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Cold Extrusion
PROCESS Chipless method wherein components are formed by striking a cold slug of metal contained in a die cavity. Metal slug is forced to flow by plastic deformation under compression around a punch. The wall thickness is controlled by clearance between punch and die.
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Non-ferrous Ferrous
Cold Extrusion
METHOD OF EXTRUSION Backward extrusion
Forward extrusion
Combined extrusion
Cold Extrusion
BACKWARD EXTRUSION
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BACKWARD EXTRUSION
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BACKWARD EXTRUSION
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FORWARD EXTRUSION
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FORWARD EXTRUSION
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FORWARD EXTRUSION
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FORWARD EXTRUSION
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COMBINATION EXTRUSION
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COMBINATION EXTRUSION
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PRESSES
Mechanical
Hydraulic
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MECHANICAL PRESSES Short stroke
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HYDRAULIC PRESSES Long stroke High and uniform force Slower speed requirements Production is small Long size
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TOOLING
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TOOLING
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TOOLING
Punch
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Die
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SLUG PREPARATION Blanking Sawing
Cutoff
Shearing
Coining
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SLUG TREATMENT Annealing Cleaning Coating Lubricating
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DESIGN RECOMMENDATION
Symmetry: Avoids lateral movement of tooling punches Unequal wall thickness.
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DESIGN RECOMMENDATION
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DESIGN RECOMMENDATION
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DESIGN RECOMMENDATION
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DESIGN RECOMMENDATION
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Cold Extrusion
DESIGN RECOMMENDATION
More difficult
Easier
Inclined interior surfaces and rounded outside corners assist metal flow in backward extrusion
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DESIGN RECOMMENDATION
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DESIGN RECOMMENDATION
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DESIGN RECOMMENDATION
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Cold Extrusion
DESIGN RECOMMENDATION for forward extrusion
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DESIGN RECOMMENDATION
Flanges should be atleast as thick as the sidewall (a) Located at or near the end (b)
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DESIGN RECOMMENDATION
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Recommended wall thickness
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Tolerance
mm + 0.05 + 0.13
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Automotive Industry: Airbag components, gear shift assemblies .... Electronics Industry: Capacitor cans,relay housings Textile Industry:
Defence
Candle Molds
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Economic Production Quantity
Aluminum parts : 50,000
Steels
10,000 for parts weighing 1 to 2 g 5000 for parts weighing 2 to 500 g 3000 for parts weighing over 500 g
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