Extrusion

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Extrusion is a method of forming in which metals or plastics are forced through a die
or series of dies, resulting in a specific shape of constant cross-section. With the proper
tooling, extrusions may be tapered or stepped. Extrusions can be either very thick in
cross-section or very thin and be either solid or hollow. The extruded stock, which can
be 100 feet in length or longer, is then cut to a convenient stock size and used as
specific products, assembly components, or as raw stock material for further
processing. In the extrusion process, the billet is placed in a container and pushed
through the die opening using a ram and dummy block. Both ram and billet move.

Extrusion Parameters:

Extrusion ratio: It is the ratio of the area of the cross-section of the billet to the area of
the cross-section of the extrude. R = Ao/Af

Another parameter used in extrusion is the shape factor. It is the ratio of the perimeter
to the cross-section of the part. An extruded rod has the lowest shape factor.

Types of Extrusion:
Extrusion is classified in general into four types. They are:
 Direct extrusion,
 Indirect extrusion,
 Impact extrusion and
 Hydrostatic extrusion.
Direct extrusion:

Direct extrusion, also called forward extrusion, is a process in which the billet moves
along the same direction as the ram and punch. The sliding of the billet is against a
stationary container wall. Friction between the container and billet is high. As a result,
greater forces are required. A dummy block of a slightly lower diameter than the billet
diameter is used to prevent oxidation of the billet in hot extrusion. Hollow sections like
tubes can be extruded by direct method, by using a hollow billet and a mandrel
attached to the dummy block.

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 Fig: Direct Extrusion

Fig: Indirect Extrusion

Indirect extrusion:
Indirect extrusion (backward extrusion) is a process in which the punch moves opposite
to that of the billet. Here there is no relative motion between the container and the
billet. Hence, there is less friction and hence reduced forces are required for indirect
extrusion. For extruding solid pieces, a hollow punch is required. In hollow extrusion, the
material gets forced through the annular space between the solid punch and the
container. The variation of extrusion pressure in indirect extrusion is shown above. As
seen, extrusion pressure for indirect extrusion is lower than that for direct extrusion.
Many components are manufactured by combining direct and indirect extrusions.

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Indirect extrusion can not be used for extruding long extrudes.

Hydrostatic extrusion:

In hydrostatic extrusion, the container is filled with a fluid. Extrusion pressure is

transmitted through the fluid to the billet. Friction is eliminated in this process because
there is no contact between the billet and the container wall. Brittle materials can be
extruded using this process. Highly brittle materials can be extruded into a pressure
chamber. Greater reductions are possible by this method. The pressure involved in the
process may be as high as 1700 MPa. Pressure is limited by the strength of the
container, punch, and die materials. Vegetable oils such as castor oil are used.
Normally this process is carried out at room temperature. A couple of disadvantages of
the process are: leakage of pressurized oil and uncontrolled speed of extrusion at exit,
due to release of stored energy by the oil. This may result in shock in the machinery.

This problem is overcome by making the punch come into contact with the billet and
reducing the quantity of oil through less clearance between the billet and the container.
Hydrostatic extrusion is employed for making aluminum or copper wires-especially
for reducing their diameters. Ceramics can be extruded by this process. Cladding is
another application of the process. Extrusion ratios from 20 (for steels) to as high as 200
(for aluminum) can be achieved in this process.

Fig: Hydrostatic Extrusion

Impact extrusion: Hollow sections such as cups, toothpaste containers are made by
impact extrusion. It is a variation of indirect extrusion. The punch is made to strike the

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slug at high speed by impact load. Tubes of small wall thickness can be produced.
Usually, metals like copper, aluminum, a n d lead are impact extruded.

Tube extrusion:

By employing a hollow billet and a mandrel at the end of the ram, hollow sections
such as tubes can be extruded to closer tolerances. The mandrel extends up to the
entrance of the die. Clearance between the mandrel and die wall decides the wall
thickness of the tube. The mandrel is made to travel along with the ram to make
concentric tubes by extrusion.

Fig. Tube extrusion

Tubes are made using a solid billet and a piercing mandrel to produce the hollow. The
piercing mandrel is made to move independently with the help of a hydraulic press. It
moves along with the ram coaxially. First, the ram upsets the billet, keeping the
mandrel withdrawn. Next, the mandrel pierces the billet and ejects a plug of material
from the center. Then the ram and mandrel together are moved in and extrude the
billet.

Metal Extrusion
Metal extrusion processes may be performed hot, warm, or cold. Each method has its
own unique operating parameters.

Hot Extrusion uses heated feedstock, called a billet, that ranges in temperature from
200° to 2,300° Fahrenheit, or 90° to 1,260° Celsius depending on the material.
Aluminum is the most common hot extruded material, with billet temperatures ranging
from 575° to 1,100° Fahrenheit, or 300° to 600° Celsius.
Hot extrusion is always performed at temperatures much higher than the
recrystallization temperature of the material to be extruded. The heated billet is
confined in a container, force is applied and the billet is extruded through a die or dies.
Hot extrusion is used to produce close tolerance dimensions as well as smooth, fine
surfaces. Additionally, and depending on the metal used, improved microstructures are
obtained. The process is also very economical in that most of the metal extruded is
usable.

The primary type of hot extrusion is direct, or forward, extrusion. Direct extrusion is
commonly performed in horizontal hydraulic presses. The heated billet is loaded into a
thick-walled container from which it is pushed through the extrusion die by a ram.
Between the ram and the billet is an intermediate dummy block. Lubrication is used to
reduce friction along the billet length and its container. In operation, force
increases rapidly as the billet is upset to fill the container, then increases further as a
breakthrough force before extrusion begins. Upon breakthrough, the force declines as
billet length decreases until a minimum force is reached. As the billet thins, the force
rapidly rises again to continue metal flow radially toward the die opening.

Hot extrusion presses are rated in force capacity which relates to available ram
pressure on the billet. Ram pressure requirements are based upon:
 Billet material and temper
 Cross-section dimensions
 Complexity of the extrusion
 Extrusion length and temperature
 Another factor in determining ram force requirements is the extrusion ratio.
This is determined by dividing the cross-sectional area of the container liner by
the cross-sectional area of the die openings.

Warm and Cold Extrusion Processes

Warm extrusion refers to the extruding of feedstock or billet while it is above room
temperature, but well below the recrystallization temperatures used in hot extrusion.
Cold extrusion refers to extrusion at room temperature. Because the feedstock is at
lower temperatures, no micro-structural changes occur during processing. Warm and
cold extrusion processes increase the strength and hardness of the finished extrusion.
Reduced heat also lowers pollution concerns and eliminates costly high-temperature
tooling. While virtually all metals may be warm and cold extruded, those having the
highest ductility are more suited for processing. Warm and cold extrusion processes
are commonly integrated into continuous and semi-continuous manufacturing
operations, with the three primary methods including:
  Indirect extrusion
 Combination extrusion
 Impact extrusion

Indirect extrusion, which is also called backward extrusion, is used to produce

hollow shapes with the inside diameter defined by the male punch and the outside
diameter controlled by the female die. Combination extrusion combines various types
of extruding including direct and indirect methods to produce more complex shapes.
Impact extrusion is similar to the other extrusion methods described, but is a much
faster process. Using shorter strokes and shallower dies, punch impact moves the
feedstock slug either up, down, or in both directions at once, without being completely
confined by either the punch or die walls. Ductile and low melting point metals such as
tin, aluminum, zinc, and copper are well suited for impact extruding.