See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/326210297

A study on metal extrusion process

Article · July 2018

CITATIONS READS
3 15,253

1 author:

Yogesh Dewang
LNCT Group of Colleges
47 PUBLICATIONS 209 CITATIONS

SEE PROFILE

All content following this page was uploaded by Yogesh Dewang on 05 July 2018.

The user has requested enhancement of the downloaded file.

 International Journal of LNCT, Vol 2(6)
ISSN (Online): 2456-9895
A study on metal extrusion process
Rahul Ranjan Yadav1, Yogesh Dewang2 and Jitendra Raghuvanshi2
M.tech scholar, Department of Mechanical Engineering, LNCT Bhopal, India1
Assistant Professor, Department of Mechanical Engineering, LNCT Bhopal, India2

Abstract
Extrusion is a manufacturing process used to create
objects of a fixed cross-sectional profile. A material is
pushed through a die of the desired cross-section. A brief
and concise review of the contributions made by the
previous researchers in the area of extrusion process has
been presented. Steel material and aluminium alloys are
mostly used by researchers as die and billet material in
extrusion process. FEM modeling of extrusion process is
carried out by employing axisymmetric conditions in most
cases. Meshing of the work piece is generally done by
using axisymmetric quadrilateral elements. Experimental
set-up and tools utilized in formation of extrusion process Figure 1 Direct extrusion [29]
are presented and discussed. FEM results are presented
in terms of variation of punch stroke, punch force.

Keywords
Tube extrusion process, Finite element simulation, Mesh
adaptivity, Thermo mechanical coupled extrusion.

1.Introduction
Extrusion is metal forming process which is widely
used in industry and daily life equipment . It is
another kind of manufacturing process which
involves shearing and compression. Practical
application of extrusion includes railing for sliding Figure 2 Indirect extrusion [29]
doors, tubing having various cross sections, structural
and architectural shapes, and door and window In indirect extrusion process a hollow ram drives the
frames. Extruded products can be cut into desired die back through a stationary, confined billet. Since
lengths, which then become discrete parts such as no relative motion, friction between the billet and
brackets, gears and coat hangers. It is a process in chamber is eliminated and the required force is lower.
which required product can be formed are formed by In impact extrusion process the extruded part are
using round die or it may various shapes. A round stripped by the use of stripper plate, because they
billet is placed in a chamber and force through a die tend to sticks to the punch.
opening by hydraulically driven ram or pressing or
pressing stem. This process usually comprises of
axisymmetric die.

The die angle, reduction in cross-section, Extrusion

speed, billet temperature and lubrication all affect the
extrusion pressure. Extrusion is generally classified
into four types. They are: Direct extrusion, indirect
extrusion, impact extrusionand hydrostatic extrusion.
In direct extrusion a solid ram drives the entire billet
to and through a stationary die and must provided
additional power to overcome the frictional power to
overcome the frictional resistance between the Figure 3 Hydrostatics Extrusion [30]
surface of the moving billet and confining chamber.

124
 International Journal of LNCT, Vol 2(6)

In hydrostatics extrusion high pressure fluid applies scale surface features. Chen et al. [12] hot extrusion
the force to the workpiece through a die. Billet- experiments of AZ91 alloy were carried out at
chamber friction is eliminated, and the pressurised various ram velocities of 0.1, 0.5 and 1.0 mm/ s.
fluid acts as a lubricant between the billet and the die. They investigated the dead metal zone, shearing
In extrusion mesh distortion is the major problem of zone, inflowing zone and slight deformation zone of
FE simulation. In this study we focused on the area of the part remaining from extrusion exhibited varied
mesh adaptivity and thermo mechanical modelling of microstructure characteristics. Rattanochaikul et al.
the forming process. In past, various researchers [13] reports a preliminary research and development
contributed in the area of metal extrusion process. work of a new rheo-extrusion process using the Gas
Subramanian and, Palaniradja [1] investigated by Induced Semi-Solid (GISS) technique. The effects of
simulating tension and compression by using the plunger speeds and solid fractions on the
different extrusion textures, they found the extrudability of an aluminum 356 alloy were
differences of mechanical properties between center investigated. Pathak et al. [14] investigated a finite
and side areas of the extruded bar. Hojda et al. [2] element simulation of tube extrusion process by
used Abaqus/Standard for a 3D Finite Element different mesh adaptivity schemes. A comparison of
Method is presented that is capable of simulating the these schemes has been made based on stress, strain
highly nonlinear hybrid forward extrusion process distribution, and load-stroke curves. Khosravifard et
(thermomechanical and electric field) incorporating a al. [15] a finite element analyses of rod extrusion
remeshing routine, this model is extended to couple a process are carried out considering various
strain based damage with electrical resistivity Ab processing parameters. They investigated the effect
Rahim et al. [3] investigated the trends and the of these parameters on mechanical performance.
concept of emerging to identify the recyclability Pathak et al. [16] used genetic algorithm (GA) and
contents of the product for recycling aluminum chips dynamic material modeling (DMM) for experimental
by the hot extrusion process. Zhou et al. [4] used an verification of a proposed extrusion die profile design
analytical model for predicting the shapes of approach, which aims to satisfy micro structural
rectangular bars with variable curvatures along their criteria at maximum production speed and minimum
lengths through a novel forming method, differential left out material in the die cavity. Bovas et al. [17]
velocity sideways extrusion (DVSE) has been they investigated the effect of melt temperature on
developed on the basis of the upper bound method. the surface roughness and wettability of the catheter
Joun et al. [5] used dynamic material modeling surfaces were analyzed through ANOVA. Matli et al.
(DMM) for selection the processing parameter. [18] a nano-sized Si3N4 (0, 0.5, 1.0 and 1.5 vol%)/Al
Akhgar et al. [6] investigated hot extrusion of composites were fabricated using a powder
AA6061–5% SiCp composite to determine the metallurgy method involving microwave sintering
composite thermo-mechanical behavior during technique followed by hot extrusion. The influence of
deformation and the mechanical proper- ties of Si3N4 content on the structural, mechanical and
extruded composite. Pourbahari et al. [7] investigated thermal behaviour of Al–Si3N4 nanocomposites was
on the grain refinement by the dynamic systematically investigated. Chen et al. [19] the
recrystallisation (DRX). Tahmasbi et al. [8] used isothermal hot compression tests of homogenized
Friction stir extrusion (FSE) process in which a 7005 aluminium alloy at the deformation
sample is produced through the heat generated by the temperatures ranging from 623 K to 823 K and with
friction between die and materials, and the extrusion the strain rates ranging from 0.001 s 1 to 10 s 1 were
pressure.Yu and Zhao [9] investigated on the Fine conducted for constitutive analysis. Dong et al. [20] a
nano structures of bonding interfaces of weld seams deep understanding of hot deformation behaviour of a
formed by porthole die extrusion in the absence/ material plays a crucial role in determining process
presence of a gas-pocket behind the bridge of the parameters and designing extrusion dies during the
extrusion die to understand the underlying interfacial extrusion process of the aluminium alloy profiles.
bonding mechanisms. Sahu et al. [10] investigates the Ebrahimi et al. [21] equal channel forward extrusion
multi-hole extrusion process. Forward, backward and process as a severe plastic deformation method has
forward-backward multi-hole extrusions have been been experimentally and numerically investigated on
carried out to determine the extrusion load and the 6082 aluminium alloy. Gagliardi et al.[22]
variation of extruded product lengths. Wang and investigated the porthole die profile used to produce
Feng. [11] they were carried out experimental and hollow complex cross-section profiles. 12 geometric
numerical simulation to demonstrate that extrusion- variables of a standard porthole die, used to extrude
forging process can be used to create such micro profiles with circular section, were identified and

125
Yadav et al.

varied on three levels. 23. Parvizian et al. [23] they optimum conical and curved die has been performed
modeled and simulate hot metal forming processes in experimentally and also by finite element method.
which material undergoes large deformations with
help of the Finite Element (FE) software ABAQUS 2.Overview of extrusion process
using Lagrangian formulation. Hosseini et al. [24] a 2.1Material utilised in extrusion process
modified novel backward extrusion process Metals that are commonly extruded include
implementing severe plastic deformation is presented Aluminium, Brass, Copper, Lead and tin,
for processing of ultrafine-grained materials. The Magnesium, Zinc, steel, Titanium. Aluminium is
process was applied to commercially pure most commonly extruded material. Aluminium can
aluminium, and microstructure and micro hardness be hot or cold extruded, If it is hot extruded it is
measurements were investigated. Ramezani and heated to (300 to 6000C). Magnesium and
Neitzert [25] developed FE model can be used for Aluminium alloys have a 0.75 micrometer RMS or
investigating direct extrusion and selecting better surface finish. Titanium and steel can achieve a
appropriate die design parameters for the process. 3 micrometers RMS. Table 1 shows the description
Reddy et al. [26] investigated pure aluminium for of the author who have used variety of material as a
Equal Channel Angular Extrusion (ECAE) extruded material for manufacturing by extrusion
processing. Kapadia and Desai [27] investigated both process. It is clear from table that in majority of the
analytical and simulation result. Simulation of direct researchers have used Al materials. Some cases they
extrusion of Aluminum alloy (6063) in the form of have also used different Magnesium alloy for
round circular billet to round circular solid profile is extrusion process.
done. Ghaemi et al. (2013) [28] investigated on the
shape of die profile. Extrusion process through both

Table 1 Metal used work piece by previous researchers

Author Year Material

Subramanian and, Palaniradja [1] 2018 Magnesium alloy

Akhgar et al. [6] 2011 AA6061-5% Sicp

Pourbahari et al. [7] 2018 MG-Gd-Al-Zn magnesium alloy

Tahmasbi et al. [8] 2018 Aluminium alloy AA7022

Chen et al. [12] 2018 Az 91 alloy

Rattanochaikul et al. [13] 2017 Aluminium 356 alloy

Matli et al. [18] 2017 Al-Si3N4 nano compoites

Chen et al. [19] 2015 7005 Aluminium alloy

Dong et al. [20] 2016 AA6N01

Ebrahimi et al. [21] 2016 6082 Aluminium alloy

Ramezani and neitzert et al.[25] 2016 Ti-6Al-4v powder alloy

Kobayashi et al.[27] 1989 Al alloy (6063)

2.2FEM modelling of extrusion process using aluminum as billet material and steel as die-
Finite element simulation is considered as a powerful material. Figure 4 shows the schematic illustration of
and efficient methodology for obtaining defect free tube extrusion process and Figure 5 shows FEM
products in extrusion process, as various researchers model of axisymmetrical tube extrusion. Table 2
applied this method in the past. Jain et al. [14] shows the material properties of the billet and die.
conducted FEM simulation of tube extrusion process
126
 International Journal of LNCT, Vol 2(6)

Materials for die and tube are die steel and

aluminium, respectively

Figure 4 Tube extrusion setup [14]

Figure 6 (a) Solid forward extrusion process with

resistive heating

Figure 5 FEM Simulation [14]

Table 2 Material properties of billet and die materials

Material Billet Die
Properties

Young’s 70000 220000

Modulus (Mpa)

Yield Strength 80 1200

(Mpa)

Poisson ratio 0.3 0.3

Figure 6 (b) Shape of the formed part and computer
Hardening 0 0 tomographic image of cold and warm formed
Component

Hirt et al. (2017) utilized commercial software

package ABAQUS for three-dimensional FEM
simulation of hybrid forward extrusion process. They
performed a thermo- mechanical and electrical
analysis of forward extrusion process. Figure 6 (a)
shows the solid forward extrusion process with
resistive heating, Figure 6 (b) shape of the formed
part and computer tomographic image of cold and
warm formed part in the region of extrusion shoulder
three. Figure 6 (c) shows geometry of extrusion die
.Figure 6 (d) shows the flow curves for different
temperatures at at a constant strain rate of 1 s-1.
Figure 6 (c) Shows geometry of extrusion die

127
Yadav et al.

Figure 6 (d) Shows the flow curves for different Figure 7 Mesh topology in simulation of forging
temperatures at constant strain rate of 1 s-1 process using remeshing scheme
Figure 6 a)solid forward extrusion process extended
3.Result and discussion
with resistive heating b) shape of the formed part and
The FE model presented different types of result
computer tomographic image of cold and warm
there are force predicted by the FE simulation, the
formed part in the region of extrusion shoulder three
forces are shown together with the corresponding
c) geometry of the extrusion die d) flow curves for
measured force from experimental for three condition
different temperatures at a constant strain rate of 1 s-1.
cold, preheated and hybrid condition in Figure 3. As
[2] Mahnken et al. (2010) (23) they modelled and
a good match of the rising force at each projection at
simulate hot metal forming processes in which
nearly the same punch stroke in experiment and
material undergoes large deformations with help of
simulation is an indication of the properly
the Finite Element (FE) software ABAQUS using
implemented re meshing procedure and volume loss
Lagrangian formulation. The microstructure
is negligible.
evolution is modelled effectively with the help of
internal state variables. Element distortion and
contact during the re meshing simulation of large
deformation processes is controlled with the help of a
custom adaptive remeshing system based on Python
scripting and utilisable in commercial programs such
as ABAQUS. Element distortion of material can be
by using an adaptive remeshing scheme. They
improved the quality of the mesh of number of
elements during the simulation. Figure 6 is done by
using the adaptive refinement. After each small time
step, the distorted elements will be identified in a
post processing step. Then the distorted elements
divided into smaller elements. The number of
elements started from around 2000 at beginning of
the simulation and increases up around8000 at the
end of the simulation.

Figure 6 Simulation of extrusion process using

adaptive mesh refinement
128
 International Journal of LNCT, Vol 2(6)

[2] Hojda S, Sturm KJ, Terhorst M, Klocke F, Hirt G.

Damage dependent material properties in a Finite
Element Simulation of a hybrid forward extrusion
process. Procedia Engineering. 2017; 207:437-41.
[3] Ab Rahim SN, Lajis MA, Ariffin S. A review on
recycling aluminum chips by hot extrusion process.
Procedia CIRP. 2015; 26:761-6.
[4] Zhou W, Shi Z, Lin J. Upper bound analysis of
differential velocity sideways extrusion process for
curved profiles using a fan-shaped flow line model.
International Journal of Lightweight Materials and
Manufacture. 2018; 1(1):21-32.
[5] Joun MS, Hwang SM. Die shape optimal design in
three‐dimensional shape metal extrusion by the finite
element method. International Journal for numerical
Figure 8 Comparison of measured and simulated methods in engineering. 1998; 41(2):311-35.
punch forces for (a) cold (b) pre-heated to 450°C and [6] Akhgar JM, Mirjalili A, Serajzadeh S. An
investigation into the deformation behaviour of
(c) hybrid condition.[2] AA6061-5% SiCp composite during and after hot
extrusion process. Proceedings of the Institution of
The thermo mechanically coupled extrusion process Mechanical Engineers, Part L: Journal of Materials:
of aluminium alloys and forging of steels, both are Design and Applications. 2011; 225(1):22-31.
[7] Pourbahari B, Mirzadeh H, Emamy M, Roumina R.
implemented as user material subroutines (UMAT) in
Enhanced ductility of a fine‐grained Mg–Gd–Al–Zn
FE software ABAQUS. The CAX4TR element which magnesium alloy by hot extrusion. Advanced
is quadrilateral axisymmetric element are applied Engineering Materials. 2018:1701171.
with temperature as a degree of freedom in a coupled [8] Tahmasbi K, Mahmoodi M. Evaluation of
temperature-displacement simulation. ABAQUS microstructure and mechanical properties of aluminum
gives to the output database of the simulation results AA7022 produced by friction stir extrusion. Journal of
by using the Python programming language. The Manufacturing Processes. 2018; 32:151-9.
system enables us to check the mesh quality or any [9] Yu J, Zhao G. Interfacial structure and bonding
other remeshing criteria in a post processing step. mechanism of weld seams during porthole die
extrusion of aluminum alloy profiles. Materials
Characterization. 2018; 138:56-66.
4.Conclusion and future work [10] Sahu RK, Das R, Dash B, Routara BC. Finite element
In the body of work presented in this paper, extrusion analysis and experimental study on forward, backward
process is studied by considering various aspects of and forward-backward multi-hole extrusion process.
extrusion process. A brief and concise review of the Materials Today: Proceedings. 2018; 5(2):5229-34.
contributions made by the previous researchers in the [11] Wang J, Feng Z. Manufacturing of surface features
area of extrusion process is also presented. It is found from extrusion forging and extrusion rolling of sheet
metals. Manufacturing Letters. 2018; 15:42-5.
that researchers have utilized aluminium material for
[12] Chen L, Liang M, Zhao G, Zhou J, Zhang C.
extrusion as workpiece material in majority of cases, Microstructure evolution of AZ91 alloy during hot
however in the recent past, the usage of steel alloy extrusion process with various ram velocity. Vacuum.
has also been started. It has also been found that 2018; 150:136-43.
researchers carried out FEM modelling of extrusion [13] Rattanochaikul T, Janudom S, Memongkol N,
process by employing axisymmetric conditions and Wannasin J. Development of an Aluminum semi-solid
modelled problem with half and quarter geometry. extrusion process. Journal of Metals, Materials and
Meshing of the die is done by using axisymmetric Minerals. 2017; 20(2):17-21.
quadrilateral elements. FEM simulation is found be [14] Pathak KK, Patil PD, Kalinadh AR, Jain KC.
Comparison of Mesh Adaptivity Schemes in Finite
powerful and efficient methodology in analysis of
ElementSimulation of Tube Extrusion Process.
metal extrusion process. Defence Science Journal. 2008; 58(3):415-21.
[15] Khosravifard A, Ebrahimi R. Investigation of
References parameters affecting interface strength in Al/Cu clad
[1] Subramanian C, Palaniradja K. Experimental bimetal rod extrusion process. Materials & Design.
investigation of mechanical properties on Al 7075 2010; 31(1):493-9.
using electroless Ni-P/Ni-B duplex coating with nano [16] Pathak KK, Lomash S, Jha AK. Die profile design for
SiC. International Journal of Advanced Technology tube extrusion and its experimental verification.
and Engineering Exploration. 2018; 5(39):30-6.

129
 Yadav et al.

Journal of the Brazilian Society of Mechanical [24] Hosseini SH, Abrinia K, Faraji G. Applicability of a
Sciences and Engineering. 2010; 32(2):160-4. modified backward extrusion process on commercially
[17] Bovas BC, Karunamoorthy L, Chuan FB. Effect of pure aluminum. Materials & Design (1980-2015).
extrusion process melt temperature on polyurethane 2015 ; 65:521-8.
catheter surfaces. Materials and Manufacturing [25] Ramezani M, Neitzert T. Computer simulations of
Processes. 2018; 33(2):180-5. direct extrusion of sintered Ti-6Al-4V alloy at
[18] Matli PR, Ubaid F, Shakoor RA, Parande G, Manakari elevated temperature. International Journal of Applied
V, Yusuf M, et al. Improved properties of Al–Si 3 N 4 Engineering Research. 2016; 11(6):3848-52.
nanocomposites fabricated through a microwave [26] Reddy MV, Reddy MC, Reddy PV. Investigating the
sintering and hot extrusion process. RSC Advances. Mechanical Properties of FCC Structured Material
2017; 7(55):34401-10. Processed by Equal Channel Angular Extrusion.
[19] Chen L, Zhao G, Yu J, Zhang W. Constitutive analysis International Journal of Applied Engineering
of homogenized 7005 aluminum alloy at evaluated Research. 2018; 13(6):3716-8.
temperature for extrusion process. Materials & Design [27] Kobayashi S, Oh SI, Altan T. Metal forming and the
(1980-2015). 2015; 66:129-36. finite-element method. Oxford University Press on
[20] Dong Y, Zhang C, Zhao G, Guan Y, Gao A, Sun W. Demand; 1989.
Constitutive equation and processing maps of an Al– [28] Ghaemi F, Ebrahimi R, Hosseinifar R. Optimization of
Mg–Si aluminum alloy: Determination and application die profile for cold forward extrusion using an
in simulating extrusion process of complex profiles. improved slab method analysis. Iranian Journal of
Materials & Design. 2016; 92:983-97. Science and Technology. Transactions of Mechanical
[21] Ebrahimi M, Gholipour H, Djavanroodi F. A study on Engineering. 2013; 37(M2):189.
the capability of equal channel forward extrusion [29] Groover MP. Fundamentals of modern manufacturing:
process. Materials Science and Engineering: A. 2016; materials processes, and systems. John Wiley & Sons;
650:1-7. 2007.
[22] Gagliardi F, Ciancio C, Ambrogio G. Optimization of [30] Chittenden RH. History of the Sheffield Scientific
porthole die extrusion by Grey-Taguchi relational School of Yale University, 1846-1922. Yale
analysis. The International Journal of Advanced University Press; 1928.
Manufacturing Technology. 2018; 94(1-4):719-28.
[23] Parvizian F, Schneidt A, Svendsen B, Mahnken R.
Thermo‐mechanically coupled modeling and
simulation of hot metal‐forming processes using
adaptive remeshing method. GAMM‐Mitteilungen.
2010; 33(1):95-115.

130

View publication stats