Extrusion is a process that uses pressure to force heated metal material through a die to create parts with a constant cross-section. There are two main types of extrusion: direct and indirect. Direct extrusion involves pushing the material through the die in the same direction as the ram movement, while indirect extrusion moves the material in the opposite direction of the ram. Extrusion can be performed hot or cold depending on the material, with hot extrusion allowing for more complex shapes from more readily extrudable metals like aluminum. Proper die material and lubrication are important for reducing friction during extrusion.
It is a near net shape process in which casting and forging is done in single step.
It is Referred by many names such as “squeeze casting” , “pressure infiltration”, “liquid metal forging”, “extrusion casting”, “liquid pressing'', “pressure crystallization”.
It is a near net shape process in which casting and forging is done in single step.
It is Referred by many names such as “squeeze casting” , “pressure infiltration”, “liquid metal forging”, “extrusion casting”, “liquid pressing'', “pressure crystallization”.
Tensile, Impact and Hardness Testing of Mild SteelGulfam Hussain
The main purpose of this report is to study the mechanical properties and
failure mode of mild steel. Three types of standard tests i.e. tensile test, impact
test, and hardness test were conducted on the standard specimens of mild steel.
From the tests, results were obtained; Tensile strength, Impact strength, and
hardness were calculated. It was observed that Tensile Strength, Impact Strength
and Hardness of MS specimen were 1450.833 N/mm², 29.5 J & 59.25 HRB.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
Quality defects in TMT Bars, Possible causes and Potential Solutions.PrashantGoswami42
Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
TECHNICAL TRAINING MANUAL GENERAL FAMILIARIZATION COURSEDuvanRamosGarzon1
AIRCRAFT GENERAL
The Single Aisle is the most advanced family aircraft in service today, with fly-by-wire flight controls.
The A318, A319, A320 and A321 are twin-engine subsonic medium range aircraft.
The family offers a choice of engines
Courier management system project report.pdfKamal Acharya
It is now-a-days very important for the people to send or receive articles like imported furniture, electronic items, gifts, business goods and the like. People depend vastly on different transport systems which mostly use the manual way of receiving and delivering the articles. There is no way to track the articles till they are received and there is no way to let the customer know what happened in transit, once he booked some articles. In such a situation, we need a system which completely computerizes the cargo activities including time to time tracking of the articles sent. This need is fulfilled by Courier Management System software which is online software for the cargo management people that enables them to receive the goods from a source and send them to a required destination and track their status from time to time.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Automobile Management System Project Report.pdfKamal Acharya
The proposed project is developed to manage the automobile in the automobile dealer company. The main module in this project is login, automobile management, customer management, sales, complaints and reports. The first module is the login. The automobile showroom owner should login to the project for usage. The username and password are verified and if it is correct, next form opens. If the username and password are not correct, it shows the error message.
When a customer search for a automobile, if the automobile is available, they will be taken to a page that shows the details of the automobile including automobile name, automobile ID, quantity, price etc. “Automobile Management System” is useful for maintaining automobiles, customers effectively and hence helps for establishing good relation between customer and automobile organization. It contains various customized modules for effectively maintaining automobiles and stock information accurately and safely.
When the automobile is sold to the customer, stock will be reduced automatically. When a new purchase is made, stock will be increased automatically. While selecting automobiles for sale, the proposed software will automatically check for total number of available stock of that particular item, if the total stock of that particular item is less than 5, software will notify the user to purchase the particular item.
Also when the user tries to sale items which are not in stock, the system will prompt the user that the stock is not enough. Customers of this system can search for a automobile; can purchase a automobile easily by selecting fast. On the other hand the stock of automobiles can be maintained perfectly by the automobile shop manager overcoming the drawbacks of existing system.
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
2. Extrusion is the process by which a
block/billet of metal is reduced in cross
section by forcing it to flow through a die
under high pressure.
It is a manufacturing process, in which a
block of metal enclosed in a container is
forced to flow through the opening of a
die.
• The metal is subjected to plastic
deformation & it undergoes reduction
& elongation.
Extrusion
3. In general, extrusion is used to produce cylindrical bars
or hollow tubes or for the starting stock for drawn rod,
cold extrusion or forged products.
Most metals are hot extruded due to large amount of
forces required in extrusion. Complex shape can be
extruded from the more readily extrudable metals such
as Aluminium.
The products obtained are also called extrusion.
What Is Extrusion
4. CLASSIFICATION OF EXTRUSION PROCESSES
Extrusion
By Direction
By
Equipment
By Operating
Temperature
Indirect /
Backward
Direct /
Forward
Hot Cold Horizontal Vertical
5. It is a process in which the metal billet, placed
in a container is forced by a ram to pass
through a die.
In this type the direction of flow of metal is,
in same as that of movement of ram.
The punch closely fits the die cavity to
prevent backward flow of the material.
The dummy block or pressure plate, is placed at
the end of the ram in contact with the billet.
Friction is at the die and container wall
requires higher pressure than indirect
extrusion.
Direct Extrusion
6. To repeatedly transmit the force of the ram, at high
temperature, to the alloy.
To expand quickly under load and maintain a secure seal
with the container wall.
To separate cleanly from the billet at the end of the stroke.
To cause no gas entrapment that can result in blistering, or
damage the face of the container and/or dummy block.
To compensate for minor press misalignment.
To be quickly and easily removed and replaced.
To function effectively until a production run is complete.
Function Of Dummy Block
7. It is a process in which a hollow ram
containing the die is forced into the
container, containing metal.
Hollow ram limits the applied load.
The movement of metal is opposite to
the direction of ram motion.
The hollow ram containing the die is
kept stationary and the container with
the billet is caused to move.
Friction at the die only (no relative
movement at the container wall)
requires roughly constant pressure.
Hollow ram limits the applied load.
In-direct Extrusion
8. It is done at fairly high temperatures, approximately
50 to 75% of the melting point of the metal.
Die life and components are effected due to the high
temperatures and pressures, which makes lubrication
necessary. Pressures Ranges: 35-700 Mpa.
Hot extrusion is a hot working process, which means it
is done above the material's recrystallization
temperature to keep the material workable hardening
and to make it easier to push the material.
The biggest disadvantage of this process is its cost for
machinery.
Hot Extrusion
9. TYPES OF HOT EXTRUSION
Hot Extrusion
Lubricated HydrostaticNon-Lubricated
10. Before the billet is inserted into the hot
extrusion container, a suitable lubricating
system is positioned immediately ahead of
the die in order to reduce frictional
stresses.
Oil and graphite are used at lower
temperature whereas at higher
temperatures, glass powder is used.
Copper alloys, titanium alloys, alloy steels,
stainless steels, and tool steels are
extruded using lubrication.
LUBRICATED HOT EXTRUSION
11. No lubrication is used on the billet,
container, or die for reducing
frictional stresses.
It has the ability to produce very
complex sections with excellent
surface finishes and low dimensional
tolerances.
Solid and hollow dies with flat shear
faces are typically used.
NON-LUBRICATED HOT EXTRUSION
12. • In the hydrostatic extrusion process the billet is
completely surrounded by a pressurized liquid,
except where the billet contacts the die.
• The rate, with which the billet moves when
pressing in the direction of the die, is thus not
equal to the ram speed, but is proportional to
the displaced hydrostatics medium volume.
• The process must be carried out in a sealed
cylinder to contain the hydrostatic medium.
• Pressure = 1400 Mpa (approx.)
HYDROSTATIC EXTRUSION
13. Advantages & Limitations
Advantages:
• Elimination of large friction force
between the billet and the
container wall.
• Possible to use dies with a very low
semi cone angle (α-200).
• This process can be done hot, warm,
or cold, however the temperature
is limited by the stability of the fluid
used.
Limitations:
•Not suitable for hot-working due
to pressurized liquid.
•A practical limit on fluid pressure is
around 1.7GPa currently exists
because of the strength of the
container.
•The liquid should not solidify at
high pressure this limits the
obtainable.
14. HOT EXTRUSION
ADVANTAGES
Complex solid or hollow
shapes can be produced.
Small quantities can be
economically produced.
Delivery times are often far
shorter than alternative
processes.
DISADVANTAGES
High equipment set up and
maintenance cost.
Extrusion process for metals is at very
high temperatures.
Die is preheated to increase its life, so
there are chances of oxidation of hot
billet.
Process Wastage is higher as
compared to rolling.
Non-homogeneous.
15. Cold extrusion is the process done at room
temperature or slightly elevated temperatures.
This process can be used for materials that can
withstand the stresses created by extrusion.
Cold extrusion is done at room temperature or
near room temperature. The advantages of this
over hot extrusion are the lack of oxidation,
higher strength due to cold working, closer
tolerances, good surface finishing.
Examples of products produced by this process
are: collapsible tubes, fire extinguisher cases, and
shock absorber cylinders.
Cold Extrusion
16. COLD EXTRUSION
ADVANTAGES
Improved Mechanical
properties.
Good control of dimensional
tolerances.
Improved surface finish.
No need for heating billet.
No oxidation takes place.
DISADVANTAGES
Tooling cost is high, therefore
large production lot size is
required.
Special coating is required to
reduce friction and to maintain a
lubricant film throughout.
Limited deformation can be
obtained.
17. Cu, Pb, Sn, Al Alloys, Ti, Mo, V, Steel, Zr parts
can be extruded.
Tubes, Gear Blanks, Aluminum Cans,
Cylinders, Fire Extinguisher Cases, Shock
Absorber Cylinders, and Automotive Pistons
are manufactured.
Application Of Cold Extrusion
18. • A manufacturing process in which a
small shot of solid material is placed
in the die and is impacted by a ram,
which causes cold flow in the
material.
• It may be either direct or indirect
extrusion and it is usually performed
on a high- speed mechanical press.
Impact extrusion
19. Although the process is generally
performed cold, considerable heating
results from the high speed
deformation.
A short lengths of hollow shapes,
such as collapsible toothpaste tubes or
spray cans.
Requires soft materials such as Al, Pb,
Cu or Sn.
Applications
20. The layout of operating
machine is horizontal and
movement of billet as well
as of ram is horizontal in
direction.
15-50 MN capacity.
It is mostly used for
commercial extrusion of
bars and shapes.
Horizontal extrusion process
21. Vertical extrusion process
• The movement of billet and ram is vertical in orientation.
• 3-20 MN capacity.
• Mainly used in the production of thin-wall tubing.
23. DIE MATERIALS
Commonly used materials are Tool Steels and Carbides
Diamond dies are used for fine wire.
For improved wear resistance, steel dies may be chromium
plated, and carbide dies may be coated with titanium nitride
For Hot drawing, cast-steel dies are used .
Dies are made from highly alloy tools steels or ceramics
(Si3N4).
Heat treatments such as nitriding are required (several
times) to increase hardness (1000-1100 Hvor 65-70 HRC).
This improves die life.
24. LUBRICATION
NEED-
Proper lubrication is essential in extruding, in order to
improve die life, reduce drawing forces and
temperature, and improve surface finish.
Types of Lubrication-
a) Wet : Dies and Rods are completely immersed in
lubricant.
b) Dry : Surface of the rod to be drawn is coated with a
lubricant.
c) Coating : Rod or Wire is coated with a soft metal that
acts as a solid lubricant.
d) Ultrasonic Vibration : of the dies and mandrels.
25. FACTORS AFFECTING THE EXTRUSION FORCE
1. Type of extrusion
2. Extrusion ratio
3. Working temperature
4. Deformation
5. Frictional conditions at the die and the container wall
26. MATHEMATICAL RELATIONS
1. Extrusion ratio, R -
It is defined as the ratio of the initial cross-sectional area ,
Ao, of the billet to the final cross-sectional area , Af, after
extrusion.
fA
A
R 0
R ~ 40:1 for hot extrusion of steels.
R ~ 400:1 for aluminum.
2.Fractional reduction in area, r -
0
1
A
A
r
f
r
R
1
1
27. Contd..
3. Velocity -
Velocity of extruded product = (Ram velocity) x (R)
4. Extrusion force -
where k = extrusion constant,
fA
A
kAP 0
0 ln
28. EXTRUSION DEFECT
Inhomogeneous deformation -
In direct extrusion, a dead zone along the outer surface
of the billet due to the movement of metal in the centre being
higher than the periphery.
After 2/3 of the billet is extruded, the outer surface of the
billet (normally with oxidised skin) moves toward the centre
and extrudes to the through the die, resulting in internal oxide
stringers.
29. Surface cracking
It is the ranging from a badly roughened surface to
repetitive transverse cracking called fir-tree cracking.
It is due to longitudinal tensile stresses generated as the
extrusion passes through the die.
In hot extrusion, this form of cracking usually is
intergranular and is associated with hot shortness.
30. It can occur at low
extrusion ratio due to
low frictional conditions
on the zone of
deformation at the
extrusion die.
High friction(at a the
tool-billet interface).
Low friction centre burst.
Centre burst or chevron cracking
31. Structure & properties are varied within the extrusions due to
non-uniform deformation for example at the front and the
back of the extrusion in both longitudinal and transverse
directions.
Regions of exaggerated
grain growth, due to high
hot working temperature.
Variations in structure and properties
Grain
Growt
h
32. (in aluminium extrusion)
High temperatures generated cause incipient
melting, which causes cracking.
Hot shortness
Editor's Notes
At lower temperature, sticking in the die land and the sudden building up of pressure and then breakaway will cause transverse cracking.