescope
containers

Analysis of the stress state

in forward extrusion of solid bars
• The general solution of the differential equation for conical converging dies
m 1 m
z , ált
Ce k fk .
m
• Stress boundary condition following from the process
z z z1 0.
1 m
C k fk em 1
• Since z=z1, j= j 1=2ln (R/rb), thus m
• and thus the final solution

1 m
z k fk 1 em 1


• The additional stress component arising from the torsion in the cone
z ,torz
0.77k fk
• which introducing it together with some elementary conversions leads to
z ,max
k fk 1
1 0.77 .
1
• A further additional stress component may be calculated due to the friction

along the recipient wall.


• Supposing Coulomb friction (t=mp) and nearly hydrostatic stress state in
the container (pkf0), the friction force may be calculated as
Fsúrl Asúrl k f 0 D h,
• and from it the additional stress component

Fsúrl kf 0D h 4 k f 0h
z , súrl 2
.
D Ap D
4
• Summing it up to the former solution obtained for the conical die
h
z , teljes
k fk 1
1 0.77 4 kf 0 .
1 D

Calculation of the extrusion force and work
• For the extrusion force we get
h D2
Fmax z ,max
Ap k fk 1
1 0.77 4 kf 0 ,
1 D 4
• and for the extrusion work
Wextr Fmax h c,
– where
» h the punch displacement,
» c the so-called filling coefficient of the extrusion force vs punch
displacement diagram, c=0.7-0.8.

Pressure distribution on the punch and

in the extrusion die
• The average pressure on the extrusion punch
Fmax h
pátl k fk 1
1 0.77 4 kf 0 ,
Ap 1
D
• The pressure distribution in the die may be determined starting out of the
yield condition
– The pressure in the conical die
pb kf z
.
– The pressure in the cylindrical recipient

r t z pr

Strength calculation of the punch and the die

in extrusion
• The strength calculation of the punch should be performed for permitted
surface pressure,
Fmax h
pátl k fm 1
1 0.77 4 kf 0 pmeg ,
Ap 1
D
• and it should be checked for buckling (Fmax)

h D2
Fmax z ,max
Ap k fk 1
1 0.77 4 kf 0 ,
1 D 4
• The die should be checked also for permitted surface pressure for its
highest value.

The pressure distribution in the extrusion die
• It may be concluded from the Pressure distribution in the die

figure
pb(z) kf(z)
– the axial stress is monotonically
increasing both in the cone and kfki
kf0
in the cylindrical recipient,
– there is a sharp discontinuity in z, max
pb(z)
the die pressure at the edge of z(z)
the cone entry
» The value of this
discontinuity may be taken
as Dp=kfo.
F
z=z0 z=z1 z

Determination of the billet diameter to get

equal strength solution in the head and the axis
Determination of the original billet diameter

– Basic principle: the volume constancy j fej  j szár
• The equal strength condition applying
extrusion and heading
d fej de
– The same strength can be get if 2 ln  2 ln
– The equivalent strain is also equal
de d szár
• From this condition the equations on the
right follow.
d e  d fej d szár

Billet preparation for extrusion
• Operation steps
– Cutting of the billet according to the volume constancy of the
billet and the final component
– Straitening with preforming
– Heat-treatment
– Surface treatment
» Surface coating with lubricant carrier
» lubrication

• Cutting may be done by

– swaging
– turning
– plain-strain cutting with cold deformation
• Straitening, preforming (calibrating)

– Deformation caused by cutting operation should be reduced even fully
diminish
– The preforming practically is an upsetting in closed die

• Heat-treatment is necessary
– Since there are very high strains in the extrusion process and,
– to get as mild materials before extrusion as possible
• The applied heat treatment

– Before extrusion: annealing for grain-coarsed pearlitic structure
– Intermediate heat-treatment: recrytallization annealing

• Appropriate surface treatment is the precondition of successful extrusion:

– burr removal in wear-drums
– removal of oxides and rust with
» mechanical
» chemical or
» electrochemical methods
• The most crucial element of surface treatment: surface coating
– coating with lubricant carrier (e.g. phosphating)
– lubrication

Tooling for direct extrusion of solid bars

1
2,3
4
5
6 8
10 9
11 12
13
14
component 15

Tooling for backward extrusion of cans

adjustable stops head
plate
pressure
plate
stripper
punch
die
extruded
part
Prestressing
ring
Counter
ejector
punch

Extrusion tool elements
dsz
a α=
17
0°
c
b dsz
α=
17
0°
0,3  0,7 d B
dB
Assembled pre-stressed die

dB
Solid and assembled punch

Lecture 10 - Bulk Forming - Reduction & Extrusion

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Miskolci Egyetem Mechanikai Technológiai Tanszék

Bulk metal forming

Extrusion and reduction processes

Prof. Dr. Miklós Tisza

Képlékenyalakítás 1 12. előadás

• Definition of reduction in bulk Schematic view of bulk reduction

• Reduction is regarded as a bulk 

Képlékenyalakítás 2 12. előadás

Main application fields

Képlékenyalakítás 3 12. előadás

Combined reduction and upsetting processes

• Combined application of reduction and

– When the end of the billet arrives to the d r

Képlékenyalakítás 4 12. előadás

The stress state in reduction

• The general solution of differential equation

z ,teljes z ,id z , súrl z ,torz

• The stress condition of reducibility

The forming force and die pressure

• The force of reduction

D2 D2 The pressure distribution

• Since the force of reduction is

Képlékenyalakítás 6 12. előadás

Képlékenyalakítás 7 12. előadás

Classification of extrusion processes

1. According to the material flow

2. According to the shape of the parts

Képlékenyalakítás 8 12. előadás

Direct ()forward) extrusion of solid bars

The most often applied billet

Képlékenyalakítás 9 12. előadás

Forward (direct) extrusion of hollow parts

• It may be done applying

• Main application fields component

Képlékenyalakítás 10 12. előadás

Direct (forward) extrusion of hollow parts from solid

• It is less often used than the

• Typical application field

Képlékenyalakítás 11 12. előadás

Backward (indirect) extrusion of hollow parts

• The most widely applied backward extrusion process

Képlékenyalakítás 12 12. előadás

Direct/indirect extrusion of hollow parts

Direct/indirect mixed extrusion

During the extrusion

Képlékenyalakítás 14 12. előadás

Analysis of the stress state

• and thus the final solution

Képlékenyalakítás 15 12. előadás

Analysis of the stress state

• which introducing it together with some elementary conversions leads to

• A further additional stress component may be calculated due to the friction

Képlékenyalakítás 16 12. előadás

Analysis of the stress state

• and from it the additional stress component

Képlékenyalakítás 17 12. előadás

Calculation of the extrusion force and work

• For the extrusion force we get

Képlékenyalakítás 18 12. előadás

Pressure distribution on the punch and

– The pressure in the cylindrical recipient

Képlékenyalakítás 19 12. előadás

Strength calculation of the punch and the die