Differential velocity sideways

extrusion (DVSE)
(Curved Shapes)
BITS Pilani PUSHPESH KUMAR: 2017H1060117H
Hyderabad Campus
Introduction
There are various conventional extrusion methods:
• Direct Extrusion: frictional resistance between the surface of the moving billet
and the confining chamber is more.
• Indirect Extrusion: No relative motion, friction between the billet and the
chamber is eliminated.
• Impact Extrusion
• Hydrostatic Extrusion: Billet‐chamber friction is eliminated.

Techniques for curved profiles(cold forming)

• stretch bending,
• press bending,
• rotary draw bending
• roll bending.
intrinsic problems such as cross-sectional distortion and springback remain to be
controlled using secondary operations and the tools are expensive.
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The following diagram will introduce a new concept of extrusion having curved
profile.
Differential velocity sideways extrusion (DVSE)

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Basic Principle : Profiles are extruded and bent simultaneously, due to the
velocity gradient at the die exit caused by the different relative moving
velocities of the two extrusion punches.

 Contrary to the axial flow of conventional extrusion, flows radially (normal to

the extrusion chamber) outwards through an aperture.

 Punch velocity ratio and extrusion ratio were process parameters.

 cross-sectional distortion and springback of curved profiles can be greatly

reduced by superposition of torsion or compressive stress with external
bending moment.

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Purpose and Scope

Using this arrangment we Performed series of experiments in which punch

velocity ratio and extrusion ratio were process parameter.

• Initially make Auto-cad and cryo models using line command only.

• Simulate the above models using simulation software.

• Get round bar and round tube extruded samples having curved profile
using Al AA1050 as billet.

• Find the values of extrusion ratio(λ) and Curvature

(k).

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Design Parametres
• For producing straight or curved, solid/tubular components (rod, tube, cup)
whose cross sections are decided by the die opening/orifice and the
mandrel.
• D2: diameter of the die exit orifice.
D3: diameter of the mandrel.
t: extrudate thickness. = (D2 – D3 ) / 2
V2 / V1 = 0, 1/3, 1/2 etc.
λ: extrusion ratio.= A0 / Af

• Work-piece/tool friction
The friction factor in the hot extrusion of metal is normally between 0.2 and
0.4 when the process is well lubricated using graphite-based lubricants and
between 0.7 and 1.0 without lubricant.
• Thin layer of Vaseline covered with fine soap powder provided an initial
friction factor of 0.3.
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Working Diagram

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 Tool specification
Dimension Material

Container D=25.6mm Carbon steel

H=150mm

Billet D=25.4mm Plasticine/ Al AA1050

H=130mm

Extrusion Dies D2 =15 or 20mm AISI H13

50HRC (tempered)

Mandrel D3 =7-13mm ----

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 Table of content

D2 D3 t V2 / V 1 Extrusion Curvature
ratio (λ) (k)

Round Bar 20 -- -- 0 1.61 0.026

1/3 0.021
1/2 0.019
15 -- -- 0 2.87 0.029
1/3 0.024
1/2 0.021
Round Tube 15 7 4 3.67

15 9 3 4.48

15 11 2 6.20

20 11 4.5 2.31
20 13 3.5 2.79
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Comparison of Process Parametres
 λ (ER) is constant
And (V2 / V1 ) increases as 0, 1/3, 1/2 etc.
Radius of curvature Rc (cm) will increase.
so curvature K(mm-1 ) will decrease.

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 (V2 / V1 ) is constant
As λ (ER) will increase
curvature K(mm-1 ) will increase.

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 (V2 / V1 ) = 1 (special case)

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First phase analysis (creo & cad models)

1. Creo model

proper clearance is taken between

the billet and container (0.1mm) and
punch dimensions is taken between
the billet & container i.e clearance
from container is (0.05mm).

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2. CAD model
Firstly various parts of Extrusion process is
made of specified dimension i.e container,
billet, punch etc.

It gives two dimensional view of process,

here cad model is made by using only line
diagram because it is further used in
simulation process.

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Second phase analysis (simulation)

In second phase simulation is done to verify thetheoretical knowledge get in

previous process.

Measures which can be obtained

by a simulation analysis are
applied to large process.
•Parts produced per unit time
•Time spent in system by parts
•Time spent by parts in queue
•In time deliveries made
•Inventory in process
•Percent utilization of machines
and workers. BITS Pilani, Hyderabad Campus
Defects

Surface Cracking: developed due to

• High extrusion temperature
•High ram speed
•High Friction

Internal Cracking: Cracks are developed in the center of extruded

material.
• This is also named as Center Cracking /Center Burst / Chevron
Cracking /Arrow head Cracking.
• It occurs due to difference in velocity and tensile stresses in center of the
material.

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• These are caused by using:
i. Large die angle
ii. Friction
iii. Low Extrusion Ratio
iv. Impurities in the work metal
• Large die angle causes larger h/L which cause
secondary tensile stress at centre, because the material
at centre has not reached plastic stage – due to non-
homogeneous deformation centre burst occurs.

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Observation & Result
 Extrusion ratio and velocity ratio v2/v1 both affect curvature. However, the
effect of velocity ratio v2/v1 is more pronounced than that of the extrusion
ratio. The effect of extrusion ratio is small when velocity ratio v2/v1 is greater
than 0.5, below this value the effect of extrusion ratio increases as velocity
ratio v2/v1 decreases.
• The curvature of bar and tube is reduced as the diameter D2 of the die exit
orifice increases, moreover for the same D2 the curvature of the tube is
reduced with increase of wall thickness of the tube.
• curvature of tubes increases significantly with reducing velocity ratio, while
curvature of bars varies relatively slowly with variation of extrusion velocity
ratio.
• eccentricity ratio e^ = e/ D2
where e is the distance between the dividing line and the boundary
extension line of the exit channel closer to the faster punch, D2 is the
diameter of the exit channel

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Future aspect

 Instead of using two different methods to get extruded curved profiles if

we use this then our manufacturing cost will reduced.

 Straight extruded profiles are also generated by this using velicity ratio 1.

 More precise control on curvature is achived by using proper tools and

methods & by reducing tool friction.

 Scope of this process is high because it eliminates cross-sectional

distortion spring-back effect, which arises generally in conventional
extrusion & bending.

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