Extrusion Metal working

Defined
• Extrusion is the process by which a block/billet
of metal is reduced in cross section by forcing it
to flow through a die orifice under high
pressure.
• 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 reaction of the extrusion billet with the container and
die results in high compressive stresses which are effective
in reducing cracking of materials during primary
breakdown from the ingot.
• This helps to increase the utilization of extrusion in the
working of metals that are difficult to form like stainless
steels, nickel-based alloys, and other high-temperature
materials.
Cold or Hot Extrusion
• Similar to forging, lower ram force and a fine grained
recrystallised structure are possible in hot extrusion.
• However, better surface finish and higher strengths (strain
hardened metals) are provided by cold extrusion.
Extrusion products
 Forward extrusion

Backward extrusion
 Cold Extrusion
For continuous or steady state processes, the
mean flow stress calculated from equation
3.32 is used

The extrusion pressure can be calculated from

In extrusion processes where no lubricant is used,
the frictional resistance can be high and extrusion
equipment must be able to handle not only the
deformation resistance, but the frictional
resistance as well. Meaningful coefficients of
friction for extrusion are difficult to obtain and it is
generally considered better to estimate an extreme
value based on sticking friction conditions.
 Hot Extrusion
As might be expected, strain rate effects
become important during hot extrusion. A
detailed analysis of the extrusion processes of
Fig. 4.12 gives the mean strain rate during
extrusion as
Example
Solution
thickness

Given
 Example: Extrusion
• A cylindrical billet that is 100 mm long and 40
mm in diameter is reduced by indirect
(backward) extrusion to a 15 mm diameter.
Die angle = 90°. If the Johnson equation has a
= 0.8 and b = 1.5, and the flow curve for the
work metal has K = 750 MPa and n = 0.15,
determine: (a) extrusion ratio, (b) true strain
(homogeneous deformation), (c) extrusion
strain, (d) ram pressure, and (e) ram force.
 Summary
• Extrusion: Push billet through die to reduce x-
sect;
Hot for lower force, better ductility
• Extrusion Factors: Die design; extrusion ratio;
billet temperature; lubrication; speed.
Cold
• improves some mechanical properties
• Solve the problem sheet assigned