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.
Forklift Classes Overview by Intella PartsIntella Parts
Discover the different forklift classes and their specific applications. Learn how to choose the right forklift for your needs to ensure safety, efficiency, and compliance in your operations.
For more technical information, visit our website https://intellaparts.com
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
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.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
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.
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
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.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
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.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
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/
2. WHAT IS EXTRUSION?
Extrusion is the process by which a block/billet of metal is reduced
in cross section by forcing it to flow through a die orifice under high
pressure.
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.
3. The reaction of 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.
This helps to increase the utilization of extrusion in the working of
metals that are difficult to form like stainless steels, nickel-based alloys,
and other high temperature materials.
Similar to forging, lower ram force and a fine grained recrystallized
structure are possible in hot extrusion.
However, better surface finish and higher strengths (strain hardened
metals) are provided by cold extrusion.
4. Extrusion Products
Typical parts produced by extrusion are trim parts used in automotive and
construction application, window frame members, railings, aircraft structural
parts.
Example: Aluminium extrusion are used in commercial and domestic
buildings for window and door frame systems, prefabricated houses/building
structures, roofing and exterior cladding, curtain walling, shop fronts, etc.
Furthermore, extrusions are also used in transport for airframes, road and rail
vehicles and in marine applications.
5. CLASSIFICATION OF EXTRUSION PROCESSES
Extrusion
By
Direction
By
Equipment
By Operating
Temperature
Indirect /
Backward
Direct /
Forwar
d
Hot Cold Horizontal Vertical
6. Direct 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 the billet.
Friction is at the die and container wall requires higher pressure than indirect
extrusion.
Indirect 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.
7. Forward extrusion:
Metal is forced to flow in the same direction as the punch.
The punch closely fits the die cavity to prevent backward flow of the
material.
Backward Extrusion:
Metal is forced to flow in the direction opposite to the punch movement.
Metal can also be forced to flow into recesses in the punch, see Fig.
8. Cold extrusion:
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.
Materials that are commonly cold extruded include: lead, tin, aluminum,
copper, zirconium, titanium, molybdenum, beryllium, vanadium, niobium,
and steel. Examples of products produced by this process are: collapsible
tubes, fire extinguisher cases, shock absorber cylinders and gear blanks.
Advantages
No oxidation takes place.
Good mechanical properties due to severe cold working as long as the
temperatures created are below the re- crystallization temperature.
Good surface finish with the use of proper lubricants.
9. Hot Extrusion:
Hot extrusion is a hot working process, which means it is done above the
material's recrystallization temperature to keep the material from work
hardening and to make it easier to push the material through the die. The
biggest disadvantage of this process is its cost for machinery.
Hot extrusion is done at fairly high temperatures, approximately 50 to 75% of
the melting point of the metal. The pressure can range from 35-700 MPa .
Due to the high temperature and pressure and its detrimental effect on the die
life as well as other components,
good lubrication is necessary. Oil and
graphite work at lower temperatures,
whereas at higher temperatures glass
powder is used.
10. TYPE OF HOT EXTRUSION
Hot
Extrusion
Lubricated HydrostaticNon-Lubricated
11. Lubricated Hot Extrusion:
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.
12. Non-Lubricated Hot Extrusion:
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.
13. HYDROSTATIC EXTRUSION:
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.)
14. Advantages and disadvantages in hydrostatic extrusion
Advantage
Pressure = 1400 MPa (approx.)
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.
Applications:
Making wires of less ductile materials
Nuclear reactor fuel rods
16. EXTRUSION EQUIPMENT (PRESSES, DIES AND TOOLS)
1) Presses
Most extrusions are made with hydraulic presses.
These can be classified based on the direction of travel of the ram
Horizontal presses
Vertical presses
2) Extrusion Dies
Die design, Die materials
3) Tools
Typical arrangement of extrusion tools.
17. Horizontal extrusion presses
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.
18. Vertical extrusion presses
The movement of billet and ram is vertical in orientation.
3-20 MN capacity.
Mainly used in the production of thin-wall tubing.
19. Die Materials
Dies are made from highly alloy tools steels or ceramics
Commonly used materials are Tool Steels and Carbides
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 .
Heat treatments such as nitriding are required (several times) to increase
hardness (1000-1100 Hvor 65-70 HRC). This improves die life.
(1) extruder mounting plate; (2) die adapter
plate; (3) transition plate; (4) preland plate; (5)
die land plate; (6) die bolt hole; (7) alignment
dowel pin hole; (8) thermocouple well;
There are two general types of extrusion dies:
Flat-faced dies
Dies with conical entrance angle
20. HOT EXTRUSION
FACTORS AFFECTING THE EXTRUSION FORCE
1. Type of extrusion (direct/indirect)
2. Extrusion ratio
3. Working temperature
4. Deformation
5. Frictional conditions at the die and the container wall
21. Extrusion pressure = extrusion force/cross sectional area
The rapid rise in pressure during initial ram travel is due to the initial
compression of the billet to fill the extrusion container.
For DIRECT EXTRUSION, the metal begins to flow through the die at the
maximum pressure, the break through pressure.
As the billet extrudes through the die the pressure required to maintain flow
progressively decreases with decreasing length of the billet in the container.
At the end of the stroke, the pressure rises up rapidly and it is usual to stop the
ram travel so as to leave a small discard in the container.
For INDIRECT EXTRUSION, extrusion pressure is ~ constant with
increasing ram travel and represent the stress required to deform the metal
through the die.
Since hollow ram is used in indirect extrusion, size of the extrusion and
extrusion pressure are limited.
22. Extrusion Ratio
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.
Fractional Reduction in area, r
R ~ 40:1 for hot extrusion of steels.
R ~ 400:1 for aluminum.
fA
A
R 0
0
1
A
A
r
f
r
R
1
1
23. Velocity –
Velocity of extruded product = (Ram velocity) x (R)
Extrusion force –
where k = extrusion constant,
fA
A
kAP 0
0 ln
24. A 120 mm diameter billet is to be extruded to 75mmdiameter. The working
temperature of 700⁰ C and the extrusion constant is 300MPa.
Calculate,
1. Extrusion ratio
2.Fractional Extrusion reduction in area
3.Force required for drawing process.
25. EFFECTS OF TEMPERATURE ON HOT EXTRUSION
The temperature of the work piece in metal working depends on:-
The initial temperature of the tools and the materials.
Heat generated due to plastic deformation.
Heat generated by friction at the die/material interface.
Heat transfer between the deforming material and the dies and surrounding environment.
26. Relationships between extrusion ratio, temperature and pressure
For a given Extrusion pressure, Extrusion ratio R increases with
increasing Extrusion temperature.
For a given extrusion temperature, a large extrusion ratio R can be
obtained with a higher extrusion pressure.
Relationships between extrusion speed and heat dissipation
27. DEFORMATION, LUBRICATION, AND DEFECTS IN
EXTRUSION
Low container friction and a well lubricated billet – nearly homogeneous
deformation.
Increasing container wall friction – producing a dead zone of stagnant
metal at corners which undergoes little deformation. Essentially pure
elongation in the center and extensive shear along the sides of the billet.
The latter leads to redundant work.
For high friction at the container – billet interface, metal flow is
concentrated toward the center and an internal shear plane develops –
due to cold container. In the sticky friction, the metal will separate
internally along the shear zone. A thin skin will be left in a container and
new metal surface is obtained.
28. Extrusion Defects
1) Inhomogeneous deformation -
In direct extrusion, a dead zone along the outer surface of the billet due to the
movement of metal in the center being higher than the periphery.
After 2/3 of the billet is extruded, the outer surface of the billet (normally with
oxidized skin) moves toward the center and extrudes to the through the die,
resulting in internal oxide stringers. – transverse section can be seen as an
annular ring of oxide.
If lubricant film is carried into the interior of the extrusion along the shear
bands, this will sow as longitudinal laminations in similar way as oxide.
29. 2) 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.
The most common case is too high ram speed for the extrusion
temperature.
30. 3) Centre burst or chevron cracking
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 center burst.
31. 4) Variations in structure and properties
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.
Grain
Growth
32. 5) Hot shortness (in aluminum extrusion)
High temperatures generated cause incipient melting, which causes
cracking.