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.
Die casting process: Principles, applications and industrial useMayurjyotiNeog
The short presentation gives insights to some die casting process, its principles, applications and some industrial use. It also includes different die casting methods.
Die casting process: Principles, applications and industrial useMayurjyotiNeog
The short presentation gives insights to some die casting process, its principles, applications and some industrial use. It also includes different die casting methods.
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.
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.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
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.
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.
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.
2. contents
• Introduction
• Classification
• Extrusion Equipment
• Extrusion Pressure
• Extrusion Ratio
• Hydrostatic Extrusion
• Extrusion Defects
• Features Of Extrusion
3. 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.
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 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.
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.
4. Classification of extrusion processes
There are several ways to classify metal extrusion processes
By direction
direct or forward extrusion
indirect or backward extrusion
By operating temperature
hot extrusion
cold extrusion
By equipment
horizontal and vertical extrusion
5. Direct extrusion or forward extrusion
Indirect extrusion or backward extrusion
6. Hot extrusion
Hot extrusion is done at fairly high temperatures,
approximately 50 to 75 % of the melting point of
the metal.
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 high temperatures and pressures , there
is a need of good lubrication.
Oil and graphite work at lower temperatures,
whereas at higher temperatures glass powder is
used.
7. Cold extrusion
Cold extrusion is the process done at room temperature or slightly elevated temperatures.
This process can be used for most materials subject to designing robust enough tooling that
Can withstand the stresses created by extrusion.
Examples : lead , tin, aluminium alloys, copper.
Examples of parts that are cold extruded are collapsible tubes, aluminium cans,
cylinders, gear blanks…
Advantages
No oxidation takes place
Good surface finish with the use of proper lubricants.
Significant savings in metal and energy costs.
Lubricants: zinc phosphates and molybdenum disulphide.
8. 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 and vertical presses.
2) Extrusion dies
die design and die materials
3) Tools
9. Die design
Die design is the heart of efficient extrusion production.
Dies must withstand considerable amount of stresses, thermal shock and oxidation.
Die design consideration
Wall thickness: different wall thicknesses in one section should
be avoided
Simple shapes: the more simple shapes, the more cost effective.
Symmetrical: more accurate.
Sharp or rounded corners: sharp corners should be avoided.
Tolerances: tolerances are added to allow some
distortions(industrial standards)
10. Die materials
Dies are made from high alloy tool steels or ceramics (zirconia,
Si3N4)
Heat treatments such as nitriding are required(several times) to
increase
hardness. This improves die life, avoiding unscheduled press
shutdown.
Wall thickness as small as 0.5 mm(on flat dies) or 0.7 mm(on
hollow dies) can be made for aluminium extrusion
11. 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.
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 extrusions and extrusion pressure are limited.
12. Extrusion ratio
Extrusion ratio, R, is the ratio of the initial cross-sectional area, A0 of the billet to the final
Cross sectional area, Af , after extrusion.
R = A0/Af
R is 40:1 for hot extrusion of steels (approximately)
R is 400:1 for aluminium
Fractional reduction in area, r
r = 1- A0/Af and R = 1/(1-r)
13. The velocity of the extruded product is given by
Velocity of the extruded product = ram velocity * R
Extrusion force may be expressed as
P = k A0 ln(A0/Af)
Where k = extrusion constant, an overall factor which accounts for the flow stress,
Friction, and inhomogeneous deformation.
14. Effects of temperature on hot extrusion
Decreased flow stress or deformation resistance due to increasing extrusion temperature
Use minimum temperature to provide metal with suitable plasticity.
The top working temperature should be safely below the melting point.
Oxidation of billet and extrusion tools.
Difficult to provide adequate lubrication.
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(highest)
Heat transfer between the deforming material and the dies and the
surrounding
Environment.
Working temperature in extrusion is normally higher than used in forging and rolling
due to relatively large compressive stresses in minimizing cracking.
15. Hydrostatic extrusion
The billet in the container is
surrounded with fluid media, is also
called hydrostatics medium.
The billet is forced through the die by
a high hydrostatic pressure.
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 billet should may have large
length-to-diameter ratio and may have
an irregular cross section.
extrusion
16. Extrusion defects
Inhomogeneous deformation: in direct extrusion there occurs a dead zone along the
Outer surface of the billet due to the movement of the metal in the centre being higher
than the periphery.
Surface cracking: this is due to longitudinal tensile stresses generated as the
Extrusion passes the die. And also due heavy die friction. At lower temperatures, sticking in
the die land and the sudden building up of pressure and then breakaway will cause
transverse cracking
Variations in structure and properties: 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. Exaggerated grain growth can occur due to high hot working
Temperature.
Hot shortness (in aluminium extrusion): high temperatures generated cause incipient
Melting which causes cracking.
17. Features of Extrusion Process:
Cost effective: Minimizes the need for secondary
machining process.
Surface finish: For steel is 3 μm, for Aluminium and
Magnesium -0.8 μm
Cross-section: Wide variety of cross-sections can be
made.
Minimum thickness: For steel 3 mm, for Aluminium
and Magnesium 1mm
Minimum cross section
18. References
Mechanical Metallurgy by George E.Dieter.
Introduction to Extrusion by Paul
N.Richardson.
Experience and applications of extrusion by
Mary Cristensen.
www.wikipedia.org