Chapter3b Metal Forming - 012153

Extrusion
Extrusion is a compression forming process in which

the work material is forced to flow through a die
opening taking its shape
In general, extrusion is used to produce long parts of
uniform cross-sections
37
Cont.
Types of Extrusion
Extrusion can be classified based on the following:
(1) Physical Configuration
• Direct extrusion
• Indirect extrusion
(2) Working temperature (3) Process type

• Cold extrusion • Continuous process
• Warm extrusion • Discrete process
• Hot extrusion
38
Cont.
Direct Extrusion
Is also called Forward Extrusion
A metal billet is loaded into a container, and a ram
compresses the material, forcing it to flow through
one or more openings in a die at the opposite end of
the container
Starting billet cross section usually round, but final
shape is determined by die opening
39
Cont.
Hollow sections (for example, tubes) are possible in
direct
extrusion
The starting billet is prepared with a hole parallel to its

axis. This allows passage of a mandrel that is attached
to the block.
As the billet is compressed, the material is forced to flow

through the clearance between the mandrel and the die
opening
40
Cont.
Indirect Extrusion
Also called Backward Extrusion or Reverse Extrusion is
illustrated in figure below
41
Cont.
Hot versus Cold Extrusion
• Extrusion can be performed either hot or cold,

depending on the work metal and amount of strain to
which it is subjected during deformation
• Metal typically extruded hot include aluminum,

copper, magnesium, zinc, tin, and their alloys. These
same metals are sometimes extruded cold
42
Cont.
• Steel alloys are usually extruded hot, although more
ductile grades are sometimes cold extruded (for
example low-carbon steel)
• Aluminum is probably the most ideal metal for

extrusion (hot and cold), and many commercial
products are made by this process (for example, door
and window frames)
43
Cont.
Continuous versus Discrete Extrusion
• Some extrusion operations producing very long
sections in one cycle, but these operations are limited
by the size of the billet that can be loaded into the
extrusion container
• These processes are more accurately described as
semi-continuous extrusion
• In a discrete extrusion operation, a single part is
produced in each extrusion cycle
44
Cont.
 Advantages of Extrusion
 Relatively low die cost
 Good accuracy and excellent finish at high
production speeds
 Shapes of high strength can be produced
 Unlimited length of continuous cross-section
 Applications
 Rods
 Tubes (tooth paste tubes, shaving cream
tubes, cans
9
Analysis of Extrusion
Extrusion ratio also called the reduction ratio, it is
defined as
Ao
rx 
Af
where
rx = extrusion ratio;
Ao = cross-sectional area of the starting billet; and
Af = final cross-sectional area of the extruded section
Applies to both direct and indirect extrusion

45
Cont.
The True Strain in Extrusion
For ideal deformation process:
  ln rx
The actual true strain is given by the following empirical
equation:
  a  b ln r
x x
where x = extrusion strain; a and b are empirical

constants for a given die angle. Typical values of these
constants are a = 0.8 and b = 1.2 to 1.5
46
Cont.
Extrusion Pressure
For ideal deformation process:
p  Y f ln rx
For indirect extrusion:
p  Yf  x
where
Yf is the average flow stress during deformation based on
ideal strain 
47
Cont.
Extrusion Force and Power
The ram force in direct and indirect extrusion is simply
given as
F  p Ao
where F = ram force in extrusion (N), p = extrusion
pressure (MPa), and Ao = billet area (mm2)
48
Cont.
The power required to carry out the extrusion operation
is simply
PFv
where P = power in (J/s); F = ram force (N), and v =
ram velocity (m/s)
49
Impact Extrusion (Cont..)
 This is a cold impact extrusion carried out
at room a punch driven at a given speed
to extrude the blank work-piece into a
diem temperature: it involves
 Advantages
 No waste of materials
 Tolerances maintained
 High rate of production
 Better surface finish
15
Impact Extrusion (Cont..)
 Products
 Cold rolled screws (strong)
 Engine valve seats etc
16
Wire and Bar Drawing
Drawing is an operation in which the diameter of a wire
or bar is reduced by pulling it through a die opening
(bar drawing) or a series of die openings (wire drawing)
Similar to extrusion except in drawing operation the

work is pulled through the die
In extrusion operation, the work is pushed through the

die
50
Cont.
51
Cont.
Wire Drawing versus Bar Drawing
• The basic difference between wire drawing and bar
drawing is the stock size that is processed
• Wire Drawing applies to small-diameter stock. Wire

sizes down to 0.03 mm are possible
• Bar Drawing is the term used for large-diameter bar

and rod stock
52
Cont.
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
53
Cont.
Wire Drawing
Continuous drawing machines consisting of multiple draw dies
(typically 4 to 12) separated by accumulating drums
• Each drum 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
54
Cont.
55
Cont.
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
56
Cont.
57
Cont.
Preparation of the Work for Wire and Bar Drawing
• Annealing – to increase ductility of stock
• Cleaning - to prevent damage to work surface and
draw die
• Pointing – to reduce diameter of starting end to allow
insertion through draw die
58
Analysis of Drawing
Reduction Ratio: Change in size of work is usually
given by area reduction:
Ao  A f
r
Ao
where
r = area reduction in drawing;
Ao = original area of work (mm2) ; and
Af = final work (mm2)
59
Cont.
Draft: The difference between original and final stock
diameters
d  Do  D f
where
d = draft (mm),
Do = original diameter of work (mm), and
Df = final work diameter (mm)
60
Cont.
True Strain
If no friction occurred in drawing, true strain could be
determined as follows:
Ao 1
  ln  ln
Af 1 r
Drawing Stress
The stress that results from this ideal deformation is
given by A
  Y f   Y f ln o
Af
61
Cont.
Drawing Force
The draw force is then the area of the drawing cross
section multiplied by draw stress
F  Af 
62

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Extrusion

Extrusion is a compression forming process in which

(2) Working temperature (3) Process type

The starting billet is prepared with a hole parallel to its

As the billet is compressed, the material is forced to flow

• Extrusion can be performed either hot or cold,

• Metal typically extruded hot include aluminum,

• Aluminum is probably the most ideal metal for

Applies to both direct and indirect extrusion

where x = extrusion strain; a and b are empirical

Similar to extrusion except in drawing operation the

In extrusion operation, the work is pushed through the

• Wire Drawing applies to small-diameter stock. Wire

• Bar Drawing is the term used for large-diameter bar

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