The document provides an overview of the extrusion process for metals. It discusses different types of extrusion including direct/indirect, hot/cold, and hydrostatic extrusion. It also covers extruding tubes and pipes. Key points include:
- Extrusion involves pushing heated metal billets through a die to reduce the cross-section and shape the material.
- Direct extrusion uses a stationary container and moving ram, while indirect uses a stationary die and moving container.
- Hot extrusion is done at 50-75% melting temperature for better formability, while cold extrusion is at or near room temperature.
- Hydrostatic extrusion surrounds the billet with pressurized
1. Sheet metal forming operations include bending, stretching, deep drawing, and other processes where sheets are formed. Bending involves shaping a straight length into a curve and can be done using presses or rolls.
2. Deep drawing uses a die and punch to shape flat sheets into cup-shaped parts. Stretch forming clamps sheet edges and stretches the sheet over a die into the desired shape.
3. Successful forming requires considering the material properties, die and process parameters to avoid defects like cracks, wrinkles, and non-uniform thinning. Minimum bend radii, lubrication, and holding pressure all impact the quality of formed parts.
The document discusses various metal forming processes used to shape metals. It begins by explaining how metals are typically supplied in ingot form and then processed through hot or cold working operations like rolling, forging, or extrusion to produce materials in standard shapes. The key metal forming processes of rolling, forging, extrusion and drawing are described as bulk deformation processes. Sheet metalworking operations like bending, drawing and shearing are also outlined. The document provides details on other relevant topics like hot versus cold working, temperature effects in metal forming, and lubrication.
Press tool operations, Shearing action, Shear operations, Numerical problems, Drawing, Draw die design, Spinning, Bending, Stretch forming, Embossing and coining, Types of sheet metal dies, Analysis of sheet metal
Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify.
Rod, wire and tube drawing is a metalworking process where a rod, wire or tube is pulled through a die to reduce its cross-sectional area and increase its length. It involves applying both tensile and compressive forces. Products include wire, rods, and tubes used in applications like electrical wiring, springs and hydraulic tubing. The process offers close dimensional control, lower costs than rolling or extrusion, and can produce very small cross-sections. Lubrication and annealing are important to control work hardening during multiple drawing passes. Dies are commonly made of alloy steels, carbides or diamond to withstand wear from the process.
This document discusses deep drawing, a sheet metal forming process where a punch is used to push a flat sheet into a die cavity. It describes the typical tool setup, components made via deep drawing like cups and conical shapes, and calculations for blank diameter. Stress patterns in different regions during drawing are explained. Factors affecting drawability and defects in formed components like wrinkling and bottom fracture are also summarized. Formulas for total punch force and drawability ratio are provided. Methods to improve drawability like redrawing and controlling texture are outlined.
Okay, here are the steps:
1) UTS of 5052-O aluminum = 280 MPa
2) Thickness, t = 1.8 mm
3) Cutting edge length, L = πD = π * 25 mm = 78.5 mm
4) Using the empirical formula:
Fmax = 7.0 * UTS * t * L
= 7.0 * 280 * 1.8 * 78.5
= 3,400 N
So the estimated maximum punch force required is 3,400 Newtons.
1. The document discusses sheet metal forming processes including shearing, bending, and springback. It provides definitions and formulas for calculating forces in shearing and springback in bending.
2. An lab experiment is described that involves bending aluminum strips using a finger brake machine and measuring the resulting bend radii and angles to analyze springback.
3. Finite element analysis simulations are shown illustrating the deformation during bending and springback.
1. Sheet metal forming operations include bending, stretching, deep drawing, and other processes where sheets are formed. Bending involves shaping a straight length into a curve and can be done using presses or rolls.
2. Deep drawing uses a die and punch to shape flat sheets into cup-shaped parts. Stretch forming clamps sheet edges and stretches the sheet over a die into the desired shape.
3. Successful forming requires considering the material properties, die and process parameters to avoid defects like cracks, wrinkles, and non-uniform thinning. Minimum bend radii, lubrication, and holding pressure all impact the quality of formed parts.
The document discusses various metal forming processes used to shape metals. It begins by explaining how metals are typically supplied in ingot form and then processed through hot or cold working operations like rolling, forging, or extrusion to produce materials in standard shapes. The key metal forming processes of rolling, forging, extrusion and drawing are described as bulk deformation processes. Sheet metalworking operations like bending, drawing and shearing are also outlined. The document provides details on other relevant topics like hot versus cold working, temperature effects in metal forming, and lubrication.
Press tool operations, Shearing action, Shear operations, Numerical problems, Drawing, Draw die design, Spinning, Bending, Stretch forming, Embossing and coining, Types of sheet metal dies, Analysis of sheet metal
Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify.
Rod, wire and tube drawing is a metalworking process where a rod, wire or tube is pulled through a die to reduce its cross-sectional area and increase its length. It involves applying both tensile and compressive forces. Products include wire, rods, and tubes used in applications like electrical wiring, springs and hydraulic tubing. The process offers close dimensional control, lower costs than rolling or extrusion, and can produce very small cross-sections. Lubrication and annealing are important to control work hardening during multiple drawing passes. Dies are commonly made of alloy steels, carbides or diamond to withstand wear from the process.
This document discusses deep drawing, a sheet metal forming process where a punch is used to push a flat sheet into a die cavity. It describes the typical tool setup, components made via deep drawing like cups and conical shapes, and calculations for blank diameter. Stress patterns in different regions during drawing are explained. Factors affecting drawability and defects in formed components like wrinkling and bottom fracture are also summarized. Formulas for total punch force and drawability ratio are provided. Methods to improve drawability like redrawing and controlling texture are outlined.
Okay, here are the steps:
1) UTS of 5052-O aluminum = 280 MPa
2) Thickness, t = 1.8 mm
3) Cutting edge length, L = πD = π * 25 mm = 78.5 mm
4) Using the empirical formula:
Fmax = 7.0 * UTS * t * L
= 7.0 * 280 * 1.8 * 78.5
= 3,400 N
So the estimated maximum punch force required is 3,400 Newtons.
1. The document discusses sheet metal forming processes including shearing, bending, and springback. It provides definitions and formulas for calculating forces in shearing and springback in bending.
2. An lab experiment is described that involves bending aluminum strips using a finger brake machine and measuring the resulting bend radii and angles to analyze springback.
3. Finite element analysis simulations are shown illustrating the deformation during bending and springback.
Metal forming processes are used to shape metals into useful products. Rolling is the most common forming process and accounts for around 90% of metal forming. It involves passing metal between rolls to reduce thickness or change cross-section. Forging uses dies and compression to shape hot or cold metal. Extrusion forces heated metal through a die to create shapes like rods, tubes and structural sections. Drawing pulls metal through a die to make wires, rods and tubes from both hot and cold workpieces. Deep drawing specifically makes cylindrical parts like cups from sheet metal.
The document discusses various types of forging processes including open die forging, impression die forging, and flashless forging. Open die forging involves compressing metal between flat dies, allowing lateral flow. Impression die forging uses dies with cavities to impart shapes, constraining flow. Flashless forging completely fills dies with no excess flash. Forging is used to make strong components for industries like automotive and aerospace. Equipment includes forging hammers that apply impact and presses that apply gradual pressure.
Rolling is a metal forming process where metal stock is passed through one or more pairs of rolls to reduce the thickness and change the cross section of the metal. There are both hot and cold rolling processes. The metal is compressed between the rolls through frictional forces, changing the shape of the metal. Rolling processes can produce shapes like plates, sheets, rods, bars, pipes and rails. Rolling mills can have two, three, four or multiple rolls depending on the specific application and required shape. Rolling is used to mass produce metal products and form complex cross sections.
The document discusses various metal forming processes including hot working and cold working of metals. It describes processes like forging, rolling, extrusion, drawing, and spinning. Forging can be done through open die forging or closed die forging using various machines. It involves operations like upsetting, drawing down, punching, bending, and forging welding. Rolling involves processes like flat rolling and shape rolling. Extrusion can be done through hot or cold working. The document compares the characteristics and advantages and limitations of hot working versus cold working of metals.
Forging is the operation where the metal is heated and then a force is applied to manipulates the metals in such a way that the required final shape is obtained.
This document discusses sheet metal processes. It begins by defining sheet metal working as a chipless manufacturing process that forms various components from sheet metal using punching and other forming operations. It then discusses various sheet metal cutting operations like blanking and punching as well as forming operations like bending, drawing, and coining. Specific processes like fine blanking, deep drawing, and springback compensation techniques are also covered. The document provides examples of applications for sheet metal working and discusses concepts like tooling dimensions, forces, and developed lengths.
The document discusses various metal forming processes including forging. It defines forging as a process where a metal is heated and compressed in a die to obtain a final shape. The key types of forging are closed die forging using two dies and open die forging with simple shaped dies. Forging can be done hot or cold based on the temperature of the workpiece. Common forging operations aim to reduce cross-sectional area or change thickness. Forging produces grain structures that improve mechanical properties.
This document provides an overview of sheet metal forming processes. It discusses both cutting (shearing) operations like punching, blanking, and notching as well as forming operations like bending, drawing, squeezing, and hydroforming. The document describes various bending operations including V-bending, roll bending, and tube bending. It also discusses processes for forming parts like deep drawing, ironing, redrawing, and the multi-step metal forming process used to produce aluminum beverage cans.
The document discusses various sheet metal processes including shearing, bending, drawing, and special forming processes. It provides details on:
- Common shearing operations like punching, blanking, and notching used to cut sheet metal.
- Forming processes like bending, stretching, and drawing that cause shape changes without cracking or excessive thinning.
- Special high-pressure forming techniques like hydroforming, rubber pad forming, spinning, and super plastic forming.
- Factors that influence formability and properties of sheet metals like strength, ductility, formability, and factors that affect drawing operations.
The document discusses various fundamentals of metal forming processes including hot working, cold working, and warm working operations. It describes different metal forming techniques like forging, rolling, extrusion, and describes tools used in smithy like anvil, hammers, swages, and forging operations like upsetting, drawing, bending, and punching.
Sheet metal is a thin piece of metal between 0.006 and 0.25 inches thick. Sheet metal can be cut, bent, and stretched into various shapes through forming and cutting operations. Common forming operations include bending, deep drawing, and roll forming. Common cutting operations include shearing, blanking, punching, notching, and slitting. Sheet metal workers use tools like dies and presses to perform these operations and shape the metal.
The document provides guidelines for a sessional course on metal forming and sheet metal working. It discusses safety guidelines for experiments and report requirements. It also outlines the marking scheme and distribution of marks. The document then discusses sheet metal, its thickness measurements and common materials used. It describes various sheet metal forming processes like bending, press brake forming, and calculations related to bending including bend allowance, deduction, and springback compensation. Roll bending and bending tube without a mandrel are also summarized.
Coining is a cold working process that uses high pressure to plastically deform a workpiece between two closed dies to conform to their shapes. It provides a finer, more detailed surface finish than other processes like stamping. Coining does not require cutting or expensive machinery. It work hardens the surface of the material, making the finished parts more impact and abrasion resistant and eliminating the need for further finishing steps. Industrial applications of coining include minting coins and medals, making jewelry, precision springs, electronic parts, and other complex parts requiring polished surfaces.
This document discusses various manufacturing technologies related to forging. It describes forging as a metalworking process involving plastic deformation between dies to achieve a desired shape. Forging can be classified based on the process (open die or closed die) or equipment (drop, power hammer/press, hand, or machine forging). The document outlines the key characteristics and applications of these different forging methods. It also describes various forging tools and common forging operations like upsetting, drawing down, setting down, bending, punching, welding, and cutting.
Thread manufacturing involves creating screw threads through various processes. Threads can be made through machining using lathes, mills, and grinding machines with single-point or multi-point tools. Threads are also produced through forming methods like rolling, which yields threads with better surface finish in a single pass compared to machining. Rolling methods include in-feed and through-feed rolling with circular or flat dies on various machines. Threads can also be manually produced using taps and dies on a lathe or by hand. Machining generally results in lower quality threads than forming but provides more flexibility.
This chapter aims to provide basic backgrounds of different types of machining processes and highlights on an understanding of important parameters which affects machining of metals with their chip removals.
Metal cutting or Machining is the process of producing workpiece by removing unwanted material from a block of metal. in the form of chips. This process is most important since almost all the products get their final shape and size by metal removal. either directly or indirectly.
The major drawback of the process is loss of material in the form of chips. In this chapter. we shall have a fundamental understanding of the basic metal process.
The document provides information about shaping and planing processes. It discusses the shaping machine, including its principal parts like the base, column, ram and tool head. It describes the shaping operations of producing flat surfaces, slots and contours. The quick return mechanism is explained, along with specifications, tool materials and cutting motions. Formulas for cutting speed, feed, depth and machining time calculations are also presented.
This document provides an overview of sheet metal forming processes. It discusses various sheet metal operations including cutting (shearing) operations like punching, blanking, and trimming as well as forming operations like bending, drawing, and squeezing. Bending operations including V-bending and edge bending are described. Drawing operations for forming hollow shapes are also covered along with squeezing processes like embossing and coining.
The document discusses the process of extrusion. It begins with an introduction to extrusion, defining it as reducing the cross-section of metal by forcing it to flow through a die under high pressure. It then covers the basic extrusion process using diagrams. The document goes on to classify extrusion processes and describe various types like direct/indirect, hot/cold, lateral, and hydrostatic extrusion. It also covers die design, defects, variables that affect extrusion, and applications of extrusion.
Extrusion is a process where a block of metal is reduced in cross-section by forcing it to flow through a die under high pressure. There are different types of extrusion classified by direction (direct/indirect), temperature (hot/cold), and equipment (horizontal/vertical presses). Key equipment includes presses, dies, and tools. Dies must withstand high stresses and be designed for the desired shape. Process variables like temperature, extrusion ratio, and friction affect the required extrusion force. Hot extrusion near 50-75% of melting temperature is most common to reduce deformation resistance.
Metal forming processes are used to shape metals into useful products. Rolling is the most common forming process and accounts for around 90% of metal forming. It involves passing metal between rolls to reduce thickness or change cross-section. Forging uses dies and compression to shape hot or cold metal. Extrusion forces heated metal through a die to create shapes like rods, tubes and structural sections. Drawing pulls metal through a die to make wires, rods and tubes from both hot and cold workpieces. Deep drawing specifically makes cylindrical parts like cups from sheet metal.
The document discusses various types of forging processes including open die forging, impression die forging, and flashless forging. Open die forging involves compressing metal between flat dies, allowing lateral flow. Impression die forging uses dies with cavities to impart shapes, constraining flow. Flashless forging completely fills dies with no excess flash. Forging is used to make strong components for industries like automotive and aerospace. Equipment includes forging hammers that apply impact and presses that apply gradual pressure.
Rolling is a metal forming process where metal stock is passed through one or more pairs of rolls to reduce the thickness and change the cross section of the metal. There are both hot and cold rolling processes. The metal is compressed between the rolls through frictional forces, changing the shape of the metal. Rolling processes can produce shapes like plates, sheets, rods, bars, pipes and rails. Rolling mills can have two, three, four or multiple rolls depending on the specific application and required shape. Rolling is used to mass produce metal products and form complex cross sections.
The document discusses various metal forming processes including hot working and cold working of metals. It describes processes like forging, rolling, extrusion, drawing, and spinning. Forging can be done through open die forging or closed die forging using various machines. It involves operations like upsetting, drawing down, punching, bending, and forging welding. Rolling involves processes like flat rolling and shape rolling. Extrusion can be done through hot or cold working. The document compares the characteristics and advantages and limitations of hot working versus cold working of metals.
Forging is the operation where the metal is heated and then a force is applied to manipulates the metals in such a way that the required final shape is obtained.
This document discusses sheet metal processes. It begins by defining sheet metal working as a chipless manufacturing process that forms various components from sheet metal using punching and other forming operations. It then discusses various sheet metal cutting operations like blanking and punching as well as forming operations like bending, drawing, and coining. Specific processes like fine blanking, deep drawing, and springback compensation techniques are also covered. The document provides examples of applications for sheet metal working and discusses concepts like tooling dimensions, forces, and developed lengths.
The document discusses various metal forming processes including forging. It defines forging as a process where a metal is heated and compressed in a die to obtain a final shape. The key types of forging are closed die forging using two dies and open die forging with simple shaped dies. Forging can be done hot or cold based on the temperature of the workpiece. Common forging operations aim to reduce cross-sectional area or change thickness. Forging produces grain structures that improve mechanical properties.
This document provides an overview of sheet metal forming processes. It discusses both cutting (shearing) operations like punching, blanking, and notching as well as forming operations like bending, drawing, squeezing, and hydroforming. The document describes various bending operations including V-bending, roll bending, and tube bending. It also discusses processes for forming parts like deep drawing, ironing, redrawing, and the multi-step metal forming process used to produce aluminum beverage cans.
The document discusses various sheet metal processes including shearing, bending, drawing, and special forming processes. It provides details on:
- Common shearing operations like punching, blanking, and notching used to cut sheet metal.
- Forming processes like bending, stretching, and drawing that cause shape changes without cracking or excessive thinning.
- Special high-pressure forming techniques like hydroforming, rubber pad forming, spinning, and super plastic forming.
- Factors that influence formability and properties of sheet metals like strength, ductility, formability, and factors that affect drawing operations.
The document discusses various fundamentals of metal forming processes including hot working, cold working, and warm working operations. It describes different metal forming techniques like forging, rolling, extrusion, and describes tools used in smithy like anvil, hammers, swages, and forging operations like upsetting, drawing, bending, and punching.
Sheet metal is a thin piece of metal between 0.006 and 0.25 inches thick. Sheet metal can be cut, bent, and stretched into various shapes through forming and cutting operations. Common forming operations include bending, deep drawing, and roll forming. Common cutting operations include shearing, blanking, punching, notching, and slitting. Sheet metal workers use tools like dies and presses to perform these operations and shape the metal.
The document provides guidelines for a sessional course on metal forming and sheet metal working. It discusses safety guidelines for experiments and report requirements. It also outlines the marking scheme and distribution of marks. The document then discusses sheet metal, its thickness measurements and common materials used. It describes various sheet metal forming processes like bending, press brake forming, and calculations related to bending including bend allowance, deduction, and springback compensation. Roll bending and bending tube without a mandrel are also summarized.
Coining is a cold working process that uses high pressure to plastically deform a workpiece between two closed dies to conform to their shapes. It provides a finer, more detailed surface finish than other processes like stamping. Coining does not require cutting or expensive machinery. It work hardens the surface of the material, making the finished parts more impact and abrasion resistant and eliminating the need for further finishing steps. Industrial applications of coining include minting coins and medals, making jewelry, precision springs, electronic parts, and other complex parts requiring polished surfaces.
This document discusses various manufacturing technologies related to forging. It describes forging as a metalworking process involving plastic deformation between dies to achieve a desired shape. Forging can be classified based on the process (open die or closed die) or equipment (drop, power hammer/press, hand, or machine forging). The document outlines the key characteristics and applications of these different forging methods. It also describes various forging tools and common forging operations like upsetting, drawing down, setting down, bending, punching, welding, and cutting.
Thread manufacturing involves creating screw threads through various processes. Threads can be made through machining using lathes, mills, and grinding machines with single-point or multi-point tools. Threads are also produced through forming methods like rolling, which yields threads with better surface finish in a single pass compared to machining. Rolling methods include in-feed and through-feed rolling with circular or flat dies on various machines. Threads can also be manually produced using taps and dies on a lathe or by hand. Machining generally results in lower quality threads than forming but provides more flexibility.
This chapter aims to provide basic backgrounds of different types of machining processes and highlights on an understanding of important parameters which affects machining of metals with their chip removals.
Metal cutting or Machining is the process of producing workpiece by removing unwanted material from a block of metal. in the form of chips. This process is most important since almost all the products get their final shape and size by metal removal. either directly or indirectly.
The major drawback of the process is loss of material in the form of chips. In this chapter. we shall have a fundamental understanding of the basic metal process.
The document provides information about shaping and planing processes. It discusses the shaping machine, including its principal parts like the base, column, ram and tool head. It describes the shaping operations of producing flat surfaces, slots and contours. The quick return mechanism is explained, along with specifications, tool materials and cutting motions. Formulas for cutting speed, feed, depth and machining time calculations are also presented.
This document provides an overview of sheet metal forming processes. It discusses various sheet metal operations including cutting (shearing) operations like punching, blanking, and trimming as well as forming operations like bending, drawing, and squeezing. Bending operations including V-bending and edge bending are described. Drawing operations for forming hollow shapes are also covered along with squeezing processes like embossing and coining.
The document discusses the process of extrusion. It begins with an introduction to extrusion, defining it as reducing the cross-section of metal by forcing it to flow through a die under high pressure. It then covers the basic extrusion process using diagrams. The document goes on to classify extrusion processes and describe various types like direct/indirect, hot/cold, lateral, and hydrostatic extrusion. It also covers die design, defects, variables that affect extrusion, and applications of extrusion.
Extrusion is a process where a block of metal is reduced in cross-section by forcing it to flow through a die under high pressure. There are different types of extrusion classified by direction (direct/indirect), temperature (hot/cold), and equipment (horizontal/vertical presses). Key equipment includes presses, dies, and tools. Dies must withstand high stresses and be designed for the desired shape. Process variables like temperature, extrusion ratio, and friction affect the required extrusion force. Hot extrusion near 50-75% of melting temperature is most common to reduce deformation resistance.
The document discusses various aspects of extrusion, a manufacturing process where a block of metal is forced to flow through a die opening. It describes different types of extrusion like hot and cold, direct and indirect, lubricated and hydrostatic. It also discusses defects in extrusion and the drawing process which is similar but uses a pulling force. The key information provided includes how extrusion allows shaping of solid and hollow metal sections, the operating principles and classifications of extrusion, and factors that affect the extrusion force.
The document discusses the extrusion manufacturing process. Extrusion involves forcing a block of metal through a die to create solid or hollow shapes. There are different types of extrusion classified by direction (direct, indirect), operating temperature (hot, cold), and equipment (horizontal, vertical). Hot extrusion is done at high temperatures using lubrication while cold extrusion is done at room temperature. The document also discusses defects, drawing as a related process, and factors that affect extrusion forces.
This document summarizes the extrusion manufacturing process. Extrusion involves forcing a block of metal through a die opening to produce solid or hollow sections. It can be performed hot or cold, and produces parts through direct or indirect methods. Key advantages are producing complex shapes efficiently in small batches, though high costs and potential defects exist. The document also briefly outlines the related drawing process of pulling wire or tubing through a die to reduce its cross-section.
Extrusion is a process where a block of metal is forced to flow through a die to reduce its cross-section. It is commonly used to produce cylindrical bars, tubes, or stock for other processes. Most metals require hot extrusion due to the large forces. Extrusion produces products with uniform properties and microstructure. Common extrusion defects include cracking, non-uniform deformation, and variations in grain structure. Extrusion equipment includes hydraulic presses in horizontal or vertical orientations and dies made of hardened tool steel. Process parameters like temperature, speed, and lubrication affect the required extrusion pressure.
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.
The document discusses the extrusion process. It begins by defining extrusion as forcing a block of metal through a die under high pressure to reduce its cross-section. Extrusion is commonly used to produce cylindrical bars or tubes from metals like aluminum. The document then covers the basic extrusion process, common extrusion products, different types of extrusion processes based on direction and temperature, and key equipment used like presses and dies. It concludes by listing factors that affect the required extrusion force.
Extrusion is a process where a billet is compressed and forced to flow through a die opening, acquiring the shape of the opening. In direct extrusion, the billet is pushed through the die by a ram. Indirect extrusion uses backward flow where the die is fixed to the ram and the billet flows in the opposite direction of ram movement. Extrusion can produce a variety of cross-sectional shapes from metals like aluminum, copper, steel, and plastics. Drawing is a similar process where a wire or rod is pulled rather than pushed through a die to reduce its cross-sectional area.
This document provides an overview of various metal forming processes including rolling, extrusion, drawing, forging, bending, punching, blanking, deep drawing, and stretch forming. It discusses the basic mechanisms, types, defects, and forces involved in each process. Key points covered include how rolling reduces thickness through plastic deformation between rolls, the differences between direct and indirect extrusion, how drawing reduces cross-sectional area by pulling metal through a die, and common defects that can occur in deep drawing like wrinkling, tearing, and earing.
Extrusion Extrusion Types and Applications by polayya chintadaPOLAYYA CHINTADA
This document summarizes information about the extrusion production technology, including:
- Extrusion is a metal forming process where a metal workpiece is forced through a die to reduce its cross-section or form a specific shape. It uses compressive force and can be done hot or cold.
- In direct extrusion the metal flows in the direction of the punch, while in indirect extrusion it flows in the opposite direction. Hydrostatic extrusion uses a fluid instead of direct contact to apply pressure.
- Hot extrusion occurs above the metal's recrystallization temperature for lower forces, while cold extrusion is below this temperature resulting in higher forces but better mechanical properties without oxidation.
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Extrusion is a process that uses pressure to force a billet through a die opening to create an object with a constant cross-section. Most metals are hot extruded due to the large forces required. Extrusion can produce complex shapes, especially for more readily extrudable metals like aluminum. Common extruded products include automotive and construction parts. Factors like temperature, pressure, and lubrication affect the extrusion process and properties of the final product. Defects can occur due to non-uniform deformation or temperatures that cause cracking.
Extrusion is a process that uses pressure to force a billet through a die opening to create an object with a constant cross-section. Most metals are hot extruded due to the large forces required. Extrusion can produce complex shapes, especially for more readily extrudable metals like aluminum. Common extrusion products include automotive and construction parts. Factors like temperature, pressure, and lubrication affect the extrusion process and properties of the final product. Defects can occur due to non-uniform deformation or temperatures that cause cracking.
Metal forming process, Non chip forming machining processSuyog Lokhande
Mechanical forming processes include rolling, forging, and extrusion. Rolling involves passing metal through opposing rollers to reduce thickness. Forging involves compressing metal between dies or a hammer to shape it. Extrusion uses a container and die to force metal through an opening to create a shape. These processes deform metal through compression and are used to make common parts like gears, aircraft components, and tubing.
Extrusion is a metalworking process that produces continuous lengths of material with a uniform cross-sectional shape. It works by forcing billet material through a restricted opening called a die. There are three main components in an extrusion press: the container, die, and ram. Extrusion can be used to manufacture rods, tubes, and a variety of shapes like circular, square, rectangular, and hexagonal. There are different methods of extrusion including direct, indirect, impact, and hydrostatic extrusion which uses pressurized fluid instead of friction to shape the material. Extrusion can be classified as hot or cold based on the temperature of the material during the process.
Extrusion process presentation final (1).pptxAhmedWail2
The document discusses different types of extrusion processes including hot and cold extrusion, direct and indirect extrusion, and impact and hydrostatic extrusion. It explains the key factors that affect extrusion quality such as extrusion ratio, billet temperature, lubrication, and die design. Various extrusion products are also presented including tubes, hollow pipes, frames, and plastic objects.
This document discusses various metal forming processes including extrusion and drawing. It provides details on:
1. Direct and indirect extrusion processes where a billet is forced through a die to reduce the cross-section. Extrusion can be hot or cold.
2. Drawing involves pulling a solid or hollow workpiece through a die to reduce or change its cross-section. It is commonly used to produce wire and tubes.
3. Key process parameters for extrusion and drawing like die design, lubrication, equipment used, and their effects on forming forces and product quality.
4. Examples of industrial applications of these processes to manufacture intricate parts, heat sinks, tubes, and fine wire are presented
This document provides an overview of the extrusion process. It defines extrusion as forcing a block of metal through a die under high pressure to reduce its cross-section. Extrusion can be hot or cold, direct or indirect. It discusses extrusion equipment, pressures, ratios, defects, and features like its cost-effectiveness and ability to produce complex cross-sections. Hydrostatic extrusion is also introduced, where the billet is surrounded by a fluid and forced through the die.
This document discusses extrusion and drawing manufacturing processes. Extrusion involves forcing a billet through a die to reduce its cross-section into a constant shape. Drawing reduces the cross-section of a round rod or wire by pulling it through a die. Both processes involve controlling variables like temperature, speed, lubrication, and die design to shape the material and minimize defects from stresses, cracking, or non-uniform flow.
Understanding Inductive Bias in Machine LearningSUTEJAS
This presentation explores the concept of inductive bias in machine learning. It explains how algorithms come with built-in assumptions and preferences that guide the learning process. You'll learn about the different types of inductive bias and how they can impact the performance and generalizability of machine learning models.
The presentation also covers the positive and negative aspects of inductive bias, along with strategies for mitigating potential drawbacks. We'll explore examples of how bias manifests in algorithms like neural networks and decision trees.
By understanding inductive bias, you can gain valuable insights into how machine learning models work and make informed decisions when building and deploying them.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
A review on techniques and modelling methodologies used for checking electrom...nooriasukmaningtyas
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2. Objectives:
Introduction
Classification of extrusion processes
Cold extrusion and cold-forming
Hot extrusion
Hydrostatic extrusion
Extrusion of tubing
Production of seamless pipe and tubing
Extrusion equipment (Presses, dies and tools)
Deformation, lubrication, and defects in extrusion
3. What is
extrusion?• It is the process by which a block of metal is reduced in cross-
section by forcing it to flow through a die orifice under high
pressure
The products of extrusion are generally called "extrudates".
4. Process
• A heated billet cut from continuous casting is located in a
heated container.
• By applying pressure by means of a ram to one end of the billet the
metal flows through the die, located at the other end of the container to
produce a section, the cross sectional shape of which is defined by the
shape of the die
Extruded partBilletRam
Die
ContainerDummy plate
(extrusion pad)
5. Extruded partBilletRam
• In general, extrusion is used to produce cylindrical bars or
hollow tubes or for the starting stock for drawing 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.
• If better properties are required then it may be heat
treated or cold worked
Die
6. • The reaction of the extrusion billet with the container and die
results in high compressive stresses which are effective in
reducing cracking of materials during primary breakdown
from the ingot.
Extruded partBillet
Die
Pressure
Compressive stresses will help in increasing the utilisation of
extrusion in the working of metals that are difficult to form like
steels, nickel-based alloys, and other high-temperaturestainless
materials.
8. There are several ways to classify metal extrusion
processes
By Direction
• Direct / Indirect extrusion
• Forward / backward extrusion
By temperature Hot /cold extrusion
By equipment Horizontal and verticalextrusion
10. Cold Extrusion
Cold extrusion is the process done at room temperature or
slightly elevatedtemperatures.
This process can be used for most materials-subject to designing
robust enough tooling that can withstand the stresses created by
extrusion.
Examples: of the metals that can be extruded are
lead, tin, aluminium alloys, copper, titanium,
molybdenum, vanadium, steel. Examples of parts
that are cold extruded are collapsible tubes,
aluminium cans, cylinders, gear blanks.
11. COLD EXTRUSION
ADVANTAGES
• Improved Mechanical
properties.
• Good control of
dimensional tolerances.
• Improved surfacefinish.
• No need for heating
billet.
• No oxidation takesplace.
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.
12.
13. Hot extrusion
• Hot extrusion is done at fairly high temperatures
approximately 50 to 75 % of the melting point of the metal.
• The pressures can range from 35-700 MPa
• The most commonly used extrusion process is the hot direct
process.
• The cross-sectional shape of the extrusion is defined by the
shape of the die.
• Due to the high temperatures
detrimental effect on the die
and pressures and its
life as well as other
components, good lubrication isnecessary.
• Oil and graphite work at lower temperatures, whereas at
higher temperatures glass powder is used.
14. HOT EXTRUSION
ADVANTAGES
Complex solid or hollow
shapescanbeproduced.
Small quantitiescan be
economically produced.
Delivery timesare 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.
16. Cold extrusion
• It is done at room temp or
near room temp
• The advantages of this
over hot extrusion are the
lack of oxidation, higher
strength due to cold
working, closer tolerances,
better surface finish, and
fast extrusion
Hot extrusion
• It is fairly done at high temp
• Good
since
temp
used)
(0.5-0.7 Tm) (above
recrystallization temp)
lubrication is needed
it works at elevated
(glass powders are
• Due to the high temperatures
and pressures and its
detrimental effect on the die
life as well as other
components.
• So, good lubrication is
necessary.
17. Direct/forward extrusion
The metal billet is placed in a container and driven through the die
by the ram.
The dummy block or pressure plate, is placed at the end of the ram
in contact with thebillet.
Friction is at the die and container wall requires higher pressure
than indirect extrusion.
Extruded partBilletRam
Die
ContainerDummy plate
(extrusion pad)
18. 1 Extrusion
2 Die backer
3 Die
4 Billet
5 Dummy block
6 Pressing ram
7 Container liner
8 Container body
19. To repeatedly transmit the force of the ram, at high
temperature, tothe alloy.
To expand quickly under load and maintain a secure seal with the
container wall.
Toseparate 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.
Tocompensate for minorpress misalignment.
Tobe quickly and easily removedand replaced.
Tofunction effectively until a production run is complete.
Function Of DummyBlock
20. Process:
Hot metal billet is placed in the container
Compressive forces are applied on the metal billet by ram
(hydraulically driven)
Compressive forces will make the metal advance in the
container, and then through the die opening
Hot Metal is placed
in the container
Metal is pressed byRam
Metal will advance in
container, and then
through die
Metal will flow through
the die opening
Extruded metal will
further be processed
21. Extruded partBillet
Die
ContainerClosure plate
Ram
Indirect extrusion / Backward extrusion :
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.
22. Typical curves of extrusion Vs. ram travel for direct and
indirect extrusion
23. Lateral extrusion
• Container
position
is in vertical
and the die is
located in the side
• The metal is kept in the
container such that the
vertical ram applies force on
the metal
• The extruded part comes
outfrom the bottom die
• This is suitable for very light
alloys that have low melting
points
24. Impact Extrusion
Impact extrusion is a cold manufacturing process similar to extrusion and
drawing by which products are made with a metal slug.
• The slug is pressed at a high velocity with extreme force into a die/mould
by a punch.
• Process is restricted to soft metals like lead, aluminum, and copper
It uses heavy duty mechanical
presses
Metal collapsible tubes,
disposable tubes, ointment
tubes, deodorant bottles are
produced by this process
25.
26. Impact Extrusion
Advantages
• Simple and very
economical
• Suitable for collapsible
tubes
• Production cost very low
• Excellent surface finish
• Fast production rates
•Simple and very economical
•Suitable for collapsible
tubes
•Production cost very low
•Excellent surface finish
•Fast production rates
Limitations
• Limited to soft metals like
Pb, Al, and Cu
• More wear
• Feeding lubricant is bit
difficult since it splashes
out
27. 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
spraycans.
Requires soft materials such asAl, Pb, Cuor Sn.
Applications
28. Hydrostatic Extrusion
• In this process the billet is completely surrounded by a
pressurized liquid, except where the billet contacts the die.
• This process can be done hot, warm, or cold, however the
temperature is limited by the stability of the fluid used.
• The process must be carried out in a sealed cylinder to
contain the hydrostatic medium.
• The fluid can be pressurized in two ways:
• Constant-rate extrusion: A ram or plunger is used to pressurize
the fluid inside the container.
• Constant-pressure extrusion: A pump is used, possibly with a
pressure intensifier, to pressurize the fluid, which is then pumped
to the container.
29. Pressure is applied through a fluid surrounding the billet
Fluid pressure forces the billet into die
Die compresses the metal with very less friction
30. Hydrostatic Extrusion
• No friction between the
container and the billet reduces
force requirements.
• This ultimately allows for faster
speeds, higher reduction ratios,
and lower billettemperatures.
• Usually the ductility of the
material increases when high
pressures are applied.
• An evenflow of material.
• Large billets and large cross-
sections can be extruded.
• No billet residue is left on the
container walls.
Advantages Limitations
• The billets have to be
prepared by tapering one
end so that it matches the
die entry angle.
• Only cold extrusion is
possible
• It can be difficult to contain
the fluid, under the effects
of high pressures (up to 2
GPa).
31. The layout of operating machine is horizontal and
movement of billet aswell asof ram is horizontal in
direction.
15-50MN capacity.
It is mostly used for
Commercial extrusion of bars
and shapes.
Horizontal extrusionprocess
32. Vertical extrusionprocess
• The movement of billet and ram is vertical in orientation.
• 3-20MN capacity.
• Mainly used in the production of thin-wall tubing.
33. TUBE EXTRUSION & PIPE MAKING
•Tubes can be produced by extrusion by attaching a mandrel to the end of the
ram. The clearance between the mandrel and the die wall determines the wall
thickness of the tube.
•Tubes are produced either by starting with a hollow billet or by atwo- step
extrusion in which a solid billet is first pierced and then extruded.
34. Extrusion of tubing
•To produce tubing by extrusion from a
solid billet, the ram may also be fitted with
a piercing mandrel. As the ram moves
forward, the metal is forced over the
mandrel and through the hole in the die,
causing a long hollow tube. Just like
toothpaste, only hollow.
Extrusion of tubing from a solid billet
Extrusion of tubing from a hollow billet
•If the billets are hollow, a rod that matches
the diameter of the cast hole in the billet (but
slightly smaller than the hole in the die at the
opposite end of the chamber) are used.
•Note: the bore of the hole will become
oxidized resulting in a tube with an
oxidized inside surface.
35. EXTRUSION TUBING WITH A PORTHOLE
DIE •The metal is forced to flow into
separate streams and around the
central bridge, which supports a short
mandrel.
•The separate streams of metal
which flow through the ports are
brought together in a welding
chamber surrounding the mandrel,
and the metal exits from the die as a
tube.
•Since the separate metal streams
are jointed within the die, where there
is no atmosphere contamination, a
perfectly sound weld isobtained.
•Porthole extrusion is usedto
produce hollow unsymmetrical
shapes in aluminium alloys.
A sketch of a porthole extrusion die
Porthole extrusion
Example: pyramid porthole dies
36. Extrusion of seamless tubes
(With a fixedmandrel)
Ram
Die
ContainerDummy plate
(extrusion pad)
BilleMtandrel
37. Extrusion of seamless tubes
(With a floatingmandrel)
Ram
Die
ContainerDummy plate
(extrusion pad)
BilletMandrel
38. • Both the operations can be carried out with hallow
billet or solid one
• Solid billets are always preferable since creating a
hallow billet consumes time and wastes more
material
Ram
Die
ContainerDummy plate
(extrusion pad)
M a ndrelBillet
39. DIE MATERIALS
Commonlyused materials areTool Steelsand Carbides
Diamonddies are used for fine wire.
For improved wear resistance, steel dies may be chromium
plated, and carbide dies maybe 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 (1000-1100Hvor 65-70HRC). Thisimproves dielife.
40. LUBRICATION
NEED-
Proper lubrication is essential in extruding, in order to
improve die life, reduce drawing forces and
temperature, and improve surfacefinish.
Typesof Lubrication-
a) Wet : Dies and Rods are completely immersed in
lubricant.
b) Dry : Surface of the rod to be drawn is coated witha
lubricant.
c) Coating: Rod or Wire is coated with asoft metal that
acts asasolid lubricant.
d) Ultrasonic Vibration :of thedies and mandrels.
41. 1. Typeof extrusion
2. Extrusion ratio
3. Working temperature
4. Deformation
5. Frictional conditions at the die andthe containerwall
Factors affecting the extrusion force
42. MATHEMATICAL
RELATIONS
1.Extrusionratio, 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
R
A0R~40:1for hot extrusion of steels.
R~400:1 for aluminum.
2.Fractional reduction in area, r -
A 0
r 1
A f
1 r
R
1
43. Contd..
3. Velocity -
Velocity of extruded product =(Ram velocity) x (R)
4. Extrusion force -
where k =extrusionconstant,
fA
A0
0P kA ln
44. Forces in Extrusion
Process Variables in Direct Extrusion
Process variables in direct extrusion. The die angle, reduction in cross-
section, extrusion speed, billet temperature, and lubrication all affect the
extrusion pressure.
45. Extrusion Force
Extrusion constant k for various metals at different temperatures.
Source: After P. Loewenstein
Extrusion force, F Aol ln
Ao
Af
46. Extrusion Defects
• Defects in extruded products occur predominantly
friction and non-homogeneous material
temperature variations
due to
flow.
• Further,
during hot extrusion can
across the billet
also leadto
inhomogeneous deformation.
• Three types of defects are prominent in extrusion.
• They are:
1. Inhomogeneous deformation
2. Surface cracks
3. Internal cracks
47. • Inhomogeneous deformation in direct extrusion
provide the dead zone along the outer surface of the billet
due to the movement of the 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 transverse section can be seen as an
annular ring of oxide.
Container wall
friction
Container wall
temp
Extrusion Defects
Extrusion Defects
48. • Surface cracking, ranging from a badly roughened surface
to repetitive transverse cracking called fir-tree cracking, see
Fig.
• This 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.
• The most common case is too high ram speed for the
extrusion temperature.
• At lower temperature, sticking in the die land and the
sudden building up of pressure and then breakaway will
cause transverse cracking.
Surface cracks from heavy die
friction in extrusion
49. Internal cracks or centre burst:
• It occurs because the stresses within the workpiece
break the material causing cracks to form along the
central axis of the extruded region
• High die angles will favour centre cracking
• Metal must be free from inclusions to avoid centre
burst
• High extrusion ratio also will favour centre burst