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    Extrusion

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    Salim Chohan
    Extrusion is a process that forces metal or plastic through a shaped die opening, plastically deforming the material under compression. It can be done hot or cold depending on the material's ductility. While tooling costs are high, manufactured parts are inexpensive at scale. Common materials extruded include aluminum, copper, steel, and plastics, with aluminum and plastics most suitable. Parts made through extrusion can have complex features to reduce assembly costs. Cross sections and minimum wall thicknesses are dependent on the material and shape.

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    Extrusion

    Uploaded by

    Salim Chohan
    35 views11 pages
    Extrusion is a process that forces metal or plastic through a shaped die opening, plastically deforming the material under compression. It can be done hot or cold depending on the material's ductility. While tooling costs are high, manufactured parts are inexpensive at scale. Common materials extruded include aluminum, copper, steel, and plastics, with aluminum and plastics most suitable. Parts made through extrusion can have complex features to reduce assembly costs. Cross sections and minimum wall thicknesses are dependent on the material and shape.

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    Extrusion

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    Extrusion is a process that forces metal or plastic through a shaped die opening, plastically deforming the material under compression. It can be done hot or cold depending on the material's ductility. While tooling costs are high, manufactured parts are inexpensive at scale. Common materials extruded include aluminum, copper, steel, and plastics, with aluminum and plastics most suitable. Parts made through extrusion can have complex features to reduce assembly costs. Cross sections and minimum wall thicknesses are dependent on the material and shape.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    35 views11 pages

    Extrusion

    Uploaded by

    Salim Chohan
    Extrusion is a process that forces metal or plastic through a shaped die opening, plastically deforming the material under compression. It can be done hot or cold depending on the material's ductility. While tooling costs are high, manufactured parts are inexpensive at scale. Common materials extruded include aluminum, copper, steel, and plastics, with aluminum and plastics most suitable. Parts made through extrusion can have complex features to reduce assembly costs. Cross sections and minimum wall thicknesses are dependent on the material and shape.

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    Extrusion Process

    Extrusion Process
    Extrusion is a process that forces metal or plastic to flow through a
    shaped opening die. The material is plastically deformed under the
    compression in the die cavity. The process can be carried out hot
    or cold depending on the ductility of the material.

    The tooling cost and setup is expensive for the extrusion process,
    but the actual manufactured part cost is inexpensive when
    produced in significant quantities.
    Materials that can be extrudes are aluminum, copper, steel,
    magnesium, and plastics. Aluminum, copper and plastics are most
    suitable for extrusion.

    Aluminium is particularly good for


    manufacturing complex parts with
    multiple features, which can help
    reduce costs through easier assembly
    and a lower number of parts.

    An extruded aluminium sunroof channel

    Extruded aluminium roof rails.

    Side intrusion beams made from


    extruded aluminium

    Examples of parts made by extrusion

    The cross section of the extrusion can be tailored-made for a


    relatively small cost

    Examples of parts made by extrusion

    Extrusion - Design Consideration


    The minimum wall thickness which can
    be extruded for aluminum is dependent
    of the particular shape, and the smallest
    circumscribed circle as well as the alloy.

    Circumscribed
    circle

    Extrusion
    shape

    Circumscribing Circle Diameter


    (CCD): smallest diameter circle
    into which the extruded cross
    section will fit.

    Extrusion - Design Consideration

    Extrusion - Design Consideration


    Tolerances
    Standard industry tolerances usually provide adequate precision
    for most applications

    Angular tolerances will be 1 to 2 degrees

    Flatness tolerance across a profile is .004 per inch of width.

    Extrusions will be straight within 0.0125 inch per foot of length.

    The approximate twist tolerance will be .5 degrees per foot.

    General Design Recommendations


    Limit irregular shapes, sharp corners,
    and very thin sections.
    Avoid thin walls sections
    Commonly specified minimum wall
    thicknesses include:
    Aluminum 1 mm
    Carbon steels 3 mm
    Stainless Steel 5 mm

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