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Metal Extrusion
Definition
Extrusion is the conversion of an ingot or billet into lengths of uniform cross section by forcing metal to flow plastically through a die.
Indirect Extrusion [Backward Extrusion]: The extrusion die is fixed to a hollow ram (extrusion ram and metal flow are in opposite direction); the required extrusion forces are lower because of no relative movement between billet and container. [Stationary ram & die and moving container]
Lecture Notes
Metal Extrusion
Lecture Notes
Metal Extrusion
Extrusion Forging: Extrusion forging is a combined process of forging and extrusion. A common example is the production of engine valves, where the billet is partially extruded to form the valve shank, and the rest of the billet is forged to form the valve head.
Lecture Notes
Metal Extrusion
Lecture Notes
Metal Extrusion
Tubes and hollow sections can be produced by extrusion by attaching a mandrel, the clearance between the mandrel and die wall determines the wall thickness of the tube. Fixed Mandrel:
Moving Mandrel:
Lecture Notes
Metal Extrusion
Lecture Notes
Metal Extrusion
Extrusion dies are made from different types of hot working tool steels. The figure below shows schematic sketches for (a) Taper die for hot extrusion of steels with molten glass as a lubricant, and (b) flat die commonly used for non-ferrous materials. The cross section explains the entrance angle, die land and relief angle.
Lecture Notes
Metal Extrusion
Lecture Notes
Metal Extrusion
The flow pattern in extrusion is important because of its effect on the quality and mechanical properties of the final product, where the improper metal flow during extrusion can produce various defects. In extrusion metal flow longitudinally like a fluid flow, so the extruded products have an elongated grain structure.
A common technique for investigating the flow pattern is to section the billet into two longitudinal halves and mark the sectional face with a square grid pattern, the two halves are placed in the chamber together and partially extruded, and then they are taken apart and studied.
Low friction
High Friction
Lecture Notes
Metal Extrusion
Due to improper material conditions and process variables, several types of defects can be developed in extruded products. There are three principle extrusion defects: Surface cracks (also called speed cracks) Cause: high speed or high speed and friction. These cracks are intergranular (along the grain boundaries) and are usually caused by hot shortness. Hot shortness is the tendency for some alloys to separate along grain boundaries when stresses of deformed at high temperatures due to the low melting point constituents segregated at grain boundaries. Solution: Reduce billet temperature and extrusion speed. Piping (also called fish tailing) Cause: Surface oxides and impurities. According to the metal flow pattern, surface oxides and impurities are drawn towards the center during deformation, as much as one third of the extruded product length may contain this type of defect, and have to be cut off as scrap. Solution: Piping can be minimized by modifying the flow pattern and controlling friction, or by machining the billet outer surface before extrusion to remove surface scales. Internal cracks Cause: high internal stresses at the centerline. Internal cracks are due to high internal stresses near the centerline in the deformation zone of the extrusion die. The tendency y for center cracking: Increases with the increase of die angle and amount of impurities. Decreases with the increase of extrusion ratio and friction. Solution: Select proper die geometry and extrusion variables.
Lecture Notes
10
Metal Extrusion
Lecture Notes
11
Metal Extrusion
Material Lead alloys Magnesium alloys Aluminum alloys Copper alloys Titanium alloys Nickel alloys Steels
Cold Extrusion Cold extrusion is a general term often denoting a combination of operations, such as direct or indirect extrusion and forging to produce short solid or hollow shaped products. Workpieces are often cup-shaped and have wall thicknesses equal to the clearance between the punch and die. Ductility must be restored between operations by annealing, and any scale formed during annealing must be removed by blasting or pickling before COLD EXTRUSION is so called because the slug or subsequent extrusion. preform enters the extrusion die at room temperature. Cold-Extruded Metals in the order Any subsequent increase in temperature, which may of decreasing extrudability are amount to several hundred degrees, is caused by the Aluminum and aluminum alloys, conversion of deformation work into heat. Cold copper and copper alloys, low- extrusion involves backward (indirect), forward carbon and medium-carbon (direct), or combined backward and forward (indirectsteels, modified carbon steels,
Lecture Notes
12
Metal Extrusion
Lecture Notes
13
Metal Extrusion
This lecture is concerned with the plastic deformation of metals through conical tapered and circular dies. The forming process is called Drawing when the metal is forced through the die by tensile force applied to metal at the exit of the die, and it is called Extrusion when a compressive force is applied at the entry of the die. Rod and shape Drawing: In rod drawing operations, one end of the a bar is reduced or pointed, inserted through a die (with smaller cross sectional area than the original bar), gripped and pulled in tension, and drawing the remainder of bar through the die. The reduction in area per pass is usually restricted to (20% - 50%) to avoid tensile fracture. Therefore, multiple draws through a series of dies may be required to produce a desired final size. Intermediate annealing may be required to restore ductility and enable further working. Tube Drawing: Tube drawing is a reduction process in which one end of a tube is grasped and pulled through a die that is smaller than the tube diameter. To obtain the desired size, a series of successive reductions, or passes, may be necessary. Because of its versatility, tube drawing is suited for both small and large production runs.
Lecture Notes
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Metal Extrusion
Wire Drawing: Wire drawing is a metal-reducing process in which a wire rod is pulled or drawn through a single die or a series of continuous dies, thereby reducing its diameter. Because the volume of the wire remains the same, the length of the wire changes according to its new diameter. Various wire tempers (hardness) can be produced by a series of drawing and annealing operations. A wire drawing die is a tool that consists of a highly polished, shaped hole through which wire is drawn to reduce its diameter. The choice of die material, viz. natural or synthetic single crystal diamond, polycrystalline diamond, carbide etc. depends on the material of the wire to be drawn and the operating parameters.
Extrusion
Drawing
= yield Ln (AF/AO)
Axial Stress 15
Lecture Notes
16
Metal Extrusion