Extrusion process presentation final (1).pptx

Manufacturing Technology
• Ibrahim Ahmed Elsisi
• Ibrahim Said Assy
• Ibrahim Mohamed Hussien
• Ahmed Ibrahim Elgndy
1st Group members:
Benha University
Benha Faculty of Engineering
Mechanical engineering department
Supervised by : Dr Ahmed Qassem

Manufacturing
Manufacturing refers to the conversion of row materials into finished
product employing suitable techniques
There are several process of manufacturing such as
1. Metal casting
2. Metal forming
3. Metal machining
4. Metal joining
5. finishing

Metal forming
Metal forming is an important manufacturing operation.
Of these manufacturing process forming is a widely used process that
changing the shapes and dimension of the material
It enjoys industrial important among various production operation due
to its advantages such as cost effectiveness ,enhanced mechanical
properties ,flexible operation ,higher productivity considerable
material saving .

Metal Forming process
Forming process occur on materials at the plasticity stage and
preferable those materials are :-
low yield strength & high ductility
In this forming process ,material is completely displaced and
deformed into require shape.
Good surface finishing for the products.
Metal forming occurs without chip removing .

Stress - Strain Curve
Under a tensile or compressive stress ,a component goes through two
stages :
1. The elastic range ,where the component if unstressed at any point in
this range would revert back to its original geometrical shape.
2. The plastic range ,where the component can be deformed up to its
Ultimate Tensile stress value and breaks –up after this stress

Classification of Metal forming
We can classify metal forming based on Temperature of operation:
Hot forming
• It is above recrystallization temperature.
Cold forming
• It is usually carried in room temperature.

Classification of metal forming
Bulk metal
Forming
Sheet metal
forming
Metal forming

Bulk Forming Processes
Bulk-forming is accomplished in forming presses with
the help of a set of tool and die. Examples for products
produced by bulk-forming are gears, valves, engine
parts such as valves, connecting rods, hydraulic valves,
etc
Bulk deformation refers to the use of raw materials for
forming which have a low surface area to thickness ratio.
Rolling, forging, extrusion, and drawing are bulk forming
processes. In bulk deformation processing methods, the
nature of force applied may be compressive, and tensile,
shear or a combination of these forces

Rolling
This is a compressive deformation
process in which the thickness of a
slab or plate is reduced by two
opposing cylindrical tools called rolls.
The rolls rotate to draw the work into
the gap between them and squeeze it.
Forging
In forging, a workpiece is compressed
between two opposing dies, so that the die
shapes are imparted to the work. Forging
is traditionally a hot working process, but
many types of forging are performed cold.

Extrusion
This is a compression process in
which the work metal is forced to
flow through a die opening, thereby
taking the shape of the opening as its
cross-section.
Drawing
In this forming process, the diameter of
a round wire or bar is reduced by
pulling it through a die opening.

Sheet metal forming is a process that materials undergo
permanent deformation to produce a variety of complex three
dimensional shapes . The process is carried out in the plane of
sheet by tensile forces with high ratio of surface
area to thickness.
Sheet metal forming
•Automotive industry (e.g. doors, hoods, fenders)
•Aircraft industry (e.g. wings, fuselage)
•Home appliance industry (e.g. sinks, cooker hoods,
freezers)
•Food industry (e.g. cooking pots, canned goods)

Classification
of sheet
metal forming
Drawing Punching/Piercing
Blanking Notching
Lancing
Embossing Coining
bending

Drawing
In sheet metalworking, drawing refers to the
forming of a flat metal sheet into a hollow or
concave shape, such as a cup, by stretching the
metal. A blank holder is used to hold down the
blank while the punch pushes into the sheet
metal.
To distinguish this operation from bar and wire
drawing, the terms cup drawing or deep
drawing are often used.
Bending
Bending involves the straining of a metal sheet or
plate to take an angle along a (usually) straight
axis.

Blanking
The final part or product is removed or
“punched-out” out of the larger sheet material,
with the remaining material being discarded as
scrap.
Punching / Piercing
The material removed is discarded, and the final
product is the remaining material which then
undergoes further processing.

Lancing
A press operation in which a single line cut or
slit is made on part way across the strip stock,
without removing any metal.
Notching
Notching is a metal cutting process used on
sheet metal or thin bar stock.in notching
operation the material removes from edge of
workpiece

Coining
A cold working process similar in other respects to
forging, which takes place at elevated temperature.
Embossing
Is a stamping process for producing raised or
sunken designs or relief in sheet metal. This
process can be made by means of matched male
and female roller dies, or by passing sheet or a
strip of metal between rolls of the desired
pattern.

Overview of Extrusion
Team 2 members :-
• Ahmed Elsayed Mohamed
• Ahmed Samir Abdelkrim
• Ahmed Tarek Abdelmaqsoud
• Ahmed Shehab Mohamed
• Ahmed Emam Eldesouky

What is extrusion
?
Metal extrusion is a forming process
in which we force a metal (either hot
or cold) through a die
The material emerging from the die
is known as “extrudate ”
The pressure is applied either hydraulically or mechanically.
Overview on extrusion process
The metal endures compressive and shear stress to achieve the die shape.

Suitable materials for
extrusion
Aluminium and its alloys are greatly usedand can be either hot or cold extruded
The extrusion of steel and its alloys is also possible
Besides metals, nonmetals such as ceramic, plastic, clay, concrete, polymers, etc.
are also suitable for extrusion.
Brass, Copper, Lead & thin , Magnesium, Zinc and titinum are widely use

Extrusion
equipment
Movement of the extrusion with relation to the ram, that is,
direct or indirect extrusion.
Position of the press, either vertical or horizontal.
Either hydraulic or mechanical type of drive.
Extrusion equipment is of different variations, varying by the following
characteristics:

 Extrusion componanats
 Pressing stem : element which transfers
the power of the main cylinder on the
billet like a column.
 Dummy block : an extension of the
stem to push the billet through the
die.
 It is a critical element for extrusion
process efficiency and extruded part
quality.
container: is used to hold the billet through
the die.
Die holder : used to hold the die and make it
stable .

are thick and circular steel disks containing one or more
openings.
Extrusion dies:
must have certain mechanical characteristicsThey must also be
resistant to wear
Extrusion die must be strong and hard, capable of holding their dimensional accuracy throughout
the high stresses created during the manufacturing process
Dies for hot extrusion must have high thermal resistance and be able to maintain strength and
hardness at elevated temperatures

 Die Material
Tool steels are a common type of material for metal extrusion
molds
Extruding dies may be coated to increase wear resistance. Carbides
are sometimes used for a mold material
 Die angle
The amount of force necessary to form a certain
cross section will vary with different die angles
A lower angle will create more friction at the work-
die interface
High die angles create more material movement,
particularly in the outer regions away from the
center

Factors that affect the quality
of extrusion
extrusion ratio
billet
temperature
lubrication extrusion speed
die design

 extrusion ratio
AREA OF THE BILLET/AREA OF THE SHAPE = AO/AF
The extrusion ratio will be a clear indication to the amount
of mechanical working that will occur as the shape is being
extruded.
If the extrusion ratio of a profile section is low, then parts of
the shape will have less mechanical work performed on it
When the extrusion ratio is higher, greater pressure will be
needed to force the metal through the smaller opening in the
die, this means that intense mechanical working will occur.

 billet temperature
extrusion speed
 The speed of an extrusion varies depending on the temperature, pressure
and alloy being used for the shape being extruded
 The lower the temperature, the higher the pressure that’s required
 Lower temperature extrusions have a better surface quality and dimensions
which are more accurate.
 Higher billet temperatures and faster extrusion speeds means metal flow
becomes more fluid

 Friction & lubrication
The effect of friction on the material flow and the extrusion load can be reduced partly or
completely by a suitable and homogeneous lubrication.
Lubrication is important in hot extrusion because of its effects on
(a) material flow during extrusion
(b) surface finish and integrity
(c) product quality
(d) extrusion forces

the lubricants are used in Al:
die lubricant.
 lubricant-graphite mixture.
 molybdenumdislphide.
 soft soap and wax.
the latter two are used tube extrusion.
Copper oxide
Calcium grease
Glass is an excellent lubricant for steels, stainless steels, and high-temperature
metals and alloys

 Extrusion is a continuous high production volume process.
 Lower cost per parts manufacturing
 Better grain structure and accuracy achieved in this metal forming process.
 Less wastage of material in the extrusion process.
Advatages of
Extrusion

 This process can be used for both brittle and ductile materials
 This process working operation is easy and flexible.
 Many types of raw materials can be used
 Continuous operation

 tubes and hollow pipes
 structure work
 frames , doors , window etc. In
automotive
 plastic objects
Extrusion Products

cold
Metal extrusion
processes
working temperature
the direction of
extrusion flow
Hot direct indirect
Others
hydrostatic Impact

Classification of Extrusion
Prepared by:-
Team 3
Supervised by:-
Dr. Ahmed Kassem
Eng. Abdelmegeed El-sayed
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Manufacturing Technology (A) (M 1271) – Fall 22
12/19/2023

Classification of Extrusion
 Ahmed Abdelmoneiom Abdelsadek
 Ahmed Abdelazeem Abdelfatah
 Ahmed Magdy El-Desouqy
 Ahmed Abdalla Mohamed
 Ahmed Adel Mahmoud
Team 3 members
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12/19/2023

outlines
Become familiar with different types of Extrusion .
Advantages of each type.
Disadvantages of each type.
12/19/2023 Manufacturing Technology (A) (M 1271) – Fall 22 39

Hot Extrusion
• involves prior heating of the billet to a
temperature above recrystallization temperature.
• For metals and alloys that do not have sufficient
ductility at room temperature
• This reduces strength and increases ductility of
the metal.
• It keeps the material from work hardening.
• Increase ram speed and reduce ram force.
• High maintenance required.
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Hot Extrusion
• Cooling of the billet as it contacts the
container walls is a problem, and
isothermal extrusion is sometimes used
to overcome this problem
• Surface oxides on product may be
undesirable when good surface finish is
important.
• Dummy blocks slightly smaller in
diameter than the container.
• Glass is often used as a lubricant
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Cold Extrusion
• Cold Extrusion is a process done at room
temperature or a slightly warm
temperature (less than recrystallization
temperature). It is also known as cold
pressing.
• Soft Metals like copper , tin , titanium ,
aluminum alloys can be extruded
through the cold extrusion process.
• They are generally used to produce
discrete parts
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Cold Extrusion
Advantages:
• Work hardening leads to
improved properties, as long as
frictional heat does not cause
recrystallization.
• Good dimensional tolerances.
• Less energy required (no
preheating)
• High production rate and
relatively low cost
Disadvantages:
• Higher stresses on tooling and
dies (Especially with steel
workpieces)
• The punches are critical
component; they must have
sufficient strength, toughness,
and resistance to wear and
fatigue
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Direct Extrusion
• It is also called “Forward Extrusion”.
Advantages:
• Can be used for both hot and cold extrusion
• Simple tooling compared to other extrusion
process
Disadvantages:
• The relative motion between billet and
container wall develops high friction.
• a small portion of the billet called “butt end”
cannot be pushed through the die opening.
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Indirect Extrusion
It is also called “backward extrusion and
reverse extrusion”.
Advantages:
• The ram force is lower than in direct extrusion
because there is no friction at the container
walls.
• It can produce hollow (tubular) cross sections.
Limitations:
• Lower rigidity of the hollow ram.
• difficulty in supporting the extruded product as
it exit the die (length limitations)
• support of ram becomes a problem as work
length increases.
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Impact Extrusion
• The punch is made to strike the slug at high speed
by impact load.
• It is useful to produce short lengths of hollow
shapes like collapsible tooth paste tubes and thin
walled cans.
• It is usually a cold working process, but the high
speed of deformation develops heating.
Limitations :
• The forces acting on the punch and die are
extremely high, tooling must have sufficient
impact resistance, fatigue resistance and strength
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Impact Extrusion
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Hydrostatic Extrusion
• Friction problem can be addressed by surrounding the
billet with fluid inside the container.
• there is no friction inside the container and the friction
at the die opening is reduced.
• Extruded product has good surface finish and
dimensional accuracy.
• Brittle materials can be successfully extruded with this
process.
• Ductile metals can also be hydrostatically extruded,
and high reduction ratios are possible.
• It can be carried out at room temperature or at
elevated temperatures , therefore, special fluids and
procedures must be used in this case.
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Plastic Extrusion
Types of plastic Extrusion :
1. Tubing Extrusion.
2. Blow Film Extrusion.
3. Sheet Film Extrusion.
4. Over Jacket Extrusion.
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References
Amstead, B.H; et. al. (1987). Manufacturing Processes. John-Wiley
and Sons, New York
Fundamentals of Modern Manufacturing Materials, Processes, and
Systems Seventh Edition
12/19/2023 Manufacturing Technology (A) (M 1271) – Fall 22 50

51
12/19/2023

Prepared by:- team 4
Ahmed Mohamed Shawky
Ahmed Mohamed Emad
Ahmed Mohamed Ali
Ahmed Mahmod Ali
Ahmed Naser Saleh
Manufacturing Technology
Extrusion Machines and Materials
Supervised by:-
Dr. Ahmed Kassem

Contents
•Horizontal machines
•Vertical machines
•Materials of Die
•Plastic extrusion machine
•Limitations of extrusion

Horizontal machines
Horizontal extrusion presses:
 Used for most commercial extrusion of bar and shapes.
Disadvantages:
 Deformation is non-uniform due to
different temperatures between top and bottom parts of the billet.
• Require less floor space than horizontal presses.

Vertical machines
Vertical extrusion presses:
 used in the production of thin-wall tubing.
Advantages:
• Easier alignment between the press ram and tools.
• Higher rate of production.
• Require less floor space than horizontal presses.
• Uniform deformation, due to uniform cooling of the billet in the container.
 Requirements:
• Need considerable headroom to make extrusion of appreciable length.
• A floor pit is necessary.

Materials of Die:
To make a die, so many materials are needed to be present. These contain so
many steels of different kinds and the material of non-metallic and the casting of
non-ferrous and ferrous.

Carbon Steel:
• Manganese 0.20 to 0.45.
• Carbon 0.90 to 1.15.
• Sulphur 0.025 Phosphorus 0.025
• Silicon 0.16 are present in this Carbon steel.
Carbon Block Steel:
• manganese 0.50 to 0.70.
• carbon 0.55 to 0.65.
• chromium 0.60 to 1.10 .
• nickel 1.25 to 1.75.

Tungsten Oil Hardening Steel:
• manganese 0.25.
• tungsten 1.75 .
• carbon 1.20.
High-Alloy Oil-Hardening Steel:
•This High-Alloy Oil-Hardening Steel is the non-deforming in nature.
• It contains about chromium 12.00.
•carbons 2.15.
• manganese 0.35.
• Other elements, Tungsten, Nickel, and Vanadium can add to this steel.

Manganese Air Hardening Steel:
• manganese 2.5.
• carbon 0.90.
• molybdenum 1.00.
• chromium 1.5.
• silicon 0.30.
Chromium Air Hardening Steel:
• chromium 5.00.
• carbon 1.00.
• manganese 0.50.
• molybdenum 1.00.
• silicon 0.25.
• sometimes vanadium 0.50 can be added.

• Plastic extrusion machine is used to create a continuous process like
tire treads, pipes, etc. A plastic extrusion machine is essential to
complete a plastic extrusion process.
Plastic extrusion machine

• Raw plastic material gets pushed by a plastic extruder (a hopper) and
melted by the heat produced through turning screws.
• These screws are fixed with the barrels to melt down the material. To
ensure the quality of the final products it is essential to maintain a
constant temperature.
• The barrel is normally heated from back to front slowly. This way is
used to avoid imperfection and overheating of the components.
• A series of fans and water cooling system is used to control the
temperature accordingly.
• Extrusion dies are simply dense and oval-shaped stainless steel
plates with one or more openings used in
the production of the desired profile.

Limitations of extrusion
• High tolerances are difficult to achieve.
• The process is limited to ductile materials.
• Extruded products might suffer from surface cracking.
• It might occur when the surface temperature rise significantly
Due to high extrusion temperature ,friction or extrusion speed.
• Internal cracking might also occur.

Thank you
campeón de
medallas

• Extrution defects
• Team 5
 Adham Ashraf
 Ahmed yehia
 Ahmed hekial
 Osama zakia
 Ahmed Yasser
 Supervised by:
 Dr/Ahmed Kassem

The importance of studying
extrusion defects
• Improving the product quality
• Minimizing the defects
• Decreasing the cost
• Characteristics improvement
• Surface finish obtained is good
• High production volumes

center burst
• This defect is an internal crack that develops as a result of tensile
stresses along the centerline of the workpart during extrusion
• Center burst is an internal defect that is usually not noticeable by
visual inspection.
causes
a) High die angles.
b) Low extrusion ratio.
c) Impurities in the work
metal that serves as a
starting points for crack
Remedies
a. Ensure that the
metal is free of
impurities through
a good inspection
b. High extrution

piping
• Piping is a defect associated with a direct extrusion
• As in the above figure (b), it is the formation of a sinkhole at
the end of the billet.
Redemies
• The use of a dummy block
whose diameter is
somewhat less than that of the
billet helps to avoid a piping
defect in the extrusion process.

Surface cracking
• Is breakage on the surface of the part. Most surface defects are in
the form of cracks that extend from the surface into the parts
material, to varying degrees.
Causes
a) extrusion speed is very high
b) high friction
c) high-temperature billets
Remedies
a) Decrese extrusion speed
b) Lower extrusion
tempreture

Important consideration in die design
• Basic Considerations The objective of an extrusion die is to distribute the material
melt in the flow channel such that the material exits from the die with a uniform
velocity.
• Customer’s specifications — Usually, the part or product specification of the
customer will make it challenging to place the parting line
• Regular wall thickness Irregular extrusion wall thicknesses can also lead to
difficulties in manufacturing and increased production costs.
• The Length Allowance designs need to adapt the required extrusion length
depending on the properties of the material being used. All thermoplastics will
contract and expand with temperature

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