ME477 Fall 2004

3. Extrusion Extrusion
A compressive forming process in which the
work metal is forced to go through a die opening Die
v, F container
in a shape of desirable cross-section.
work Direct Extrusion
Direct vs. Indirect
billet
Hot, warm and cold (Forward Extrusion)
Solid, Hollow and Semi-hallow parts Ram
Continuous vs. Discrete
v, F
Advantage Indirect Extrusion
Variety of shapes but a uniform cross-section (Backward or Reverse)
no waste of material
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Extrusion Analysis I Extrusion Analysis II

A In direct extrusion, these is additional pressure, Pf,
Reduction (extrusion) ratio rx = o to overcome the friction at the container wall.
Af
Assuming no friction, true strain = ln rx p f Do2
= pcDo L = YsDo L
Pressure required: p = Y f ln rx 4
where pc = pressure of the billet against the container wall
With friction, x = a + b ln rx where a (~0.8) and b
(1.2-1.5) increase with dies angle Yf
Ys = shear yield strength =
Indirect Extrusion: p = Y f x 2

Ram Pressure
2L p f = Yf
2L
Direct
Direct Extrusion: p = Y f x + Do
Ram Force, F=pAo Do
Indirect
Power P=Fv
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Ram stroke

Extrusion Dies and Press Die Angle & Orifice Shape

2.25
C Optimum angle depends on work material,
Shape factor K x = 0.98 + 0.02 x
Cc
billet temperature, and lubrication
Cx=perimeter of the extruded cross-section Low die angle - surface area is large, leading to
Cc=Perimeter of a circle with the same area increased friction at die-billet interface, which
results in larger ram force
Formula Large die angle - More turbulence in metal flow
p = K xY f x For Indirect during reduction, which increases ram force
required
2L
p = K xY f x + For Direct Shape of die orifice affects ram pressure
D
Impact & Hydrostatic Extrusion Simplest shape = circular die orifice
As cross-section becomes more complex, higher
pressure and greater force are required
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ME477 Fall 2004

Problem 19.25 4. Wire and Bar Drawing

A billet that is 75mm long with diameter=35mm is directly extruded to
a diameter of 20mm. The extrusion die has a die angle of 75. For the The cross section of a bar, rod or wire is
work metal, K=600MPa and n=0.25. In the Johnsons equation, a=0.8
and b=1.4. Determine (a) extrusion ratio, (b) true strain, (c) extrusion pulled while deforming through a die
strain and (d) ram pressure at L=70, 40 and 10mm.
opening.
Bearing Surface
75 (land)

(a) rx=Ao/Af=(352)/(202)=3.0625
(b) =lnrx=1.119
35mm 10mm Area Reduction:
(c) x=a+blnrx=0.8+1.4(1.119)= 2.367
Df F Ao A f
(d) Yf=600(1.119)0.25/1.25=493.7MPa
r=

Entry
To L=70mm, Did extrusion took place? Do Back Relief
L=70mm; p=493.7(2.367+2(70)/35)=3143.4MPa h=(R1-R)/tan 75 Approach
Approach
(30o) Ao
L=40mm; p=493.7(2.367+2(40)/35)=2297.0MPa = 2.01mm
Angle:
(6-20o)
Lc Draft: d = Do D f
L=10mm; p=493.7(2.367+2(10)/35)=1450.7MPa
V=1/3(R2H-R12(H-h))=1223.4mm
V70mm=pDo2(75-70)/4=4810.6mm
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Drawing Analysis Maximum Reduction per pass

Ao 1
Mechanics of Drawing = ln = ln For an ideal plastic material
Af 1 r
Ao A 1
ideally = Y f ln o
A = Y f ln = Y ln o = Y ln =Y
Af Af Af 1 r
A
realistically = Y f 1 + ln o A
tan Af ln o = ln 1 = 1 max = 1
A 1 r
where = 0.88 + 0.12
D f
Lc Ao
D + Df D Df = e = 2.7183
D= o and Lc = o Af
2 2 sin
Draw Force F = A f = A f Y f 1 + ln Ao
e 1
rmax = = 0.632
tan Af e
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Problem 19.35 Drawing practice

Bar stock of initial diameter =90mm is drawn with a draft=15mm. The draw Usually cold working & round cross-sections
Die has an entrance angle=18, and the coefficient of fraction at the work-die
interface =0.08. The metal behave as a perfectly plastic material with yield Difference between bar drawing and wire
stress =105MPa. Determine: (a) area of reduction, (b) draw stress, (c) draw drawing is stock size
force required for the operation and (d) power to perform the operation of exit
velocity=1.0m/min. Bar drawing - large diameter bar and rod stock
Wire drawing - small diameter stock - wire sizes down
to 0.03 mm (0.001 in.) are possible
(a) r=(Ao-Af)/Ao=(902-(90-15)2)/902=0.3056
(b) =ln(Ao/Af)=ln1.440=0.3646 Preparation of the Work
Yf=k=105MPa Annealing to increase ductility of stock
=0.88+0.12(D/Lc) =1.288 where D=0.5(90+75)=82.5mm and
Lc=0.5(90-75)/sin18=24.3mm Cleaning - to prevent damage to work surface and
d=Yf(1+/tan)(lnAo/Af)=61.45MPa draw die
(c) F=Afd=4117.9(61.45)=271,475N
Pointing to reduce diameter of starting end to allow
(d) P=271,475(1m/min)=4524.6W
insertion through draw die
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