WORKSHOP PRESENTATION

EXTRUSION

Muhammad Umar Fayyyaz

Muhammad Asad Iqbal
Ammad Sadaqat
Shehzad Sabir
Waleed Naeem

14-ME-68
14-ME-54
14-ME-66
14-ME-42
14-ME-86

(Aluminum Extrusion)

What is extrusion?
Method of forming substances by
forcing them through a perforated plate
or die to produce tubes, rods, or other
desired
shapes
(like
squeezing
toothpaste out of a tube) under high
pressure.
In general, extrusion is used to
produce cylindrical bars or hollow
tubes or for the starting stock for
drawn rod, cold extrusion or forged
products.
Most metals are hot extruded
due to large amount of forces
required in extrusion. Complex
shape can be extruded from the
more readily extrudable metals
such as Aluminum.
The products obtained are also called
extrusion.

HISTORY:
In1797, JosephBramah patented the first extrusion process for
making lead pipe. It involved preheating the metal and then forcing it
through a die via a hand-driven plunger. The process was not further
developed until 1820 when Thomas Burr constructed the first hydraulic
powered press. At this time the process was called "squirting". In 1894,
Alexander Dick expanded the extrusion process to copper and brass alloys.

Process:
The process begins by heating the stock material
(for hot or warm extrusion). It is then loaded into the
container in the press. A dummy block is placed behind it
where the ram then presses on the material to push it out of
the die. Afterward the extrusion is stretched in order to
straighten it. If better properties are required then it may
be heat treated or cold worked.
The extrusion ratio is defined as the starting cross-sectional
area divided by the cross-sectional area of the final
extrusion. One of the main advantages of the extrusion
process is that this ratio can be very large while still
producing quality parts.

Classification of Extrusion Processes

There are several ways to classify metal extrusion processes;

By Direction

By Operating
Temperature

By Equipment

o
o

Direct / Indirect extrusion

Forward / backward extrusion

o Hot extrusion
o Cold extrusion
o Warm extrusion

o Horizontal and vertical extrusion

Hot extrusion:

Hot
extrusion
is
a hot
working process, which means it is done
above
the
material's recrystallization temperature
to
keep the material from work hardening and
to make it easier to push the material
through the die.
Most hot extrusions are done on
horizontal hydraulic presses that range from
230 to 11,000 metric tons.
Pressures range from 30 to 700 MPa (4,400
to 101,500 psi), therefore lubrication is
required, which can be oil or graphite for
lower temperature extrusions, or glass
powder for higher temperature extrusions.
The biggest disadvantage of this process is
its cost for machinery and its upkeep.
The most commonly used extrusion
process is the hot direct process.

Warm extrusion:
Warm extrusion is done above room temperature, but below
the recrystallization temperature of the material the temperatures ranges
from 800 to 1800 F (424 to 975 C).
It is usually used to achieve the proper balance of required forces, ductility
and final extrusion properties.

Cold extrusion:
Cold extrusion is done at room
temperature or near room temperature.
The advantages of this over hot extrusion
are the lack of oxidation, higher strength
due to cold working, closer tolerances and
better surface finish.
Materials that are commonly cold extruded
include: lead, tin, aluminum, copper, zircon
ium, titanium, molybdenum, beryllium, van
adium, niobium, and steel.
Examples of products produced by this
process are: collapsible tubes, shock
absorber cylinders and gear blanks.

(Collapsible tubes)

Variations of extrusion equipment

There are many different variations of extrusion equipment.
They vary by four major characteristics:
Movement of the extrusion with relation to the ram.
The position of the press, either vertical or horizontal.
The type of drive, either hydraulic or mechanical.
The type of load applied, either conventional (variable)
or hydrostatic.

Direct Extrusion
Direct extrusion, also known as forward extrusion, is the most common
extrusion process.
It works by placing the billet in a heavy walled container. The billet is pushed
through the die by a ram or screw.
The major disadvantage of this process is that the force required to extrude the
billet is greater than that needed in the indirect extrusion process because of
the frictional forces introduced by the need for the billet to travel the entire
length of the container.

Indirect Extrusion

In

indirect extrusion, also known as backwards extrusion.

The billet and container move together while the die is stationary.. The maximum length
of the extrusion is ultimately dictated by the column strength of the stem.. This leads to
the following advantages:
A 25 to 30% reduction of friction, which allows for extruding larger billets, increasing
speed, and an increased ability to extrude smaller cross-sections
The container liner will last longer due to less wear
The disadvantages are:
Impurities and defects on the surface of the billet affect the surface of the extrusion. This
process isn't as versatile as direct extrusions because the cross-sectional area is limited by
the maximum size of the stem.

Hydrostatic Extrusion

In the hydrostatic extrusion process the billet is completely surrounded by a pressurized

liquid, except where the billet contacts the die. This process can be done hot, warm, or cold,
however the temperature is limited by the stability of the fluid used.
The advantages of this process include:
No friction between the container and the billet reduces force requirements. Usually the
ductility of the material increases when high pressures are applied.
The disadvantages are:
The billets must be prepared by tapering one end to match the die entry angle.
Containing the fluid under high pressures can be difficult.

Drives
Of the hydraulic presses there are two types: direct-drive oil
presses and accumulator water drives.
Direct-drive oil presses are the most common because they are
reliable and robust.
Accumulator water drives are more expensive and larger than
direct-drive oil presses, and they lose about 10% of their pressure
over the stroke, but they are much faster, up to 380 mm/s (15 ips).

EXTRUSION
DEFECTS
Following are the defects of extrusion :
Centre bust.
Pipe.
Surface cracking.
Surface lines.

Centre burst

External cracks due to excessive tensile

stress.
It is because of high die angle and low
extrusion ratio.

Pipe

Most common defect.

Pattern caused due to surface oxides and
impurities.
Can be prevented by controlling the amount
of friction.

Surface cracking

Surface of an extrusion splits.

Caused due to extrusion temperature ,
friction and speed(high).
Can be prevented by extruding at lower
speed and temperature.

Surface Lines

Visible lines appear on the extruded surface.

It depends mainly upon the quality of the die
production.
Prevented by doing regular maintenance on
extrusion die

materials
Used in excursion

Types

Plastics.
Ceramics.
Metal.

ceramics

Ceramics is use in the process of

excursion.
Bricks are made with the help of this
process.

plastics

Plastic extrusion commonly uses plastic

in its operations.
Procedure is simple, plastic is melted
and then passed through die with
pressure.
After attaining suitable shape, it is
cooled.

metals

Aluminum, brass, copper, lead, tin, zinc,

steel, titanium etc. are the examples.
Aluminum is the most commonly use
metal in this process.
Different metals have different treatment
temperature.

APPLICATIONS OF
EXTRUSION PROCESS
There are different aplications of extrusion
process
Some of applications are discussed below:

1. Food
.

With the advent of industrial manufacturing,

extrusion found application in food processing of
instant foods and snacks.

 Products such as certain pastas, many breakfast

cereals, premade cookie dough, some french fries,
certain baby foods, dry or semi-moist pet food and
ready-to-eat snacks are mostly manufactured by
extrusion

Generally, high-temperature extrusion is used for the

manufacture of ready-to-eat snacks, while cold extrusion
is used for the manufacture of pasta and related
products intended for later cooking and consumption.

2. Drug carriers
. For use in pharmaceutical products, extrusion
through nano-porous, polymeric filters is being
used
to
produce
suspensions
of
lipid
vesicles liposomes or
transfersomes
with
a
particular size of a narrow size distribution.

The anti-cancer drug Doxorubicin in liposome delivery

system is formulated by extrusion

3. Biomass briquettes
Biomass briquettes are a biofuel substitute to coal
and charcoal . Briquettes are mostly used in
the developing world , where cooking fuels are not as
easily available

The extrusion production technology of fuel briquettes is the process of

extrusion screw wastes (straw, sunflower husks, buckwheat, etc.) or
finely shredded wood waste (sawdust) under high pressure when
heated from 160 to 350 C. The resulting fuel briquettes do not include
any of the binders, but one natural the lignin contained in the cells of

4- Extrusion moulding
Extrusion moulding is a manufacturing process used
to
make pipes, hoses, drinking
straws, curtain tracks, rods, and fibre.

The End
Thank You