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Extrusion
ME 482 - Manufacturing Systems
Rolling Process
Points:
Significant shape change
Capital intensive
Large volume
Usually hot worked (isotropic)*
Oxide scale
Tolerances difficult to hold
Rolling Products
Billet
Blooms (> 6 x 6)
Slab
Ingots
vr
Rolling Model
to
R
p
vo
vf
tf
Assumptions:
Infinite sheet
vr
R = roller radius
p = roll pressure
L = contact length
= contact angle
vr = roll speed
to = initial plate thickness
tf = final plate thickness
vo = plate entry speed
Vf = plate exit speed
Rolling Model
Define draft = d = to - tf
Draft limit = dmax = 2R
= 0.1 cold
= 0.2 warm
= 0.4 1.0 hot
Point of greatest
contact pressure =
no slip point
R (totf)/2
Extrusion
Limitation requires uniform cross-section vs length
Advantages:
Variety of shapes
Control mechanical properties in cold and warm extrusion
Little wasted material
Good tolerances
Types : Direct extrusion and indirect extrusion
Less
friction!
ME 482 - Manufacturing Systems
Extrusion Model
Assumptions:
Circular cross-section
Uniform stress distribution
Do
p = ram pressure
L = remaining billet length
Do = chamber diameter
Df = extrudate diameter
Df
Frictionless model:
ideal true strain = = ln rx
ideal ram pressure = p = Yf ln rx
With friction:
Johnson eqn x = a + b ln rx
a = 0.8
1.2 b 1.5
p = Kx Yf x
p = Kx Yf ( x + 2L Do )
Power = P = Fv
Extrusion example
A billet 3 long and 1 diameter is to be extruded as a round extrudate
in a direct extrusion operation with extrusion ratio of r x = 4. Given die
angle of 90, strength coefficient of 60,000 psi, and strain hardening
exponent of 0.18, use the Johnson formula with a = 0.8 and b = 1.5 to
estimate extrusion strain, and then determine the pressure applied to
the end of the billet as the ram moves forward.
Solution:
= ln rx = ln 4 = 1.3863
x = 0.8 + 1.5(1.3863) = 2.87945
Yf = 60,000(1.386)0.18/1.18 = 53,927 psi
ME 482 - Manufacturing Systems
Extrusion example
A billet 3 long and 1 diameter is to be extruded as a round extrudate
in a direct extrusion operation with extrusion ratio of r x = 4. Given die
angle of 90, strength coefficient of 60,000 psi, and strain hardening
exponent of 0.18, use the Johnson formula with a = 0.8 and b = 1.5 to
estimate extrusion strain, and then determine the pressure applied to
the end of the billet as the ram moves forward.
Solution continued: