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Mechanical Working of Metals (Extrusion and Drawing)

1. Extrusion is a process that forces a metal billet through a shaped die to produce a part with a uniform cross-section. It is commonly used for soft metals like aluminum and copper. 2. There are two main types of extrusion: direct and indirect. Indirect extrusion requires lower loads since there is less friction at the die-billet interface. 3. The ideal extrusion load can be calculated using the yield stress of the material, the volume of material displaced, and the reduction ratio between the initial and final cross-sectional areas.

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73 views50 pages

Mechanical Working of Metals (Extrusion and Drawing)

1. Extrusion is a process that forces a metal billet through a shaped die to produce a part with a uniform cross-section. It is commonly used for soft metals like aluminum and copper. 2. There are two main types of extrusion: direct and indirect. Indirect extrusion requires lower loads since there is less friction at the die-billet interface. 3. The ideal extrusion load can be calculated using the yield stress of the material, the volume of material displaced, and the reduction ratio between the initial and final cross-sectional areas.

Uploaded by

Michael Vincent Mirafuentes
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© © All Rights Reserved
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Mechanical Working of Metals

Extrusion and Drawing


Definition of Extrusion
The basic
process of
forcing a metal
billet through a
shaped die

Mainly used for


Soft Metals such
as Aluminum or
Copper and
done ‘hot’
EXTRUSION
Tools in Extrusion

RAM DIE
Extrusion Products
PRODUCTS OF
EXTRUSION

SOLID
Cross Sections

HOLLOW
Cross Sections
Types of Extrusion

Direct Extrusion
‘ram is separate
from the die’

Indirect
Extrusion
‘ram is with die’
Direct and Indirect Extrusion
Difference between Direct and
Indirect Extrusion
Indirect Extrusion
requires lower
extrusion loads
since less friction
is encountered!

Disadvantage in Indirect
Extrusion:
a) Difficulty in supporting
extruded products
b) Lower rigidity of die
Extrusion Load Profile
Load
Decreases
during
Increases
extrusion
after 85% of
proper
the metal has
been
extruded

Increases initially
as metal is being
upset into die
Extrusion Ratio

rx = extrusion ratio
Extrusion ratio of 35:1
Ao = area initial to 100:1 is done in the
industry!
Af = area final
Extrusion Work

Work = Force x Distance

Wx = xV lnr

Extrusion ratio affects the


amount of work required to
do extrusion!
Effect of Die Angle on
Extrusion Load
Effect of Die Angle
Low die angle
surface area is large, leading to:
• increased friction at die-billet interface & higher
friction results in larger ram force
Large die angle
• more ‘turbulence’ in metal flow during reduction:
• Turbulence increases ram force required
Optimum Die Angle

Optimum angle depends on work material, billet


temperature, and lubrication!
‘Redundant Work’

Refers to work required to bend the metal one way


and then bend it back to its original direction!
Effect of Die Shape on
Extrusion Load

VS

As the die orifice shape becomes more


complex, higher loads are required!
Extrusion Load Analysis

USE SLAB METHOD TO DETERMINE


EXTRUSION LOAD
Actual Extrusion Pressure
Summation of Forces along the horizontal:
d 02 d 02
 x  d x   Pdo d x   x  0
4 4
x = extrusion pressure profile
4x
 x   o exp
when length x is inside the
container
do o = yield stress
 = coefficient of friction
 4x 
 x   o 1   do = initial diameter
 do  x = length of billet inside the
container
Sample Problem
A 4’ long billet with diameter = 1.25” is direct
extruded to a diameter of 0.50”. For the work
metal, y = 45,000 lb/in2 and coefficient of
friction is 0.30.
Determine:
(a) extrusion ratio
(b) extrusion strain
(c) ram pressure at L = 4.0’, 2.5”, 1.0” and 0’.
Mean Extrusion Pressure
 4x 
 x   o 1  
 do 

 4Lo 
 max   o 1    min   o
 do 
When L = Lo When L =0

 max   min  2L 


 mean    o 1  
2  do 
Extrusion Load

Extrusion Force = Mean Pressure x Area of Contact

 2Lo 
Fx   o 1   Ao
 do 
Extrusion Work

RECALL: Wx = xV lnr

 2L 
Wextrusion   o 1  V ln r
 do 

This work equation may also be


transformed to calculate for the
power required to extrude a metal!
Sample Problem
For the given extrusion problem, if the ram was
moved at a rate of 1.0’ per 150 seconds,
determine:
(a) mean extrusion load
(b) extrusion work
(c) power required for this operation
(1 HP = 33,000 ft-lb/min)
Sample Problem
During the extrusion of a steel billet 1.5 m
long, 640 mm diameter it was noted that
the extrusion load was 128 MN when the
ram was 1/3 of the way through the cycle
and 111.6 MN when ½ through. Calculate
the coefficient of friction in the chamber.
Wire Drawing
Definition of Wire Drawing
• Wire drawing is a metal-reducing process
in which a wire rod is pulled through a
single die or a series of continuous dies,
thereby reducing its diameter.
• Various wire tempers can be produced by
a series of drawing and annealing
operations. (Temper refers to toughness.)
Wire Drawing
Deep Drawing
Products of Deep Drawing
Wire Drawing Products

WIRES

ROD STOCKS
Die Tandem
Drawing Series

“Since wire drawing is normally done ‘cold’,


annealing is sometimes necessary
between dies”
Drawing Die

“The longer the bearing, the


longer the life of the die!”
Features of a Draw Die

a) Entry region - funnels lubricant into the die to


prevent scoring of work and die
b) Approach - cone-shaped region where drawing
occurs
c) Bearing surface - determines final stock size
d) Back relief - exit zone - provided with a back
relief angle(half-angle) of about 30°
Die materials: tool steels or cemented carbides
Extrusion vs Drawing
Drawing Load
Drawing Load Analysis
Drawing Stress

Slab analysis will yield the equation for the


drawing stress as follows:


 1  B   d f 
2B

d  o  1   
 B   d o  

B= cot
Drawing Load

Drawing Load = Drawing Stress x Final Area


 1  B   d f 
2B
 d 2f 
Fd   o   1    
 B 
  d o   4 
 
Drawing Strain
• Drawing Strain is expressed in terms of
reduction in area, R

Ao  A f
R Ao = area initial

Ao Af = area final

In Drawing, maximum possible drawing strain is achieved


when:

drawing stress = flow stress of metal


Sample Problem

• Determine the maximum possible drawing


strain if steel wire (YS=140 MPa) is drawn
with die angle 4o and coefficient of friction
is 0.20.
Sample Problem
Rod stock is drawn through a draw die with an
entrance angle(2) of 12º. Starting diameter =
0.50” and final diameter = 0.35”. Coefficient of
friction at the die-work interface = 0.10.
Determine:
(a) area reduction
(b) drawing load for the operation
(c) horsepower to perform the operation if the
exit velocity of the stock = 2 ft/sec.
Sample Problem
• Calculate the drawing load required to
achieve 30% reduction in area on a 10-
mm diameter copper wire, given that the
yield stress of the metal is 235 MPa, die
angle is 8o and coefficient of friction is
0.08.
Advantages of Hot Working
• Decrease in energy required for
deformation
• Increased ability of metal to flow without
cracking
• Rapid diffusion decreases chemical
inhomogeneities
• Elimination of blowholes and porosities
• Refinement of coarse columnar grains to
fine equiaxed grains
Disadvantages of Hot Working
• Oxidation results to metal losses
• Reactive metals require inert atmosphere
• Decarburization of steels
• Poor surface finish
• Greater dimensional tolerance required
• Less uniform structure and properties
Ideal Extrusion Load

Work = Force x Distance

Wx = yV lnr

Px = ylnr

Fx = ylnrAo

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