Mathematical Analysis of Extrusion

Mathematical Analysis of extrusion
Let us use Figure 7.1 as a reference in discussing some of the parameters in extrusion. The
diagram assumes that both billet and extrudate are round in cross section. One important
parameter is the extrusion ratio, also called the reduction ratio. The ratio is defined:
𝐴°
𝑟𝑥 = 7-1
𝐴𝑓
Where rx= extrusion ratio; Ao= cross-sectional area of the starting billet, mm2 (in2); and Af =
final cross-sectional area of the extruded section, mm2 (in2). The ratio applies for both direct
and indirect extrusion the value of rx can be used to determine true strain in extrusion, given
that ideal deformation occurs with no friction and no redundant work:
𝐴°
𝜖 = ln 𝑟𝑥 = ln 7-2
𝐴𝑓
Under the assumption of ideal deformation (no friction and no redundant work), the pressure
applied by the ram to compress the billet through the die opening depicted in our figure can be
computed as follows:
𝑝 = 𝑌ത𝑓 ln 𝑟𝑥 7-3
Where 𝑌ഥ = average flow stress during deformation, MPa (lb/in2)
𝑓
Figure (7.1) Pressure and other variables in direct extrusion.
Friction exists between the die and the work as the billet squeezes down and
passes through the die opening. In direct extrusion, friction also exists between the
container wall and the billet surface. The following empirical equation proposed
by Johnson for estimating extrusion strain (in friction condition):
𝜖𝑥 = 𝑎 + 𝑏 ln 𝑟𝑥 7-4
Where εx = extrusion strain; and a and b are empirical constants for a given die
angle. Typical values of these constants are: a = 0.8 and b = 1.2 to 1.5. Values of a
and b tend to increase with increasing die angle.
Indirect extrusion the ram pressure to perform can be estimated based on

Johnson’s extrusion strain formula as follows:
𝑝 = 𝑌ത𝑓 𝜖𝑥 7-5
Where 𝑌ത𝑓 is calculated based on ideal strain from Eq. (7-2), rather than extrusion strain in
Eq. (7-4).
In direct extrusion, the effect of friction between the container walls and the billet causes
the ram pressure to be greater than for indirect extrusion, the following formula can be used
to compute ram pressure in direct extrusion:
2𝐿
𝑝 = 𝑌ത𝑓 𝜖𝑥 + 7 -6
𝐷°
Where the term 2L/Do accounts for the additional pressure due to friction at the
container– billet interface. L is the portion of the billet length remaining to be
extruded, and Do is the original diameter of the billet. Note that p is reduced as
the remaining billet length decreases during the process. Ram force in indirect or
direct extrusion is simply pressure p from Eqs. (7-5) or (7-6), respectively,
multiplied by billet area Ao :
𝐹 = 𝑝𝐴° 7.7
Where F = ram force in extrusion, N (lb).
Example: A billet 75mmlong and 25mmin diameter is to be extruded in a direct
extrusion operation with extrusion ratio rx = 4.0. The extrudate has a round
cross section. The die angle (half angle) = 90◦ The work metal has a strength
coefficient = 415 MPa, and strain-hardening exponent = 0.18. Use the Johnson
formula with a = 0.8 and b = 1.5 to estimate extrusion strain. Determine the
pressure applied to the end of the billet as the ram moves forward.
Sol.:Let us examine the ram pressure at billet lengths of L= 75mm (starting

value),L= 50 mm, L= 25 mm, and L= 0.We compute the ideal true strain,
extrusion strain usingJohnson’s formula and average flow stress:
L=75mm,With a die angle of 90◦, the billet metal is assumed to be forced

through the die opening almost immediately; thus, our calculation assumes that
maximum pressure is reached at the billet length of 75mm. For die angles less
than 90◦, the pressure would build to a maximum as the starting billet is
squeezed into the cone-shaped portion of the extrusion die.
L=0, Zero length is a hypothetical value in direct extrusion. In reality, it
is impossible to squeeze all of the metal through the die opening.
Instead, a portion of the billet (the ‘‘butt’’) remains unextruded and
the pressure begins to increase rapidly as L approaches zero.

Mathematical Analysis of Extrusion

Uploaded by

Copyright:

Available Formats

Mathematical Analysis of Extrusion

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Mathematical Analysis of Extrusion

Uploaded by

Copyright:

Available Formats

Mathematical Analysis of extrusion

Indirect extrusion the ram pressure to perform can be estimated based on

Sol.:Let us examine the ram pressure at billet lengths of L= 75mm (starting

L=75mm,With a die angle of 90◦, the billet metal is assumed to be forced

You might also like