Classification by Direction
Process variables in Direct Extrusion
Classification by Direction
Indirect Extrusion
Indirect Extrusion
Classification by Temperature
Hot Extrusion
Hot Extrusion
Hot Extrusion
Types of hot extrusion
Lubricated hot extrusion
Non-lubricated hot extrusion
Hot extrusion Temperature Ranges
Hydrostatic extrusion
Hydrostatic extrusion
Hydrostatic extrusion
Classification by Temperature
Advantages of cold extrusion
Disadvantages of cold extrusion
Applications of cold extrusion
Cold extrusion of a Spark Plug
Impact extrusion
Applications of Impact extrusion
Classification by Equipment
Classification by Equipment
Lubrication in Extrusion
Factors affecting Extrusion force
Factors affecting Extrusion force
Extrusion constant
Workpiece Temperature
Metal Flow in Extrusion
Metal Flow in Extrusion
Metal Flow in Extrusion
Metal Flow in Extrusion
Metal Flow in Extrusion
Metal Flow in Extrusion
Extrusion Defects
Extrusion Defects
Extrusion Defects
Extrusion Defects
Extrusion Defects
Mechanics of Extrusion
Initial compression of
billet to fill the die
At the end of the billet
the force greatly
increases because the
billet is thin and the
material must flow
radially to exit the die.
The end of the billet
(called the butt end) is
not used for this reason
Mechanics of Extrusion
Die design in Extrusion
Die design in Extrusion
Advanced Extrusion
of metals and alloys
• Reinforced Extrusion
• Curved Profile Extrusion
• Twisted Profile Extrusion
• Helical Profile Extrusion
Reinforced Extrusion
• Continuous embedding of reinforcement elements during the hot extrusion process
• Composite profiles as components for automotive or aerospace engineering using conventional billets
• Modified porthole dies are used to feed the reinforcing elements from the outside of the pressing tool
and to embed them in the material flow during the extrusion process
• The material flow of the billet is spilt into different strands
• These strands join together in the welding chamber with the reinforcing elements in-between
• The relative movement between reinforcing element and base material leads to tensile forces on the
reinforcing element, and thus no external forces are necessary to feed the reinforcements in the die
during extrusion
• Based on numerical results of a thermo-mechanically coupled finite element simulation in 2 1/2 D,
– Introduction of reinforcement elements needs to be performed in an area with low hydrostatic compressive
stresses in the matrix in order to reduce stresses orthogonal to the reinforcement element
• This can be achieved by the usage of dies which divide the forming process into different stages
– Introduction of reinforcement elements should be in an area with small velocities in longitudinal direction
• The best position for a reduction of axial stresses is in the area where the exiting velocity is (nearly)
reached
Reinforced Extrusion
® Courtesy of the Institute of Forming Technology and Lightweight Construction, TU Dortmund University, Dortmund, Germany
Reinforced Extrusion
Curved Profile Extrusion
• A substitute process for the conventional process chain to manufacture curved profiles
• The basis of this method is the kinematic shape generation
• The exiting strand is fed into a guiding tool which can be moved by a linear axis system in two dimensions
• Owing to the deflection, a moment is superimposed on the already plasticised material in the die and influences the
material flow
• Thereby the material is decelerated at the inner side of the curvature and accelerated at the outer side as a result
of the compression and the tensile stress
• Owing to the velocity profile over the die cross-section, the profile curvature is generated
• Important geometrical parameters include (a) distance between the die and the guiding tool, (b) angle between
press axis and linear axis, and (c) distance between press axis and guiding tool
• Constantly curved profiles are manufactured when the guiding tool remains in a constant position, whereas variable
curvatures are produced by a defined movement path synchronous to the extrusion process
• The synchronisation of the process is realised by an incremental measuring system attached in parallel to the ram
of the extrusion press, performing an indirect measurement of the extrusion speed
• Variably curved profiles are produced by moving the guiding tool on a path synchronously to the profile velocity
defined by the press conditions
• This forming technology causes no cross-section deformation, no springback and nearly no decrease in formability
Curved Profile Extrusion
® Courtesy of the Institute of Forming Technology and Lightweight Construction, TU Dortmund University, Dortmund, Germany
Curved Profile Extrusion
• CPE requires a maximum
force of only 34 N to deflect
the strand for the curvature
generation
• In comparison to CPE, the
warm bending process needs
initial forces which are up to
150 N to deflect the profile
• This circumstance makes the
difference between CPE and
warm bending obvious, and
also shows that it is necessary
to move the guiding tool on the
correct path without any
external influencing forces
® Courtesy of the Institute of Forming Technology and Lightweight Construction, TU Dortmund University, Dortmund, Germany
Twisted and Helical Profile Extrusion
• For the manufacturing of twisted profiles, two processes have been developed
– Twisted Profile Extrusion (TPE)
– Helical Profile Extrusion (HPE)
• TPE provides a tool which can guide and twist the profile after the extrusion process by a deflection of
the material flow
• The material flow is in semi-solid state, and twist profile is achieved by rotating the guidance tool
• The pitch angle is adjusted by means of a simple rotary drive
• The advantage of this process is that the guiding tool does not need to be rotated continuously during
extrusion but rather only gradually in the initial extrusion phase until the desired pitch angle is reached
• Hence, a constant pitch angle can be achieved along the extruded profile length
• In HPE, a die with helical shaped channel is used
• The internal twisting angle is integrated into the die, in the middle of the tool
• Further advancements can involve optimisation of the material flow by means of designing new die
geometries
• Additionally, a combination of TPE and HPE could increase the pitch angle significantly
Twisted and Helical Profile Extrusion
Twisted and Helical Profile Extrusion
Sheet Metal Forming
History of SMF
Applications of SMF
Characteristics of Sheet Metal
Basics of SMF
Basics of SMF
Basics of SMF
Basics of SMF
Basics of SMF
Forming Operations
Bending of Flat Sheet and Plate
Bending of Flat Sheet and Plate
Bending of Flat Sheet and Plate
Bending of Flat Sheet and Plate
Bending of Flat Sheet and Plate
Bending of Flat Sheet and Plate
Bending of Flat Sheet and Plate
Bending of Tubes
Roll Bending
Tube roll bending
Plate roll bending
Bulging
Shearing (Cutting)
Shearing Force
Stretch Forming
Stretch Forming
Stretch Forming
Stretch Forming Force
Rubber Forming
Sheet Hydroforming
Sheet Hydroforming
