Extrusion and Extrusion and DrawingDrawing

Manufacturing Manufacturing ProcessesProcesses

OutlineOutline

ExtrusionExtrusionExtrusion of MetalsExtrusion of MetalsExtrusion DefectsExtrusion DefectsExtrusion EquipmentExtrusion EquipmentExtrusion of NonmetalsExtrusion of NonmetalsDrawingDrawingDrawing ProcessDrawing ProcessDrawing EquipmentDrawing Equipment

ExtrusionExtrusion

A compression process in which A compression process in which the material is forced to flow the material is forced to flow through an opening to produce through an opening to produce a shape with a specific cross-a shape with a specific cross-sectionsection

pump

input

dieproduct

Examples of Extruded Examples of Extruded PartsParts

ExtrusionExtrusion

MetalsMetals

NonmetalsNonmetals

Metal ExtrusionMetal Extrusion

Direct ExtrusionDirect ExtrusionA ram compresses the A ram compresses the material, forcing it through the material, forcing it through the diedie

Indirect ExtrusionIndirect ExtrusionThe die is mounted on the ram; The die is mounted on the ram; the material is forced out in the the material is forced out in the opposite direction of the ram opposite direction of the ram movementmovement

Direct ExtrusionDirect Extrusion

Indirect ExtrusionIndirect Extrusion

ExtrusionExtrusion

ExtrusionExtrusion

Metal FlowMetal Flow

Example of an Example of an Extrusion MachineExtrusion Machine

ExtrusionExtrusion

ExtrusionExtrusion

Hot ExtrusionHot ExtrusionInvolves pre-heating the Involves pre-heating the material above the material above the recrystallization temperature to recrystallization temperature to increase ductilityincrease ductility

Cold ExtrusionCold ExtrusionDoes not pre-heat material; Does not pre-heat material; used to produce parts in used to produce parts in finished or near-finished formfinished or near-finished form

ExtrusionExtrusion

Cold extrusion advantages:Cold extrusion advantages:- Improved mechanical Improved mechanical

properties from work-hardeningproperties from work-hardening- Good control of dimensional Good control of dimensional

tolerancestolerances- Improved surface finish (no Improved surface finish (no

oxide film)oxide film)- No heating requiredNo heating required- Competitive production rates Competitive production rates

and costsand costs

Extruded MetalsExtruded Metals

Typical extruded metals (hot or Typical extruded metals (hot or cold)cold)Aluminum, copper, magnesium, Aluminum, copper, magnesium, zinc, tin and alloys of thesezinc, tin and alloys of these

Steel alloys are usually extruded Steel alloys are usually extruded hot; softer steels may be hot; softer steels may be extruded coldextruded cold

Others such as titanium and Others such as titanium and refractory metals may be refractory metals may be extruded, but with difficultyextruded, but with difficulty

Extruded MetalsExtruded Metals

Extrusion Temperature RangesExtrusion Temperature Ranges

LeadLead 200-250 °C200-250 °CAluminum and its alloysAluminum and its alloys 375-475 °C375-475 °CCopper and its alloysCopper and its alloys 650-975 °C 650-975 °C SteelsSteels 875-1300 °C 875-1300 °C Refractory alloysRefractory alloys 975-2200 °C 975-2200 °C

Extrusion DefectsExtrusion Defects

Extrusion DiesExtrusion Dies

Extrusion DiesExtrusion Dies

Example of an Example of an Extrusion DieExtrusion Die

Extrusion of NonmetalsExtrusion of Nonmetals

MaterialsMaterialsrubberrubberplasticplasticsolventssolventscandy candy glassglass

ProductsProductswindow sealswindow sealsdoor sealsdoor sealshose and tubinghose and tubingwire insulationwire insulationcandy canescandy canes

Hot Feed and Cold Hot Feed and Cold Feed ExtrusionFeed Extrusion

Heating/melting

Ribbon Pellets

Cold Feed Extrusion

Hot Feed Extrusion

Temperature zones

Extrusion of NonmetalsExtrusion of Nonmetals

candy

cone rollers

Candy Canes

Extrusion of NonmetalsExtrusion of Nonmetals

Window SealsCold Feed Extrusion

takeaway belt

windupdie

extruder

input

die

Extrusion of NonmetalsExtrusion of Nonmetals

die

cutting and

sealing

air

extruder

Plastic Bags

Example of a Dual Example of a Dual Extruded ProductExtruded Product

Dual ExtrusionDual Extrusion

Opposed Head

die

extruder extruder

extruder

extruder

Piggy Back

die

Dual Extrusion – White Dual Extrusion – White Side WallSide Wall

White rubber dieBlack rubber die

Exit die

Wire, Tube, Bar, Rod Wire, Tube, Bar, Rod DrawingDrawing

Extrusion pushes the material Extrusion pushes the material through the die; drawing pulls through the die; drawing pulls the material through the diethe material through the die

DrawingDrawing

ProductsProductselectrical wireelectrical wirecablecablewire stock for fences, hangers, wire stock for fences, hangers, shopping carts etc.shopping carts etc.rod stock for nails, screws, rod stock for nails, screws, rivets, springs etc.rivets, springs etc.metal barsmetal bars

Drawing ProcessDrawing Process

Advantages:Advantages:- Close dimensional controlClose dimensional control- Good surface finishGood surface finish- Improved strength and hardnessImproved strength and hardness- Adaptability to mass productionAdaptability to mass production

Drawing of a WireDrawing of a Wire

DrawingDrawing

DrawingDrawing

Preparation of the work material:Preparation of the work material:1.1. AnnealingAnnealing2.2. CleaningCleaning3.3. PointingPointing

Single and Multi Stage Single and Multi Stage DrawingDrawing

GoldGoldGold is the most ductile metal Gold is the most ductile metal

that exists.that exists.

4 pounds of gold can be drawn 4 pounds of gold can be drawn into a wire that stretches into a wire that stretches across the country.across the country.

Tube and Bar DrawingTube and Bar Drawing

Draw Bench Production Draw Bench Production ProcessProcess

SummarySummary

Extrusion and drawing provide Extrusion and drawing provide ways to form shapes with ways to form shapes with uniform cross sections at high uniform cross sections at high production ratesproduction rates