MDB3073

Manufacturing Technology 2

Metal Forming- Extrusion and Drawing of Metals

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Extrusion: Cylindrical billet is forced through die

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Schematic illustration of the direct-extrusion process.

Extrusions and examples of products made by sectioning off extrusions.

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Types of extrusion:
(a) indirect;
(also called reverse/
inverted / backward
extrusion)
The die moves toward the
extruded billet

(b) hydrostatic;
The pressure is transmitted
to the fluid by a ram

(c) Lateral or side extrusion

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Process variables in direct extrusion: the die angle, reduction in cross-section,

extrusion speed, billet temperature, and lubrication all affect the extrusion
pressure.

Extrusion ration R = Ao/ Af

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Extrusion Force
The force required for extrusion depends on
Strength of the billet material, extrusion ratio, friction
and process variables
For small die angle , the extrusion pressure can be
approximated as
p = Y(1+ tan /)(R cot -1)
Where coeff. Friction, Y is yield stress

The extrusion force F = Ao k ln(Ao/Af)

Where k is extrusion constant (experimental)
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Example
Calculate the extrusion force for a round billet 250 mm in
diameter, made of 304 stainless steel, and extruded at
10000 C to a diameter of 70 mm.
From Fig., k for stainless steel at 1000 C is approximately 400 MPa. The
extrusion ratio is
we have F = Ao k ln (Ao/Af) = ..

F = 50 MN

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Rod, Wire, and Tube Drawing

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Drawing: the cross-section of a rod or wire is reduced or

changed in shape by pulling through a die.
Rod and wire drawing are finishing processes and is
further processed into other shapes.
Applications such as electrical wiring, electronic
equipment, cables and springs,

Drawing Dies

Terminology of a typical die used

for drawing a round rod or wire.

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Tungsten-carbide die insert in a steel

casing. Diamond dies used in drawing
thin wire are encased in a similar manner.

Mechanics of rod and wire drawing

1. Ideal and frictionless condition
A0
The drawing force is given by F YA f ln A f

Where Y is average true stress of the material in die gap

The drawing force increases with increasing friction.
2. The Drawing force which includes frictional force is
Ao 2

F Y avg A f 1 Ln( )
Af
3

Where is die angle in radians

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Example :
Power required and die pressure in rod drawing
A round rod of annealed 302 stainless steel is being drawn from a diameter of
10 mm to 8 mm at a speed of 0.5 m/s. Assume that the frictional and redundant
work together constitute 40% of the ideal work of deformation. (a) Calculate the
power required in this operation, and (b) calculate the die pressure at the exit of
the die.

Solution
2

10
True strain is 1 ln 0.446
2
8

With K=1300 MPa and n=0.30 (For SS 302):

K1n
Y
785 MPa
n 1

a) Thus, F YAf lnA0 / Af 0.0175 MN and Power FV f 0.01750.5 8.75 kW

Actual power will be 40% higher Actual 1.48.75 12.25 kW
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Power required and die pressure in rod drawing

Solution
Flow stress of the material,
Y f K1n 13000.446

0.30

Drawing stress,
d

1020 MPa

F 1.40.0175

490 MPa
Af
0.00005

b) Thus for die pressure,

p Y f d 1020 490 530 MPa

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Mechanics of rod and wire drawing

Optimum die angle
Optimum die angle depends on ideal, friction, and
redundant work.
Maximum reduction per pass
As reduction increases, the drawing stress increases. The
max. reduction per pass (without friction)
Max reduction per pass

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A0 A f
A0

1
0.63 63%
e

Defects in drawing
Major defects: Center cracking

Tendency for center cracking increases with:

1. Increasing die angle
2. Decreasing reduction per pass
3. Friction
4. Presence of inclusions in the material.

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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, wire, and tubes

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Multistage Wire-drawing Machine

A multistage wire-drawing machine that typically is used in the making of

copper wire for electrical wiring. Source: After H. Auerswald
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