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Extrusion

Extrusion is a metal forming process that uses either impact or combined methods. Impact extrusion uses cold forming to create very thin walls, while combined extrusion forces metal to flow both up and down inside a matrix using upper and lower punches. Combined extrusion is fast, can complete parts in few steps, produces large quantities at low cost, and wastes little material. Extrusion allows for intricate shapes at low cost and increases hardness, with minimal additional machining needed after. However, high tolerances can be difficult and the process is limited to ductile metals only.

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Ved Rewatkar
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36 views18 pages

Extrusion

Extrusion is a metal forming process that uses either impact or combined methods. Impact extrusion uses cold forming to create very thin walls, while combined extrusion forces metal to flow both up and down inside a matrix using upper and lower punches. Combined extrusion is fast, can complete parts in few steps, produces large quantities at low cost, and wastes little material. Extrusion allows for intricate shapes at low cost and increases hardness, with minimal additional machining needed after. However, high tolerances can be difficult and the process is limited to ductile metals only.

Uploaded by

Ved Rewatkar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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Extrusion

- Impact extrusion is carried out as cold forming. Very thin walls


are possible by backward impact extrusion method. Eg: making
tooth paste tubes, battery cases.
- Advantages of IE: large reductions and high production rates
Combined Extrusion
• Combined extrusion uses a combination of forward extrusion
and backward extrusion. The metal is confined inside a matrix
between the lower and upper punches. This forces the metal to
flow both up and down. The extruded part is lifted from the die
on the upward stroke of the slide by a lift out on the bed of the
press.
• Some aspects of combined extrusion are:
• 1. It is fast
• 2. It can complete parts in few steps
• 3. It can produce large quantities with low unit costs
• 4. It wastes little material
• 5. It can make parts with small radii
• 6. It requires mirror tooling
Advantages of Extrusion

•1. The tooling cost is low, as well as the cost due to material
•2. Intricate cross sectional shapes, hollow shapes and shapes
with undercuts can be produced.
•3. The hardness and the yield strength of the material are
increased.
•4. In most applications, no further machining is necessary
Limitations of Extrusion
1. High tolerances are difficult to achieve.
2. The process is limited to ductile materials.
3. Extruded products might suffer from surface cracking. It
might occur when the surface temperature rise significantly
due to high extrusion temperature, friction, or extrusion
speed.
4. Internal cracking might also occur. These cracks are
attributed to a state of secondary tensile stresses at the
center line of the deformation zone in the die.
5. For a small extrusion ratio and large die angle, the center of
the extrusion is not directly deformed, but dragged along by
the stretching outer surface material. This generates tensile
stresses in the core which can lead to 'arrow-head' failure or
center-burst detects.

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