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Extrusion and Drawing Processes and Equipment

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Extrusion and Drawing Processes and Equipment IE 3130 Material Processing Module 3: Metal Extrusion and Drawing Processes and Equipment Reading 1. Chap 15, Manufacturing Engineering & Technology, 6th Edition, Serope Kalpakjian & Steve Schmid Objective of this module Upon completion of class activity, lecture, and homework, student should be able to do the following: 1. Sketch and describe an open-die forging with simple tools and complex process sequences. 2. Describe Impression and closed-die forging with complex tools and simple process sequences. 3. Sketch and describe extrusion and drawing of wire, tube and shaped sections. 4. Estimate die pressure, force, and power requirement of forging, extrusion, drawing, and rolling processes. 5. List different processes of cutting parts for further working or immediate assembly. 6. Sketch and describe bending on presses or roll-forming lines. Extrusion Extrusion – Latin root (Extrudere: to thrust out) Initially non-steady state, then steady state process Hot extrusion of aluminum is capable of producing a large variety of often very complex shape, including multihole sections, gearing, and tubing, with thin walls and significant wall-thickness variations. 80/20 – T Slotted Aluminum - Erector Set for Adults Hose Reel Assembly System – Graco Pump Minn Deburring – Parker Hannifin Load Carrying Device – Air Force Extrusion • Two types of Extrusion • Direct or forward extrusion: the product emerges in the same direction as the movement of the punch. Container friction plays big role. • Indirect or reverse extrusion: the product travels against the movement of the punch. Container friction plays no role. Billet is at rest in container. Extrusion process: (a) forward or direct without lubrication (and the associated extrusion-pressure/stroke curve; (b) forward with full lubrication; c) reverse or (indirect or backward); (d) reverse can (impact); (e) hydrostatic extrusion. Hyrdostatic extrusion - Cold extrusion of copper tubes and of composite cu-Al billets FIGURE 15.3 Types of extrusion: (a) indirect; (b) hydrostatic; (c) lateral. Hollow products may be extruded with (a) fixed or (b) piercing mandrels or with c) bridge or spider-type dies. Forward Extrusion - Classification ▪Extrusion of semifabricated products ▪Extrusion of finished components ✓Remnant in container cutoff ✓Remnant in container is integral head of part ✓Primary ✓secondary • Unlubricated (primary) • Lubricated (primary and • With a die of flat face (180 die secondary) opening) Conical entrance zone • Pb, Zn, Al, Mg and other alloys Hot: • Materials that form hard oxides • Graphite (solid lubricant) that might result in smearing the surface of the product during • Glass (solid lubricant that melts lubricated extrusion at the extrusion temperature) Cold: • Semisolids (phosphate + soap) Forward Extrusion l d1, A1 do Ao Forward Extrusion with Full Lubrication • No dead metal zone Reverse Extrusion • Lubricated or unlubricated • Primary or secondary • Hot or Cold Extrusion Analysis Extrusion Ratio: Ao RE = A1 a A1 A = ln o A1 Extrusion Force: Ao A F = A k ln 0 0 Af K is the extrusion constant which is determined experimentally. It is a measure of the strength of the material being extruded and frictional conditions FIGURE 15.4 Process variables in direct extrusion. The die angle, reduction in cross section, extrusion speed, billet temperature, and lubrication all affect the extrusion pressure. FIGURE 15.5 Extrusion constant k for various metals at different temperatures. Source: After P. Loewenstein. Extrusion Force A F = A k ln o o Af Flow Stress (Schey) K n+1 • Cold: = [ ] fm n +1 6vd2 tana • Hot: m = o A f = C m d 3 - d 3 = ln o o 1 FrictionlessA1 Extrusion Pressure pe = fmQe = fm (0.8 +1.2) for frictionless extrusion Includes inhomogeneous deformation Extrusion Force Pe = pe Ao Effect of Container Friction • Friction in container: 4 l l is the length of the billet p = p + i l e d do is the initial diameter of the o billet where: m* = 1 for sticking friction i f f = 0.5 fm m* = f i 2 Metal Flow in Extrusion Metal Flow in Extrusion has influence on the quality and mechanical properties of extruded parts, Technique of investigating flow pattern is slice, grid, and braze before extruding. FIGURE 15.6 Types of metal flow in extruding with square dies. (a) Flow pattern obtained at low friction or in indirect extrusion. (b) Pattern obtained with high friction at the billet–chamber interfaces. (c) Pattern obtained at high friction or with cooling of the outer regions of the billet in the chamber. This type of pattern, observed in metals whose strength increases rapidly with decreasing temperature, leads to a defect known as pipe (or extrusion) defect. Process Parameters • Materials: wrought alloys including aluminum, magnesium, copper, steels, stainless steels. Titanium and refratory materials are extruded with some difficulty. • Extrusion ratios: 10 to 100, up to 400 for special non ferrous alloys, at least 4 to deform the material. • Ram speeds: up to 0.5 m/s. Lower speed for aluminum, magnesium, copper. Higher speed for steels, titanium and refractory alloys. • Dimensional tolerance: E0.25 – 2.5 mm. They increase with increasing cross section. • Geometry: Extruded products less than 7.5 m (25 ft) long because of difficult handling. Can be up to 30 m (100 ft). • Handling: Most extruded products require straightening and twisting especially small cross sections. 15.3 Hot Extrusion • Application on low ductile metals • Excessive die wear. To prolong die life, die is preheated. • Low tolerance because of oxidation layer. Minimized by using dummy block placed ahead of the ram (Fig 15.1). Die Design • Square dies. • Angled dies. • T-shaped dies FIGURE 15.7 Typical extrusion–die configurations: (a) die for nonferrous metals; (b) die for ferrous metals; (c) die for a T-shaped extrusion made of hot-work die steel and used with molten glass as a lubricant. Source: (c) Courtesy of LTV Steel Company. Die Design • Tubular extrusion. • Hollow cross sections. FIGURE 15.8 Extrusion of a seamless tube (a) using an internal mandrel that moves independently of the ram. (An alternative arrangement has the mandrel integral with the ram.) (b) using a spider die (see Fig. 15.9) to produce seamless tubing. FIGURE 15.9 (a) An extruded 6063-T6 aluminum-ladder lock for aluminum extension ladders. This part is 8 mm (5/16 in.) thick and is sawed from the extrusion (see Fig. 15.2). (b) through (d) Components of various dies for extruding intricate hollow shapes. Source: (b) through (d) after K. Laue and H. Stenger. Die Material and Lubrication Hot worked die steels are used for hot extrusion Coatings such as partially stabilized zirconia may be applied to the die to extend their life. • Unlubricated (primary) • Lubricated (primary and • With a die of flat face (180 die secondary) opening) Conical entrance zone • Pb, Zn, Al, Mg and other alloys Hot: • Materials that form hard oxides • Graphite (solid lubricant) that might result in smearing the surface of the product during • Glass (solid lubricant that melts lubricated extrusion at the extrusion temperature) Cold: • Semisolids (phosphate + soap) 15.4 Cold Extrusion ➢Used widely for components in automobiles, motorcycles, bicycles, and appliances in the transportation and farm equipment. ➢Uses slugs cut from cold-finished or hot- rolled bars, wire, or plates. ➢Advantages include: ✓Improved mechanical properties. ✓Good control of dimensional tolerances. ✓Improved surface finish due to absence of an oxide film. ✓Competitive production rates and costs with other methods. FIGURE 15.12 Two examples of cold extrusion. Thin arrows indicate the direction of metal flow during extrusion. FIGURE 15.13 Production steps for a cold-extruded spark plug. Source: Courtesy of National Machinery Company. FIGURE 15.14 A cross section of the metal part in Fig. 15.13, showing the grain- flow pattern. Source: Courtesy of National Machinery Company. 15.4.1 Impact Extrusion • Usually lubricated • Usually secondary • Usually cold Pe = Ao pe or Pi = 3 fm Ap Take larger of two Similar to Piercing or Forging FIGURE 15.15 Schematic illustration of the impact-extrusion process. The extruded parts are stripped by the use of a stripper plate, because they tend to stick to the punch. FIGURE 15.16 (a) Impact extrusion of a collapsible tube by the Hooker process. (b) and (c) Two examples of products made by impact extrusion. These parts also may be made by casting, forging, or machining. The choice of process depends on the materials involved, part dimensions and wall thickness, and the properties desired. Economic considerations also are important in final process selection. 15.4.2 Hydrostatic Extrusion • The pressure required in the chamber is supplied via a piston through an incompressible fluid medium surrounding the billet. • Pressures are typically in the order of 1400 Mpa (200 Ksi). • No need for lubrication, some of the fluid transmitted to the die surface due to high pressure act as lubricant. • Typically conducted at room temperature with vegetable oils as fluid. Castor oil is a good lubricant and its viscosity is not influenced significantly by pressure. • Brittle materials can be extruded successfully by this method. • Extrusion ratios can be as high as 14,000. 1-m billet becomes 14 km-long wire. • It’s application in the industry is not common because: complex nature of tooling, experience needed with high pressures and design of specialized equipment, and long cycle times required. • Process is uneconomical for most materials and application. 15.5 Extrusion Defects 1. Surface Cracking. Too high extrusion temperature, friction, or speed will cause high surface temperature, which may cause surface cracking and tearing. Occurs in Aluminum, magnesium, and zinc alloys. Occurrence at low extrusion temperature is due to sticking of extruded part along the die land. 2. Pipe. Inhomogeneous metal flow will draw surface oxides and impurities toward the center of the billet-much like a funnel. Or too much extrusion into the die.
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