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Ao⋅ k⋅ ln
¾ Geometric Variables ¾ Circumscribing circle ¾ The extrusion force Ao
Die angel, α diameter (CCD) F
Extrusion Ratio: R required depends on Af
• Ao/Af: Ratio of the cross Billet material strength
sectional area of the billet to the
A of the extruded part
¾ k = extrusion constant
Extrusion ratio
¾ Temperature Metal and temperature
¾ Speed of ram Friction billet/chamber dependent
¾ Lubricant type and billet/die
Diameter of the smallest circle Temperature
that the cross section can fit
within. Speed
¾ Shape factor
One of the variables
determining the complexity of
extrusion
Ratio of perimeter of extruded
product to the cross sectional
area.
• Circle has the smallest shape
factor
1
Metal Flow in Extrusion Extrusion Practice
¾ Effects the mechanical ¾ Dead zone ¾ What materials are extruded? ¾ Straitening and twisting
Aluminum, copper, magnesium, May be required for small cross
properties of the part Metal at corners is almost alloys, steels sections
¾ The metal flows stationary ¾ Extrusion ratio R = Ao/Af ¾ Die angle causes a butt end
longitudinally, resulting 10 to 100 Remains in the chamber after
operation is complete
Lower for less ductile materials
in an elongated grain At least R=4 to work the Cut off as scrap
structure material in the plastic region ¾ Stepped extrusion
¾ Length of extruded materials Extruding the billet partially in
< 7.5 meters typically one die and then one or more
30 meters max dies
¾ CCD (circum scribed
diameters)
6 mm – 1m for Aluminum
¾ Ram speeds
Up to 0.5m/s
Lower for aluminum, copper
Higher for steels
2
Die Materials and Lubrication Cold Extrusion
¾Die materials ¾ Often involves different manufacturing operations such
as direct and indirect extrusion and forging.
Hot worked die steels
¾ Used in making
Coatings may be applied to extend life Tools and components in cars, motorcycles, bicycles,
¾Lubrication appliances…
¾ Advantages over hot extrusion
Glass: a glass cylinder is placed in the die entrance of Improved mechanical properties through work-hardening
the chamber. The billet heats the glass and the Good control of dimensional tolerances
molten glass acts as a lubricant at the die interface. Improved surface finish
Jacketing or canning Elimination of need for billet heating
• If the metal is likely to stick to the container walls, then the ¾ Disadvantages
billet can be enclosed by a thin-walled container of a softer Stress magnitudes on the tools are high Æ wears the die
metal.
¾ Lubrication
Applied to the workpiece
3
Extrusion Equipment The Drawing Process
¾Most common are horizontal hydraulic presses ¾ What is it? ¾ Drawing force (F)
Speed of the operation can be controlled The cross-section of a round
F Yavg⋅ Af ⋅ ln
Ao
wire/rod is reduced in size or
¾Cold extrusion changed in shape by pulling it
through a die.
Af
Yavg: average stress of material
Typically vertical hydraulic presses ¾ Variables drawn
Amount of reduction in cross- Af: exit cross-sectional area
More economical as they require less floor space sectional area Ao: initial cross-sectional area
Die angle ¾ Max reduction in cross-sectional
• Optimum angle for minimum area: 63%
drawing force can be computed.
• Other product quality dimensions
may require a different angle.
Friction along die/workpiece
Drawing speed
4
Drawing Equipment Roll Straightening
¾ Draw bench
A single die
Used for diameters Figure 15.22 Schematic illustration of roll straightening of a drawn round rod (see also Fig. 13.7).
> 20 mm
Lengths < 30 m
¾ Bull block
Usually multiple dies are
used
Lengths = several
kilometers