Extrusion and Drawing

of Metals
 Introduction

Extrusion – It is a process where a billet is forced

through a die.
• Parts have constant cross-section
• Typical Products of Extrusion – Sliding Doors,
tubing having various cross-sections, structural and
architectural shapes and door and window frames.

Drawing – It is a process where a cross-section of

solid rod, wire, or tubing is reduced or changed in
shape by pulling it through a die.
 Extrusion
Compression forming process in which the
work metal is forced to flow through a die
opening to produce a desired cross-sectional
shape
• Process is similar to squeezing toothpaste
out of a toothpaste tube .
• In general, extrusion is used to produce long
parts of uniform cross-sections.
 Extrusions

Fig : Extrusions and

examples of
products made by
sectioning off
extrusions.
 Types of Extrusion Process
Direct Extrusion (or) Forward Extrusion – Billet is
placed in a chamber and forced through a die opening by a
hydraulically-driven ram or pressing stem.

Indirect Extrusion (or) Backward Extrusion – Die

moves towards the billet.

Hydrostatic Extrusion – The billet is smaller in diameter

that the chamber, which is filled with a fluid, and the
pressure is transmitted to the billet by a ram.
Lateral Extrusion –
Impact extrusion -
Figure 19.31 - Direct extrusion
 Direct Extrusion

Fig : Schematic illustration of direct extrusion process.

 Comments on Direct Extrusion
• Also called forward extrusion
• As ram approaches die opening, a small portion of billet remains
that cannot be forced through die opening
• This extra portion, called the butt, must be separated from
extruded product by cutting it just beyond the die exit
• Starting billet cross section usually round, but final shape is
determined by die opening
Figure 19.32 - (a) Direct extrusion to produce a hollow or semi-hollow
cross-section; (b) hollow and (c) semi-hollow cross- sections
 Indirect Extrusion

Fig : Schematic illustration of direct extrusion process.

 Figure 19.33 - Indirect extrusion to produce
(a) a solid cross-section and (b) a hollow cross-section
 Comments on Indirect Extrusion
• Also called backward extrusion and reverse extrusion
• Limitations of indirect extrusion are imposed by the lower
rigidity of hollow ram and difficulty in supporting extruded
product as it exits die
 Wire and Bar Drawing
Cross-section of a bar, rod, or wire is reduced by pulling it
through a die opening
• Similar to extrusion except work is pulled through die in
drawing (it is pushed through in extrusion)
• Although drawing applies tensile stress, compression also
plays a significant role since metal is squeezed as it passes
through die opening
Figure 19.41 - Drawing of bar, rod, or wire
 Area Reduction in Drawing
Change in size of work is usually given by area
reduction:
Ao  Af
r
Ao
where r = area reduction in drawing; Ao = original
area of work; and Af = final work
 Wire Drawing vs. Bar Drawing
• Difference between bar drawing and wire drawing
is stock size
– 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
• Although the mechanics are the same, the
methods, equipment, and even terminology are
different
 Drawing Practice and Products
• Drawing practice:
– Usually performed as cold working
– Most frequently used for round cross-sections
• Products:
– Wire: electrical wire; wire stock for fences, coat hangers, and
shopping carts
– Rod stock for nails, screws, rivets, and springs
– Bar stock: metal bars for machining, forging, and other processes
 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
• This necessitates a batch type operation
 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
– Annealing sometimes required between dies
Figure 19.43 - Continuous drawing of wire
Figure 19.44 - Draw die for drawing of round rod or wire
 Tube Drawing Operations

Fig : Examples of tube-drawing operations, with and without internal mandrel. Note that a variety of
diameters and wall thickness can be produced from the same initial tube stock (which had been made
by other processes).
 SHEET METAL WORKING

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 Introduction
Sheet metal is simply metal formed into thin and
flat pieces. It is one of the fundamental forms used I n
metal working, and can be cut and bent into a variety
of different shapes. Countless everyday objects are
constructed of the material. Thicknesses can vary
significantly, although extremely thin thicknesses are
considered foil or leaf, and pieces thicker than 6 mm
(0.25 in) are considered plate.

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Sheet metal processing
The raw material for sheet metal manufacturing processes is
the output of the rolling process. Typically, sheets of metal
are sold as flat, rectangular sheets of standard size. If the
sheets are thin and very long, they may be in the form of
rolls. Therefore the first step in any sheet metal process is to
cut the correct shape and sized ‘blank’ from larger sheet.

Sheet Material:
Galvanized Iron, Tin plate, Galvannealed Iron, Zinc, Black ,
Iron Sheets, Copper, Aluminium, Stainless sheets.

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 Equipments

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 Tools and Accessories

Marking and measuring tools

Steel Rule : It is used to set out dimensions.

Try Square: Try square is used for making and testing angles of 90degree

Scriber : It used to scribe or mark lines on metal work pieces.

Divider : This is used for marking circles, arcs, laying out perpendicular
lines, bisecting lines, etc

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 Marking and measuring tools

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 Cutting Tools

Straight snip - They have straight jaws and used for straight line cutting.

Curved snip - They have curved blades for making circular cuts.

Straight snip
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 Curved snip

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Striking Tools

Mallet - It is wooden-headed hammer of round or rectangular

cross section. The striking face is made flat to the work. A mallet is
used to give light blows to the Sheet metal in bending and
finishing.

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Sheet Metal Forming processes

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Introduction

1. Sheet metal processes involve plane stress loadings

and lower forces than bulk forming
2. Almost all sheet metal forming is considered to be
secondary processing
3. The main categories of sheet metal forming are
• Shearing
• Bending
• Drawing

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Shearing
Shearing is a sheet metal cutting operation along a
straight line between two cut-ting edges by means of a
power shear.

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Blanking and punching
Blanking and punching are similar sheet metal cutting operations that
involve cutting the sheet metal along a closed outline. If the part that is cut out is
the desired product, the operation is called blanking and the product is called
blank. If the remaining stock is the desired part, the operation is called punching.
Both operations are illustrated on the example of producing a washer

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 Cutting Operations
Shearing by two sharp cutting edges.
Plastic deformation penetration fracture

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 Sheet-metal Cutting
c = at
c = clearance
a = allowance
t = thickness

Blanking:
Blanking punch dia. = Db- 2c
Blanking die dia. = Db

Punch:
Hole punch dia. = Db
0.25 to 1.5 Hole die dia. = Db+ 2c

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 Sheet-metal Cutting

Small clearance

Cutting force = StL

S = Shear strength of sheet-metal
t = Sheet-metal thickness
L = Length of cutting edge
or, Cutting force = 0.7TtL Large clearance
T = Ultimate tensile strength
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Anupam Thakur sheet-metal
MAIT) 39
 Sheet-metal Cutting Operations
Cut-off

Parting

Slotting Perforating Notching / Seminotching

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 Sheet-metal Cutting Operations
Fine blanking -
close tolerances
and smooth
edges in one
step.

Trimming - Cutting operation to remove excess metal

Shaving - Shearing with very small clearance to obtain
accurate dimensions., secondary or finishing operation.

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Bending
Bending is defined as the straining of the sheet metal
around a straight edge

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 Bending

V- bending Edge - bending

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 Bending Analysis

Spring back

Die-opening
dimension

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 Bending Operations

Straight flanging Stretch flanging Shrink flanging

Hemming Seaming Curling

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 Bending Operations

Channel bending U-bending air-bending

Offset-bending Corrugating Tube forming

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Drawing
Drawing is a sheet-metal operation to make hollow-shaped parts
from a sheet blank

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 Drawing c = Clearance
Db = blank diameter
Dp = Punch diameter
Rd = die corner
radius
Rp = Punch corner
radius
F = drawing force
Fh = holding force

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 Drawing

Initial step bending of edge straightening of side wall

Thinning and drawing final cup shape

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Drawing ratio,  2.0
where Db = blank diameter
Dp = punch diameter
t = thickness of the starting blank
Reduction,  0.5
Thickness to diameter ratio,  1%
Drawing force, , max. at 1/3 stroke.
Holding force,
Holding pressure may be set at 0.015 of the yield strength
T = Tensile strength, Y = Yield strength, Rd = die corner radius
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 Drawing Analysis
• Blank diameter can be calculated from the conservation of
volume based on the final volume of the part.
• If the limits on the drawing ratio, reduction and thickness-
to-diameter ratio are exceeded, the blank must be drawn in
steps or having annealing between the steps.
• Process optimization:
– Punch and die corner radii
– friction
– depth of draw (per step)
– material characteristics

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 Other Sheet-metal Operations
Ironing - squeezing and
drawing in conjunction
Coining & Embossing - to
produce surface details
Lancing - combination of
cutting and forming

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 Embossing
• The metal sheet embossing operation is commonly
accomplished with a combination of heat and pressure on the
sheet metal, depending on what type of embossing is required.
Theoretically, with any of these procedures, the metal thickness
is changed in its composition.
• Metal sheet is drawn through the male and female roller dies,
producing a pattern or design on the metal sheet. Depending on
the roller dies used, different patterns can be produced on the
metal sheet. The pressure and a combination of heat actually
"irons" while raising the level of the image higher than the
substrate to make it smooth. The term "impressing" refers to an
image lowered into the surface of a material, in distinction to an
image raised out of the surface of a material.
 Embossing
• In most of the pressure embossing operation machines, the
upper roll blocks are stationary, while the bottom roll blocks are
movable. The pressure with which the bottom roll is raised is
referred to as the tonnage capacity.
• Embossing machines are generally sized to give 2 inches (5 cm)
of strip clearance on each side of an engraved embossing roll.
Many embossing machines are custom-manufactured, so there
are no industry-standard widths. It is not uncommon to find
embossing machines in operation producing patterns less than 6
inches (15 cm) wide all the way up to machines producing
patterns 70 inches (180 cm) wide or more.
 Embossing
• The metal embossing manufacturing process has
these characteristics:
• The ability to form ductile metals.
• Use in medium to high production runs.
• The ability to maintain the same metal thickness
before and after embossing.
• The ability to produce unlimited patterns, depending
on the roll dies.
• The ability to reproduce the product with no
variation.
Embossing
 Coining
Coining is a closed die forging process, in
which pressure is applied on the surface of the
forging in order to obtain closer tolerances,
smoother surfaces and eliminate draft. Closed
die forging is a process in which forging is
done by placing the work piece between two
shaped dies. This process may be done in hot
or cold working conditions, but is
predominantly a cold work process.
Advantages of Coining
• The advantages of coining process are listed below:
• Produces finer and detailed surface finish
• Provides accurate bends in a consistent manner
• Does not require expensive machinery
• The work hardened surface can resist impact and
abrasion
• Eliminates the need for complex finishing processes
• Plastic flow reduces the surface grain size and work
hardens the surface.
 Spinning

Conventional
spinning

Shear spinning - thinning

and bending occur at the
same time.

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 Dies

Components of a punch and die for blanking operation

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