CHAPTER 15

Extrusion and Drawing of Metals

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 15-1

Direct Extrusion

Figure 15.1 Schematic illustration of the direct extrusion process.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Extrusions
Figure 15.2 Extrusions, and examples of products made by sectioning off extrusions. Source: Kaiser Aluminum.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Types of Extrusion

Figure 15.3 Types of extrusion: (a) indirect; (b) hydrostatic; (c) lateral.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Process Variables in Direct Extrusion

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.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 15-5

Circumscribing-Circle Diameter

Figure 15.5 Method of determining the circumscribing-circle diameter (CCD) of an extruded cross-section.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Extrusion Constant k for Various Metals

Figure 15.6 Extrusion constant k for various metals at different temperatures. Source: P. Loewenstein.
Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 15-7

Types of Metal Flow in Extruding With Square Dies

Figure 15.7 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.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 15-8

Extrusion Temperature Ranges for Various Metals

C 200250 375475 650975 8751300 9752200

Lead Aluminum and its alloys Copper and its alloys Steels Refractory alloys

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 15-9

Extrusion-Die Configurations
(a) (c)

(b)

Figure 15.8 Typical extrusion-die configurations: (a) die for nonferrous metals; (b) die for ferrous metals; (c) die for T-shaped extrusion, made of hot-work die steel and used with molten glass as a lubricant. Source for (c): Courtesy of LTV Steel Company.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Components for Extruding Hollow Shapes

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)-(d) Components of various dies for extruding intricate hollow shapes. Source: for (b)-(d): K. Laue and H. Stenger, Extrusion--Processes, Machinery, Tooling. American Society for Metals, Metals Park, Ohio, 1981. Used with permission.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 15-11

Cross-Sections to be Extruded
Figure 15.10 Poor and good examples of cross-sections to be extruded. Note the importance of eliminating sharp corners and of keeping section thicknesses uniform. Source: J. G. Bralla (ed.); Handbook of Product Design for Manufacturing. New York: McGraw-Hill Publishing Company, 1986. Used with permission.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Examples of Cold Extrusion

Figure 15.11 Two examples of cold extrusion. Thin arrows indicate the direction of metal flow during extrusion.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Cold Extruded Spark Plug

Figure 15.12 Production steps for a cold extruded spark plug. Source: National Machinery Company.

Figure 15.13 A cross-section of the metal part in Fig. 15.12, showing the grain flow pattern. Source: National Machinery Company.
Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Impact Extrusion
Figure 15.14 Schematic illustration of the impactextrusion process. The extruded parts are stripped by the use of a stripper plate, because they tend to stick to the punch.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 15-15

Examples of Impact Extrusion

Figure 15.15 (a) Two examples of products made by impact extrusion. These parts may also be made by casting, by forging, or by machining; the choice of process depends on the dimensions and the materials involved and on the properties desired. Economic considerations are also important in final process selection. (b) and (c) Impact extrusion of a collapsible tube by the Hooker process.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 15-16

Chevron Cracking
(a) (b)

Figure 15.16 (a) Chevron cracking (central burst) in extruded round steel bars. Unless the products are inspected, such internal defects may remain undetected, and later cause failure of the part in service. This defect can also develop in the drawing of rod, of wire, and of tubes. (b) Schematic illustration of rigid and plastic zones in extrusion. The tendency toward chevron cracking increases if the two plastic zones do not meet. Note that hte plastic zone can be made larger either by decreasing the die angel or by increasing the reduction in cross-section (or both). Source: B. Avitzur.
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2001 Prentice-Hall

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Hydraulic-Extrusion Press

Figure 15.17 General view of a 9-MN (1000-ton) hydraulicextrusion press. Source: Courtesy of Jones & Laughlin Steel Corporation.
Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Process Variables in Wire Drawing

Figure 15.18 Process variables in wire drawing. The die angle, the reduction in crosssectional area per pass, the speed of drawing, the temperature, and the lubrication all affect the drawing force, F.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Examples of Tube-Drawing Operations

Figure 15.19 Examples of tubedrawing operations, with and without an internal mandrel. Note that a variety of diameters and wall thicknesses can be produced from the same initial tube stock (which has been made by other processes).

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Die for Round Drawing

Figure 15.20 Terminology of a typical die used for drawing round rod or wire.

Figure 15.21 Tungsten- carbide die insert in a steel casing. Diamond dies, used in drawing thin wire, are encased in a similar manner.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Roll Straightening

Figure 15.22 Schematic illustration of roll straightening of a drawn round rod (see also Fig. 13.7).

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Cold Drawing

Figure 15.23 Cold drawing of an extruded channel on a draw bench, to reduce its cross-section. Individual lengths of straight rod or of cross-sections are drawn by this method. Source: Courtesy of The Babcock and Wilcox Company, Tubular Products Division.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Multistage Wire-Drawing
Figure 15.24 Two views of a multistage wire-drawing machine that is typically used in the making of copper wire for electrical wiring. Source: H. Auerswald.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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