Extrusion & Drawing: Presentation by

Extrusion & Drawing
Presentation by
Divya Joshi
Harshita Singh
Vaishnavi Maurya
Sourav Shakti
Aayush Kumar
Kamlesh Sahoo
01 Introduction
02 Extrusion
Overview 03 Drawing
04 Maximum Reduction
05 Conclusion
01 Extrusion
Extrusion is a manufacturing process in which an object is passed through a fixed
cross-sectional profile to give it a desired shape and cross section.
02 Classification of Extrusion Processes
03 In direct extrusion, the metal
billet is forced by the ram
In Indirect extrusion, the hollow
ram containing the die is forced
through the die through the metal billet
The direction of flow of material The direction of flow of material is
is same as that of the ram. opposite to that of the ram.
04 Hot Extrusion
• It is done at fairly high temperatures,
approximately 50 to 75% of
the melting point of the metal.
•Pressures Ranges: 35-700 Mpa.
Cold Extrusion
• Cold extrusion is the process done at room
temperature or slightly elevated temperatures.
• This process can be used for materials that
can withstand the stresses created by
extrusion.
05
ADVANTAGES OF LIMITATIONS OF
HOT EXTRUSION HOT EXTRUSION
•Complex solid or hollow • High equipment set up
shapes can be produced. and maintenance cost.
• Extrusion process for
• Small quantities can be
metals is at very high
economically produced.
temperatures.
• Process Wastage is
higher as compared to
rolling.
05 ADVANTAGES OF COLD DISADVANTAGES OF COLD
EXTRUSION EXTRUSION
• Improved Mechanical • Tooling cost is high.
properties. • Special coating is required to
• Improved surface finish. reduce friction and to maintain a
• No need for heating billet. lubricant film throughout.
• No oxidation takes place. • Limited deformation can be
obtained.
05 APPLICATIONS OF COLD EXTRUSION
• Cu, Pb, Sn, Al Alloys, Ti, Mo, V, Steel, Zr parts can be extruded.
•Aluminum Cans, Cylinders, Fire Extinguisher Cases, Tubes, Gear Blanks,
Shock Absorber Cylinders, and Automotive
Pistons are manufactured.
APPLICATIONS OF HOT EXTRUSION

Electrical wires, Bars, Tubes, Frames, Doors, Windows, Aluminum cans,
and Cylinders
05
05
06
Dies
Commonly used materials are Tool Steels and Carbides
Diamond dies are used for fine wire.
For improved wear resistance, steel dies may be chromium-plated, and carbide dies may be
coated with titanium nitride
For Hot drawing, cast-steel dies are used .
Dies are made from highly alloy tools steels or ceramics(Si3N4).
Heat treatments such as nitriding are required (several times)to increase hardness (65-70
HRC).This improves die life.
06
Lubrication
Proper lubrication is essential in extruding, in order to improve die life, reduce
drawing forces and temperature, and improve surface finish.
Types of Lubrication-
a)Wet extrusion : Dies and Rods are completely immersed in lubricant.
b)Dry extrusion : Surface of the rod to be drawn is coated with a lubricant.
c)Coating : Rod or Wire is coated with a soft metal that acts as a solid lubricant.
d)Ultrasonic Vibration : of the dies and mandrels.
07 Effect of extrusion on microstructure and mechanical
properties of metals
The extrusion process has the effect of grain size refinement and rendering
of plasticity and ductility to the material.
Extrusion temperature, type of alloy and the variables of extrusion

process(deformation, extrusion speed, extrusion ratio, type of die etc.),
together contribute to the mechanical properties like strength and ductility.
08
Optical microstructure of the Mg- Engineering stress-strain curves for

2.5Er-0.6Zr alloy (a) as-cast (b) 350 as-cast and extruded alloys
°C (c) 380 °C (d) 410 °C.
01 Extrusion and Drawing
Extrusion pushes material through a die to create shapes.
Drawing pulls material through a die to elongate and shape it.
02 Drawing
Drawing is an operation in which the cross-sectional area of a bar or tube is reduced
or changed in shape by pulling it through a converging die (dies are usually tapered).
02 Drawing
Why not simply stretch wire, rod or bar?

02 Types of Drawing
Rod Wire Tube

Drawing Drawing Drawing
03 Rod Drawing
Forming process in which the workpiece is drawn through a
tapered shape that reduces and changes the cross-sectional area.
03 Rod Drawing Products
03 Rod Drawing Process
Rods and tubes, which cannot

be coiled, are produced on
drawbenches.
Approach Angle
Half Die Angle
04 Wire Drawing
In a typical wire drawing
operation, once end of the wire is
reduced and passed through the
opening of the die, gripped and
pulled to reduce its diameter.
By successive drawing operation
through dies of reducing diameter
wires car be reduced to very small
diameters
04 Wire Drawing Products
05 Wire Drawing Process
Wire Rod Preparation

Lubrication
Drawing Process
Reduction in Diameter
Special Treatments
06 Major Processing Parameters
1. Draw dies
Draw dies have four main parts: entry, approach angle, bearing
surface, and back relief.
Entry: It's like a funnel for lubricant, preventing scoring of work and
die surfaces.
Approach angle: This is where the drawing process happens, with an
angle usually between 6º to 20º
Bearing surface: It determines the final size of the drawn stock.
Back relief: This is the exit zone of the drawing process.
2. Die Material
Die materials for drawing typically are tool Steels and carbides. For hot
drawing, cast-steel dies are used because of their high resistance to wear at
elevated temperatures.
High-carbon steels- Rod material for automatic processing, wire cables
Alloy steels-Industrial springs, welding wires
Cu and Cu alloys- Wires, wire meshes, screws, bolts and shaped parts, parts
for the electrical Industry
Al and Al alloys -Screws and bolts, shaped parts, electrical lines, etc
3. Forces and Energy

The forces and power in
wiredrawing could be analysed
by using simple tension,
deformation conditions in wire
are, in fact, far more complex
due to compressive and drag
forces generated by the die
surface.
4. Die Angle
Die angle is crucial for the success of any wiredrawing operation. Based on the
fact that frictional work increases with decreasing die angle and redundant work
increases with increasing die angle, an optimum approach angle should exist-
one which minimizes both frictional and redundant work and, as a consequence,
the drawing force
5. Temprature
Mostly it is a cold working extrusion process.
The final operation before drawing is drying above 100 degree Celsius.
Lubricant mostly used for control the temperature.
6. Lubrication Method
Wet drawing, in which the dies and the rod are immersed completely in the
Lubricant
Dry drawing, in which the surface of the rod to be drawn is coated with a
lubricant by passing it through a box filled with the lubricant
Metal coating, in which the rod or wire is coated with a soft metal, such as
copper or tin, that acts as a solid lubricant.
Mostly various kind of mineral and vegetable oils, animal fats, graphite, soap and
certain emulsions are applied as drawing lubricant
07 Tube Drawing
Tube drawing is very similar to bar

drawing, except the beginning stock is
a tube. It is used to decrease the
diameter, improve surface finish and
improve dimensional accuracy. A
mandrel may or may not be used
depending on the specific process
used.
07 Tube Drawing Products
07 Tube Drawing Processes
Tube drawing is akin to wire drawing but for producing tubes.
Utilizes drawbench and dies similar to wire drawing for reducing
tube diameter.
Involves inserting a mandrel inside the tube to support the inside
surface and control wall thickness and diameter accurately.
Mandrels can be stationary (attached to rods) or moving (pulled
through or pushed with a punch).
Stationary mandrels are positioned in the die's throat, ensuring
precise control during drawing.
Moving mandrels allow for different techniques, such as pulling
through a die with the tube or pushing a deep-drawn shell with a
punch.
Mandrels are crucial for maintaining consistent tube dimensions
and quality during the drawing process.
07 Tube Drawing Sinking
Tube sinking is a process used in tube
drawing where no mandrel is employed inside
the tube.
It can lead to variations in wall thickness, either
increasing or decreasing depending on
process conditions.
Typically used for small tubes due to
challenges in controlling wall thickness
without a mandrel.
Significant in plastic forming theory as it
represents the initial step in tube drawing
without a mandrel.
08 Max possible reduction in extrusion
The maximum possible reduction in extrusion is determined by the extrusion

ratio, which is the ratio of the billet's cross-sectional area to the extruded
product's cross-sectional area.
Extrusion ratio, R = Ao/Af
Ao = Cross-sectional area of billet

Af = Cross-sectional area of the final product
09 Max possible reduction in drawing process
In wire drawing, the maximum reduction per pass(R) is determined by the formula
where n represents the strain hardening coefficient.
For perfectly plastic material,

n = 0; the maximum reduction per pass is 63.2%.
However, for materials with higher strain hardening coefficients, the maximum reduction per pass
will be lower due to the increased resistance to deformation.
For instance, maximum reduction is not allowed to exceed 45% as it can cause lubricant breakdown
and surface-finish deterioration.
10 Factors affecting maximum reduction
Material Properties: The material's yield strength, ultimate strength, and elongation
characteristics
Ductility: Materials with higher ductility can withstand more significant deformation
before breaking.
Friction Coefficient b/w die and material: Proper lubrication is essential for reducing
friction between the material and the die.
Die Design: The die angle in extrusion and drawing processes plays a critical role. A
larger die angle can facilitate more significant reductions but must be optimized to
avoid defects like cracking and tearing.
Extrusion/Drawing Speed: Higher speeds may allow for increased reductions but
must be balanced with other process parameters to avoid material defects.
Thank You

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Extrusion & Drawing

APPLICATIONS OF HOT EXTRUSION

Extrusion temperature, type of alloy and the variables of extrusion

Optical microstructure of the Mg- Engineering stress-strain curves for

Why not simply stretch wire, rod or bar?

Rod Wire Tube

Rods and tubes, which cannot

Wire Rod Preparation

3. Forces and Energy

Tube drawing is very similar to bar

The maximum possible reduction in extrusion is determined by the extrusion

Extrusion ratio, R = Ao/Af

Ao = Cross-sectional area of billet

where n represents the strain hardening coefficient.

For perfectly plastic material,

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