Life Is Movement, Movement Is Life

Contents
• Introduction to Manufacturing Processes

• Classification of Manufacturing Processes

• Extrusion Process

• Drawing Process

• Conclusion
 Manufacturing Process
• “Physical or chemical change to alter the geometry, properties, and/or
appearance of a given starting material to enhance the value of
material”

• As a unit operation.
 Classification of Manufacturing Processes
Manufacturing processes are divide into following categories
• Processing operations
I. Shaping processes
II.Property Enhancing processes
III.Surface operations

• Assembly operations
I. Permanent joining processes
II.Mechanical fastening
Processing Operations
Hierarchy of Manufacturing Processes
 Assembly Operations
• In which two or more separate parts are joined to form a new entity

• Permanent joining processes like; welding, soldering, adhesive

bonding

• Mechanical assembly like, rivets, press fitting

 Extrusion Process
• “A compression process in which material is pushed to flow through a die
orifice to provide long continuous product whose cross-sectional shape is
determined by the shape of the orifice”.

• Products:
I. Polymer shapes such as Thermoplastic pipes, hose, tubes
II. Structural shapes such as, sheet and film, continuous filaments,
and coated electrical wire and cable
 Advantages & Disadvantages
• High compressive stresses

• Difficult to form

• Fine grained re-crystallized structure

• Surface finish and higher strengths

• Close tolerance (cold)

• No material wastage
 Types of Extrusion

Direct Extrusion
The ram forces the work billet metal to move forward to pass through the die
opening.

Indirect Extrusion
The die is mounted to the ram rather than at the opposite end of the extruder
container housing.

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Direct Extrusion

Friction increases
the extrusion
force.
Hollow section is
formed using a
mandrel.

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Indirect Extrusion
Metal is forced to flow
through the die in an
opposite direction to
the ram’s motion.

Lower extrusion force

as the work billet
metal is not moving
relative to the
container wall.

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 Extrusion Processes
Hot extrusion
Keeping the processing temperature to above the re-crystalline
temperature. Reducing the ram force, increasing the ram speed, and
reduction of grain flow characteristics. Controlling the cooling is a
problem. Glass may be used as a lubricant.
Cold extrusion
Often used to produce discrete parts. Increase strength due to strain
hardening, close tolerances, improved surface finish, absence of oxide
layer and high production rates.
 Hot Extrusion
As might be expected, strain rate effects become important
during hot extrusion.
Mean strain rate during extrusion as

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 Cold extrusion
• For continuous or steady state processes, the mean flow stress
calculated from equation
𝐾𝜀 𝑛
𝜎𝑡𝑚 =
𝑛+1
𝜎𝑡𝑚 = mean flow stress, K=strength coefficient, n=strain hardening exponent
• Extrusion Pressure
𝑝𝑒 = 𝑄𝑒 𝜎𝑡𝑚 :- (Qe=multiplying factor for extrusion)
𝐴𝑜
Extrusion Ratio Re=
𝐴𝑓
Qe=0.8+1.2(lnRe)
 Extrusion Dies
For the case of non-circular extruded section, a shape factor has to be introduced:
2.25
 Cx 
K x  0.98  0.02 
 Cc 
where Kx = shape factor
Cx = perimeter of the non-circular extruded section
Cc = perimeter of a circle that has the same cross-sectional area as the extruded
section.
For direct extrusion,

 2L 
p  K xY f   x  
 Do 
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 Impact Extrusion

Forward backward

combination

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 Impact Extrusion

• Impact extrusion is performed at higher speeds and shorter strokes than

conventional extrusion.
• It is for making discrete parts.
• Making thin wall-thickness items by permitting large deformation at high
speed.

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Example: Extrusion
A cylindrical billet that is 100 mm long and 40 mm in diameter is reduced by indirect
(backward) extrusion to a 15 mm diameter.
Die angle = 90°. If the Johnson equation has a= 0.8 and b = 1.5, and the flow curve for
the work metal has K = 750 MPa and n = 0.15.
determine: (a) extrusion ratio, (b) true strain (homogeneous deformation), c) extrusion
strain, (d) ram pressure, and (e) ram force
Solution:
(a) Re=Ao/Af= Do2/D2 =7.11
(b) 𝜀 =lnRe=ln7.11=1.962
(c) Extrusion strain Qe=a+b(lnRe) =3.742
(d) Ram pressure= pe=Qe*𝜎𝑡𝑚
1 0.15)=721.5MPa
𝜎𝑡𝑚 = ∗ (750 1.962
1.15
pe= 721.5*(3.742)= 2700 MPa
(e) Force=Pressure*(Ao)= 2700*(π/4*402)
 Extrusion Defects

• Centre-burst: internal crack due to excessive tensile stress at the centre

possibly because of high die angle, low extrusion ratio.
• Piping: sink hole at the end of billet under direct extrusion.
• Surface cracking: High part temperature due to low extrusion speed and high
strain rates.

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 Wire and bar drawing
“Work material is pulled through the die in drawing, whereas it is pushed
through the die in extrusion”

• Bar drawing is the term used for large diameter bar and rod stock

• Wire drawing applies to small diameter stock. Wire sizes down to 0.03
mm (0.001 in) are possible in wire drawing
 Contd.
• Bar drawing is generally accomplished as a single-draft operation

• Wire drawing is consisting of several hundred (or even several thousand)

feet of wire and is passed through a series of draw dies (4-12), called
continuous drawing.
• The draft is term used;

𝑑 = 𝐷𝑜 − 𝐷𝑓

d=draft, Do=original diameter, Df= final diameter

 Analysis of drawing
• It is clear that as the reduction increases, draw stress increases
• Reduction is large enough, draw stress will exceed the yield strength
• The maximum reduction ‘ratio’

ⅇ−1
𝑟𝑚𝑎𝑥 = = 0.632
ⅇ
• Reductions of 0.50 for single-draft bar drawing and 0.30 for multiple-
draft wire drawing
 Introduction to Deep Drawing Process

• Sheet metal forming to make cup‐shaped, box‐shaped, or

other complex‐curved, hollow‐shaped parts
• Sheet metal blank is positioned over die cavity and then
punch pushes metal into opening
• Products: beverage cans, ammunition shells, automobile body
panels
• Figure
a) Drawing of a cup
shaped part:
(1) start of operation
before punch contacts
work
(2) near end of stroke
(b) Corresponding work
part:
(1) starting blank
(2) drawn part
 Clearance in Drawing

• Sides of punch and die separated by a

clearance c given by:
c = 1 .1 t
where t = stock thickness
• In other words, clearance = about 10% greater
than stock thickness
 Drawing Ratio DR
• Most easily defined for cylindrical shape:
𝐷𝑏
𝐷r =
𝐷𝑝
where Dr=drawing ratio
Db = blank diameter; and Dp = punch diameter
• Indicates severity of a given drawing operation
–Upper limit = 2.0
 Reduction ‘r’

• Again, defined for cylindrical shape

𝐷𝑏−𝐷𝑝
r=
𝐷𝑏
• Value of r should be less than 0.50
 Thickness‐to‐Diameter Ratio

• Thickness of starting blank divided by blank

diameter
Thickness‐to‐diameter ratio = t/Db
• Desirable for t/Db ratio to be greater than 1%
• As t/Db decreases, tendency for wrinkling
increases
Example No.4
• A cup is to be drawn in a deep drawing operation. The height of the
cup is 75 mm and its inside diameter = 100 mm. The sheet metal
thickness =2 mm. If the blank diameter 225 mm .
• Determine:
(a) drawing ratio, (b) reduction, and (c) thickness-to-diameter ratio (d)
Does the operation seem feasible?
Solution
• (a). Dr=Db/Dp= 225/100 =2.25
• (b). r= Db-Dp/Db= 225-100/225= 0.55
• (c). t/Db= 2/225= 0.0089
• (d). No! Dr is too large (greater than 2.0), (g ), r is too large
(greater than 50%), and t/D is too
small (less than 1%)
 Shapes other than Cylindrical Cups
• Square or rectangular boxes (as in sinks),
• Stepped cups,
• Cones,
• Cups with spherical rather than flat bases,
• Irregular curved forms (as in automobile body
panels)
• Each of these shapes presents its own unique
technical problems in drawing
 Advantages
• Can handle ferrous and non-ferrous
• Rapid press time leads to ultimately high production rate
• Product consistency
• Complex design
• Less material waste
• Cost efficient
 Defects in drawing
• Wrinkling in the flange
• Wrinkling in the wall.
• Tearing
• Earing
• Surface scratches.
 Conclusion

• Advance manufacturing processes discussion

• Extrusion process, its application, products and models

• Drawing process, advantages and related issues

• Mathematical expressions and models were also discussed