The Extrusion Process

Example Calculation of Force in Hot Extrusion

A round billet made of 70-30 brass is extruded at a temperature

of 675°C. The billet diameter is 125 mm, and the diameter of the
extrusion is 50 mm. Calculate the extrusion force required.

𝑨𝑨𝟎𝟎
𝑭𝑭 = 𝑨𝑨𝟎𝟎 𝒌𝒌𝒌𝒌𝒌𝒌
𝑨𝑨𝒇𝒇
Problem 2 (proposed)

Estimate the force required in extruding 70-30 brass at 700ºC if

the billet diameter is 200 mm and the extrusion ratio is 30.
 Shearing Sheet-metal forming processes

Example 1

Calculation of Punch Force

Estimate the force required for punching a 25-mm diameter hole

through a 3.2-mm thick annealed titanium-alloy Ti-6Al-4V sheet at
room temperature.

𝑭𝑭 = 𝟎𝟎, 𝟕𝟕𝟕𝟕𝟕𝟕(𝑼𝑼𝟕𝟕𝑼𝑼)
Are the requirements for punch and die materials in powder metallurgy
different than those for forging and extrusion? Explain.
They use similar materials or the same ones. This is because the most important characteristic in
punch and die materials are their abrasive resistant. Although, isostatic pressing use flexible molds,
which are not used in forging or extrusion.

In forging, extrusion, and P/M compaction, abrasive resistance is a

major consideration in die and punch material selection. For that
reason, the dies on these operations utilize similar and sometimes
identical materials. Processes such as isostatic pressing utilize
flexible molds, which generally is not used in forging and extrusion.
 The cold isostatic pressing (CIP):
- Requires more force
- Produce a better surface
- Does not modify the internal structure of the material
The hot isostatic pressing (HIP):
- Requires lower forces
- It modifies the microstructure of the material (improve the density of the material)
- Produces irregular surfaces
- It is expensive
They hace in common that both produces compacts with effectively uniform density

Describe the relative advantages and limitations of cold and hot isostatic
pressing, respectively.

. Cold isostatic pressing (CIP) and hot isostatic pressing (HIP) both have
the advantages of producing compacts with effectively uniform
density. Shapes can be made with uniform strength and toughness.
The main advantage
of HIP is its ability to produce compacts with essentially 100% density,
good metallurgical bonding, and good mechanical properties.

However, the process is relatively expensive and is, therefore, used

mainly for components in the aerospace industry or in making special
parts
Despite the fact that PM techniques requires expensive special tooling, PM reduce much of the machining process, also can create
difficult shapes. In addition, it allows the blending of components appropriate for cutting tools.

Explain the advantages of making tool steels by P/M techniques over traditional
methods, such as casting and subsequent metalworking techniques.

From a cost standpoint, there may not be a major advantage because P/M
itself requires special tooling to produce the part. However, some tool steels
are very difficult to machine to desired shapes. Thus, by producing a P/M
tooling, the machining difficulties are greatly reduced. P/M also allows the
blending of components appropriate for cutting tools.
 There are many hazards involved in PM processing:
- Powder metal can be explosive (example: aluminium, magnesium, titanium, zirconium and thorium)
- Dust, sparks and heats from friction should be avoided
- There are general concerns associated with closing dies, where a finger may be caught

Are there any hazards involved in P/M processing?

If any, what are their causes?

There are several hazards in P/M processing; the major one is that powder
metals can be explosive (particularly aluminum, magnesium, titanium,
zirconium, and thorium). Thus, dust, sparks, and heat from friction should
be avoided. In pressing, there are general concerns associated with closing
dies, where a finger may be caught.
This types of material are weaker because of its sensitiveness to cracks, impurities and porosity. Also they have low tensile strength and
toughness.

On the other hand, in compression, the flaws in the material do not cause the stress concentrations as the y do in tension. Although, hence
compressive strength is high

Explain why ceramics are weaker in tension than in compression.

Ceramics are very sensitive to cracks, impurities, and porosity, and thus
generally have low tensile strength and toughness (see, for example, Table
8.6 on p. 454). In compression, however, the flaws in the material do not
cause the stress concentrations as they do in tension, hence compressive
strength is high.
This is because the porosity decrease the cross-sectional area that supports the external load, also it actuate as a concentrator of stress at the
holes. Although, the porosity create the perfect spots to initialize cracks, decreasing toughness.

On the other hand, at ceramics physical properties, the pores are filled with air, which has much lower thermal and no electrical conductivity in
comparison with ceramics.

Why do the mechanical and physical properties of ceramics decrease with

increasing porosity?

Porosity can be considered microscopic air pockets in the ceramic. Thus,

porosity will always decrease the strength of the ceramic because of the
smaller cross-sectional area that has to support the external load. The holes in
the material also act as stress concentrations to further lower the strength.
The porosity also acts as crack initiation sites, thus decreasing toughness.
Physical properties are affected likewise, in that pores in the ceramic are
typically filled with air, which has much lower thermal and no electrical
conductivity as compared with ceramics.
 Plastic and composite materials

Would you use thermosetting plastics in injection

molding? Explain.

Thermosetting plastics are suitable for injection molding although the process is often
referred to as reaction injection molding;

The basic modification which must be made to the process is that the molds
must be heated to allow polymerization and cross-linking of the material. The major
drawback associated with this change is that, because of the longer cycle times, the process
will not have as high a production rate as for thermoplastics.
Thermosetting plastics could be used in injection molding, but you have to modify some things to do it possible. You must heat the molds, because if you
do not do it, the polymerization and cross-linking of the material will not be made. Although, doing this, you will increase the cycle time and the production
rate will decrease.
 Plastic and composite materials

Describe the advantages of applying traditional metalworking techniques to the forming and
shaping of plastics.

Applying traditional metalworking techniques to shaping of plastics is advantageous for

several reasons. Since the stock shapes are similar (sheet, rod, tubing, etc.), well-known and
reliable processes can be applied efficiently. Being able to utilize similar machines and many
years of research, development, and experience associated with machine design and process
optimization will have major significance in plastics applications as well.

Applying this traditional techniques is the most obvious thing, because you are going to recreate similar shapes (result in similar dies), also if you use the
same processes you do not have to investigate for a new machine, you can use the other ones, this is possible (use the same machine) because to
process plastics you need less force.

In conclusion, the possibility of using the same techniques, will save a lot of money of investigations and research to the company.
 Plastic and composite materials

By inspecting plastic containers, such as for baby powder, you can see that the lettering on
them is raised and not sunk in. Offer an explanation as to why they are molded in that way.

The reason is that in making molds and dies for plastics processing, it is much easier to
produce letters and numbers by removing material from mold surfaces, such as by grinding
or end milling, similar to carving of wood.
As a result, the molded plastic part will have raised letters and numbers. On the other hand,
if we want depressed letters on the product itself, the markings on the molds would have to
protrude. This is possible to do but would be costly, time consuming..
This is because it is easier to produce letters by removing material from the mold surface (grinding, end milling). Therefore, the plastic part will have raised
lettering.

If we want the lettering depressed, we must protrude the mold, but this is expensive than the other method.