ME2030: Manufacturing Processes 1

Metal Forming: Extrusion & Drawing

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Extrusion

Rolling

Forging

Extrusion

Stamping

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Extrusion & Drawing

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.
Video
S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Some Extruded Parts

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Some Extruded Parts

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Direct Extrusion

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Extrusion Analysis
Extrusion ratio, rx

Ao
Af

Assuming all sections

are circular, ideal
deformation, no friction,
no redundant work:
ln rx

Ram pressure
p Y f ln rx

Taking into account friction, p Y f (a b ln rx )

where a =0.8 and b =1.2 to 1.5.

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Extrusion Analysis
For direct extrusion, additional pressure, pf, required by the
extruder to overcome the wall friction is related as follows:
p f Do2
pcDo L (1) [equilibrium equation]
4

For the worst case that the friction shear stress at the wall
equals to the shear yield strength of the work metal:
(2)
pc Ys Yf / 2
Subs. (2) into (1), the additional pressure:

Do

p f Yf

2L
Do

The total ram pressure: p Y f x 2 L

The power required: P Fv
S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Example
A billet 75mm long and 25mm in diameter is to be extruded in
a direct extrusion operation with extrusion ratio rx = 4.0. The
extrudate has a round cross section. The die angle (half angle)
= 900. The work metal has a strength coefficient = 415 MPa,
and strain-hardening exponent = 0.18. Use the Johnson
formula with a = 0.8 and b = 1.5 to estimate extrusion strain.
Determine the pressure applied to the end of the billet as the
ram moves forward.

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Example

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

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Extrusion Dies

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

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Extrusion Dies
For the case of non-circular extruded section, a shape factor
has to be introduced:
C
K x 0.98 0.02 x
Cc

2.25

where Kx = shape factor

Cx = perimeter of the non-circular extruded section
Co = perimeter of a circle that has the same crosssectional area as the extruded section.
For direct extrusion, the extrusion force

2L

p K xY f x
Do

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

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Metal flow

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

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Impact Extrusion
Impact extrusion is performed at higher speeds and shorter strokes than
conventional extrusion.

It is for making discrete parts.

For making thin wall-thickness items by permitting large deformation at high
speed.

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

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Hydrostatic extrusion
The pressure required for extrusion is supplied through and incompressible
fluid medium surrounding the billet

Brittle materials are extruded generally by this method

Sealing is the major problem.

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

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Extrusion Defects
a) Centre-burst: internal crack due to excessive tensile stress at the centre
possibly because of high die angle, low extrusion ratio.

b) Piping: sink hole at the end of billet under direct extrusion.

c) Surface cracking: High part temperature due to low extrusion speed and high
strain rates.

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

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Wire and Bar Drawing

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

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Have a nice day!

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

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