Spring 2019

ISyE 415

Introduction to Manufacturing
Systems Design and Analysis

Lecture 5: Extrusion and Drawing

1
 Learning Goal
n Understand what are extrusion and drawing processes

2
 Extrusion
n Work metal is forced to flow through a die opening to produce
desired cross sectional shape, used to produce long parts of
uniform cross sections.
n Similar to squeezing toothpaste out of a toothpaste tube
n A cylindrical billet is forced through a die. Large deformations take place
without fracture due to high triaxial compression

3
 Extrusion
n Typical parts
n Long pieces with wide variety of cross sections, rods, shafts, bars
for machinery, and automotive power train applications, aluminum
ladders, collapsible tubes, wire for numerous electrical and
mechanical parts and musical instruments

Extrusions and examples of products made by sectioning off

extrusions. Source: Courtesy of Kaiser Aluminum. 4
 Extrusion
n Extrusion was an industrial process invented around 1800 in
England, during the Industrial revolution.
n In 1797, Joseph Brahma patented the first extrusion process for making
lead pipe. It involved preheating the metal and then forcing it through a
die via a hand driven plunger.
n The process wasn't developed until 1820 when Thomas Burr constructed
the first hydraulic powered press. At this time the process was called
squirting.
n 1890: an important step forward made in Germany, when the first
horizontal extrusion press was built for extruding metals with higher
melting points than lead. This feature makes it possible to use a dummy
block that separates the ram from the work billet.
n In 1894, Alexander Dick expanded the extrusion process to copper and
brass alloys.
5
Extrusion

A horizontal hydraulic press

for hot aluminum extrusion
Extrusion of a round (loose dies and scrap visible
blank through a die in foreground)

6
 Extrusion
n Advantage:
n A variety of shapes are possible (especially with hot extrusion)
n Grain structure and strength are enhanced (especially in cold and warm
extrusion)
n Fairly close tolerance are possible (especially in cold extrusion)
n Little or no waste material is created
n Limitation:
n The cross section of the extruded part must be uniform throughout its
length

7
Extrusion

8
 Direct & Indirect Extrusion
§ Based on movement of the die
§ Direct extrusion: The workpiece moves on the same direction as the ram
(limitation: friction between the work surface and the container)
§ Indirect extrusion: The workpiece moves on the opposite direction as the
ram (limitation: length of the work)

Hollow cross
section

9
Direct extrusion Indirect extrusion
 Hydrostatic Extrusion
§ An adaption of direct extrusion
§ Surrounding the billet with fluid inside the container and pressurizing the
fluid by the forward motion of the ram (limitation: sealing to prevent fluid
leak)

10
 Extrusions

§ Extrusion can be economical for small and large production

runs as tool costs are low
§ Typical extrusion presses cost more than $100,000, whereas dies can
cost up to $2000

§ https://www.youtube.com/watch?v=Y75IQksBb0M
§ Extrusion process
§ https://www.youtube.com/watch?v=vHkwq_2yY9E
§ Animation

11
 Extrusions
§ Hot Extrusion: prior heating of billet to temperature above
its recrystallization temperature, about 50-70% of melting
point of the metal, to make it easier to push the material
through the die
§ Reduce strength and increase ductility of the metal
§ Permitting more size reductions and more complex shapes
§ Reduce ram force, increase ram speed
§ Aluminum, copper, magnesium, zinc, tin, and their alloys
§ Steels, structural shapes, door and window frames
§ Disadvantage: cost for machinery and its upkeep

12
 Extrusions
§ Cold Extrusion: extrusion is carried out at room
temperatures, generally used to produce discrete parts. The
term impact extrusion is used to indicate high speed cold
extrusion.
§ Close tolerance, improved surface finish
§ Materials that are commonly cold extruded include: lead, tin,
aluminum, copper, zirconium, titanium, molybdenum, beryllium,
vanadium, niobium, and steel.
§ Examples of products produced by this process are:
§ collapsible tubes,
§ fire extinguisher cases,
§ shock absorber cylinders
§ fasteners and components for bicycles, motor cycles, automotive
equipment
§ and gear blanks. 13
 Extrusion Press
• Either horizontal or vertical. Horizontal is more common
• Usually hydraulically driven, which is especially suited to direct extrusion
of long sections
• Mechanical drives - often used for cold extrusion of individual parts

General view of a 9-MN (1000-

ton) hydraulic-extrusion press.
Source: Courtesy of Jones &
Laughlin Steel Corporation.

14
 Exercise 1
n What is the limitation of extrusion process?
n Which extrusion method, direct/indirect, should be chosen if
the designed workpiece is very long?

15
 Drawing
n An operations where the cross section of solid rod, wire or
tubing is reduced or changed in shape by pulling it through a
die opening
n Usually performed as cold working, most frequently for round cross
sections
n Although drawing applies tensile stress, compression also plays a
significant role since metal is squeezed as it passes through die opening

n https://www.youtube.com/watch?v=TYtELo0Fmmg
n Silver wire drawing

16
 Drawing
n Products
n Wire: electrical wire; wire stock for fences, coat hangers, and shopping
carts
n Rod stock for nails, screws, rivets, and springs
n Bar stock: metal bars for machining, forging, and other processes

17
 Drawing
n Advantage:
n Close dimension control
n Good surface finish
n Improved strength and hardness
n Economic in batch or mass production
n Drawing and extrusion
n Drawing: Pulled through the die
n Extrusion: pushed through the die

18
 Drawing
n Bar drawing: for large diameter bar and rod stock
n Used to produce metal bars for machining, forging, and other processes
n Wire drawing: for small diameter stock- wire sizes down to
0.03 mm (0.001 in.) are possible
n Providing commercial products such as electrical wire and cable; wire
stock for fences, coat hangers, shopping carts; rod stock to produce nails,
screws, rivets, springs, and other hard ware items.
n Although the mechanics are the same, the methods, equipment,
and even terminology are different

19
 Tube Drawing Operations

Examples of tube-drawing operations, with and without an internal mandrel. Note that a
variety of diameters and wall thicknesses can be produced from the same initial tube stock
(which has been made by other processes).

20
 Bar Drawing
• Accomplished as a single-draft operation - the stock is
pulled through one die opening
• Beginning stock has large diameter and is a straight cylinder
• Requires a batch type operation

Hydraulically operated
draw bench for drawing
metal bars

21
 Wire Drawing
• Continuous drawing machines consisting of multiple draw dies
(typically 4 to 12) separated by accumulating drums
• Each drum (capstan) provides proper force to draw wire stock through
upstream die
• Each die provides a small reduction, so desired total reduction is
achieved by the series of dies
• Annealing sometimes required between dies to relieve work hardening

Continuous
drawing of
wire

22
 Multistage Wire drawing Machine

Two views of a multistage wire-drawing machine that typically is used in the making of
copper wire for electrical wiring. Source: After H. Auerswald 23
 Exercise 2
• What is the difference between drawing and extrusion?
• What type(s) forces are used in drawing? Tensile or/and
compression forces?

24