REPORT

TOPIC - EXTRUSION

DEEPAK KUMAR SINGH

SECTION:-F4003

ROLL NO:-A07

REGD NO-11006886

GROUP-1

Extrusion is a compression process in which the work part id forced to flow

through a die opening to produce a desired crossection shape. The process is
linked to squeezing toothpaste out of toothpaste tube.

1.Types of extrusion:-

1.1.Direct extrusion :-in this process billet is loaded into container ,and a ram
compreses the material forces to flow through one or more die openings in a die
at the opposite end of the container.asthe ram approaches the die the extra
portion remains in the container ,it is called “Butt”.

One of the problems in direct extrusion is the friction between the workpart
surface and the ram.which causes the irregularity in final shape.

1.2.Indirect extrusion:-In indirect extrusion die is mounted to the ram rather

than in the opposite side of the container .Indirect extrusion can be produce
hallow crossection ,In this method ,the ram is pressed into the billet ,forcing the
material to flow around the ram and take a cup shape.

1.3.Hot extrusion:-Extrusion can be perfomed in hot depending on work metal

and amount of strain which is subjected during deformation. Metal that are
extruded by this process are copper, aluminium, magnesium and tin.

It involves heating of a billet above its recrystallisation temperature.This

reduces strength and increase ductibility of the material.Complex shape can be
achived by this process.Addition advances include reduction of ram
force,increase ram speed and reduction of grain flow finish,characteristics in
final product.colling of billet in contact with the container wall is a problem ,so
isothermal extrusional is sometime used for this problem.

1.4.Cold extrusion:-this type of extrusion is used for to produce discrete

parts,often in finished form.Impact extrusion term is used to indicate the high
speed cold extrusion. Some important advances of cold extrusion include
increages strength due to strain hardening, close tolerences,improves surface

finish, absence of oxide layers and high production rates.Cold extrusion at

room temp. Also estimates the need for heating of starting billet.

1.5.Impact extrusion:- Impact extrusion is performed at higher speeds and

shorter strokesthan convention extrusion.It is usedto make individual
components.

Impacting can carried out as forward extrusion, backward extrusion and

combination of these.

1.6.Hydrostatic extrusion:-It is used to overcome the problem of friction

between billet container interface by surrounding the billet with fluid inside the
container and applying pressure to it.It reduces the ram force as that of direct
extrusion .It can be used either in room temp. Or any any elevated temp.

2.Defects in extrusion product:-

2.1.Centerburst:-this defects is an internal crack thatdevelops as aresult of

tensile stresses along the center of the workpart. The significant material
movement in the outer the surface stretches the material along centre of the
material.

2.2.Pipping:-It is a deformation of a sink hole at the end of the billet.The use of

dummy block whose diameter is slightly less than that of billet helps to avoid
this defects.

2.3.Surface cracking:-This defects results from high workpart temp. That causes
cracks to develop at the surface. They often occur when extrusion speed is too
high.

3.Analysis of extrusion:-

3.1.Extrusion ratio:- It is the ratio between initial area and the final area.

r=Ao/Af
where Ao is crossection area of initial billet and Af is crossection area of final
billet.

3.2. p=Yf *lnrx=lnAo/Af

3.3. E=ln rx

3.4.Yf=kE^n/1+n

3.5.pf=Yf*2L/Do
Where p is the pressure applied to the ram, E is the strain in the workpart and Yf
is the average flow stress.