Extrusion Parts
What is Extrusion Parts?
At its core, extrusion is a manufacturing process that involves shaping raw materials into a desired cross-sectional profile through a die. This technique extends to metals, ceramics, and food products, making it a ubiquitous method across various industries.
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Types of Extrusion Process
Metal extrusion can be subdivided and grouped into the following categories depending on the direction of extrusion flow, the medium used to apply force, working temperature, etc.
Direct Extrusion
Direct Extrusion, sometimes called Forward Extrusion is the most common type of extrusion. Begins by loading a heated billet (only for hot extrusion, discussed later) into a press cavity container where a dummy block is placed behind it.
Then the mechanical or hydraulic ram presses on the material to push it out through the die. Then, while still hot, the part is stretched to straighten.
Under direct extrusion, the high friction caused by steels at higher temperatures is reduced using molten glass as a lubricant while oils with graphite powder are used for lubrication for low temperatures. The dummy block is used to protect the tip of the pressing stem (punch or ram) in hot extrusion.
When the punch reaches the end of its stroke, a small portion of the billet called "butt end” cannot be pushed through the die opening.
Advantages Of Direct Metal Extrusion.
No billet modification required.
Can be used for both hot and cold extrusion.
Simple tooling compared to other extrusion processes.
Indirect Extrusion
In Indirect Extrusion, the die is located at the end of the hydraulic ram and moves towards the billet inside the cavity to push the material through the die. This is illustrated in figure 2 below.
This process consumes less power due to the static billet container causing less friction on the billet. However, supporting the extruded part is difficult when the extrudate exits the die.
Advantages Of In-Direct Metal Extrusion.
Less friction and less power used.
Can be used for both hot and cold extrusion.
Simple tooling compared to other extrusion processes.
Hydrostatic Extrusion
In hydrostatic extrusion, the chamber/ cavity is made smaller than the billet and filled with hydraulic fluid which transfers the force from the ram to the billet. Although tri-axial forces are applied by the fluid, the pressure improves billet formability on the billet. Sealing the fluid must be considered at the early stages to avoid any leaking and reduced pressure issues.
Although the hydraulic fluid eliminates the friction between the wall and the billet by isolating them, due to the specialized equipment requirement, the high setup time and low production rate limit its usage in the industry in comparison to other extrusion processes.
Advantages Of Hydrostatic Metal Extrusion.
Low power/force requirement due to no friction.
Fast production rates & high reduction ratios.
Lower billet temperature.
Even flow of material due to the balanced force distribution.
Large billets and large cross-sections can be extruded.
No billet residue is left in the container.
Lateral Extrusion
In Lateral Extrusion, the container is in a vertical position as shown in the image, and the die is located on the side. This process is suitable for low melting point material.
Impact Extrusion
Impact extrusion is part of the cold extrusion category very similar to In-direct extrusion and limited to softer metals such as Lead, Aluminum, and copper. The punch is pushed down at high speed and has extreme force on the slug to extrudes backward.
The thickness of the Extrude is a function of the clearance between the punch and the die cavity. The Extrudates are slide off the punch by the use of a stripper plate. For impact extrusions, a mechanical press is often used and the part is formed at a high speed and over a relatively short stroke.
Components of the Extrusion Process
Extrusion equipment typically comprises a few essential components:
Extruder
The heart of the extrusion process, the extruder is a machine that houses a screw or a ram to transport the raw material through the system. It applies heat and pressure to soften or melt the material for processing.
Die
The die is a precision tool that shapes the material as it passes through, giving it the desired profile. The die shape is designed based on the product specifications.
Cooling System
Following the shaping process, a cooling system helps solidify the material into its final form. This can involve water baths, air cooling, or other methods, depending on the material being extruded.
Aluminum extrusions come with an impressive combination of properties that make them ideal for a wide range of applications. We've created a list of popular examples from four of the biggest industry sectors to give you an idea of all the places you can already find aluminum extrusions.
Construction and architecture
The building and construction industry currently utilizes the largest share of extruded aluminum products, and for good reason. Architectural elements like large engineered skylights and canopies need strong, but lightweight structural members.
Roofing, fencing, and pretty much anything exposed to the outdoors needs to have excellent corrosion resistance, and may need additional finishing options like anodizing. And the assembly of prefabricated components on a work site needs to be fast, visually appealing, and sometimes even adjustable.
All of these needs in a variety of shapes can be met with well-designed aluminum extrusions at a reasonable cost. This is why aluminum extrusions are a great choice for creating stunning and durable structures in the construction and architecture sector.
Automotive and transportation
One of the biggest factors driving automotive makers towards aluminum products is reducing vehicle weights to help improve efficiency. Vehicle cross members, subframes, trim, and accessories can all be made efficiently from extruded aluminum to lower weight while maintaining strength. This is the same reason for choosing aluminum extrusions for a growing number of components on buses, utility trailers, off road vehicles, and even aircraft.
The corrosion resistance of aluminum is useful for improving the durability of any transport exposed to the outdoors but is especially useful in marine environments, including boats and docks. Aluminum extrusions can even be used to make lightweight battery boxes for electric vehicles (EVs) that help regulate battery temperature.
Electrical and electronics
Aside from beautiful finishes on consumer electronics and appliances, extruded aluminum can be easily formed to make electrical enclosures and cases. Its main value to the electrical and electronics sector though comes from its high thermal and electrical conductivity at a much lower cost and weight than copper. Aluminum extrusion is a popular method for making heat sinks that keep electronics from overheating, and aluminum wires are common for both high-voltage transmission lines and smaller-scale wiring.
Consumer products
While consumer products make up a smaller market than the other listed areas, aluminum extrusions are still a popular choice in this sector. Consumer products can cover a wide range of applications, so aluminum extrusions are typically chosen for their unique combination of properties while maintaining a low cost to produce. Camping chairs, baseball bats, golf clubs, bicycles, cookware, furniture pieces, beverage cans, and much more are commonly made from extruded aluminum.
A Stepwise Guide To the Aluminum Extrusion Process
Step 1: Prepare Extrusion Die
The first step is to make a round-shaped die or use an existing one if available. Preheat the die to precisely 450-500ᵒC before initiating the extrusion process. This helps to ensure that the metal passes through evenly and maximizes the die's longevity. You can load the die into the extrusion press after the preheating procedure.
Step 2: Pre-Heat Aluminum Billet
The next thing is to cut the cylindrical billet from a stretched log of material, then preheat the billet in an oven to 400-500ᵒC. This technique prepares the billet, making it malleable for the operation. It ensures that it is not molten.
Step 3: Move the Billet to the Extrusion Press
Transfer the billet into the press mechanically after preheating it. However, add lubricant to it before filling the billet into the press. In addition, ensure to put a release agent to the extrusion ram. Consequently, this helps to prevent the billet and ram from joining together.
At this point, the malleable billet is ready in the extrusion press. Here, the hydraulic ram can apply precisely 15,000 tons of pressure. This pressure forces the malleable billet into the container. The aluminum material stretches till it fills the container's walls.
Step 4: Press-up Extruded Material Against the Die
The aluminum material that fills the container's walls gets pressed against the extrusion die. You need to apply pressure to the material continuously. Hence, the extruded material emerges through the die opening fully formed.
Step 5: Quench the Extrusion
A puller grasps the extrusion, holding it in place after exiting the press. It safeguards the extrusion as it leaves the press while the alloy undergoes a "quenching” process as it moves along the table. The profile cools off evenly with a full water bath or fan.
Step 6: Shear the Extrusion to the Table Length
Once the aluminum extrusion makes the total table length, use a hot saw to shear it. However, note that temperature is essential at each step of the extrusion method. Despite the quenching process, the extrusion is not always fully cooled off yet.
Step 7: Cool Extrusion to Room Temperature
After completing the shearing process, move the extrusions to a cooling plain from the runout table. The profiles remain there till they achieve room temperature. As soon as they reach room temperature, stretching begins.
Step 8: Transfer Extrusions to the Stretcher and Stretch Them into Alignment
At this stage, you will discover certain twists in the shape of the extruded aluminum that need correcting. It would help if you had a stretcher to repair these twists. Hold each profile manually at different ends while pulling them till they are entirely straight. This procedure helps to adjust the extrusion to the desired specification.
Step 9: Transfer Extrusion to the Finish to the Finish Saw and Cut Them to Length
At this stage, when the extrusions are fully straightened and work hardened, you can now move them to the saw table. The next thing is for you to cut the extrusions into desired lengths. These lengths are usually between 8-21 feet. Move these extrusions to the oven for aging to the proper temper (T6 or T5) after completing the sawing process.
Step 10: Carry Out Secondary Operations (Heat Treatment, Fabrication, & Surface Finishing)
Upon completion of the extrusion process, you can enhance the properties of these profiles by treating them with heat. After the heat treatment, consider fabricating the extrusions if there are dimensions that need correction. In addition, adding surface finishes helps to enhance the aesthetic appearance and corrosion resistance properties of the extruded aluminum.
What is the Difference Between Extrusion and Stamping Process?
When it comes to manufacturing, many people get confused about the various methods used to create the products we use every day. Two of the most commonly utilized techniques for shaping metals are stamping and extrusion. Although both techniques have their similarities, there are also some major differences between the two. In this article, we'll explain what stamping and extrusion are, how they differ, and which one might be best for your specific manufacturing needs.
Stamping forming process that involves the use of dies to shape and cut metal into the desired shape. This technique can be used on various types of metals and alloys, including steel, aluminum, copper, and brass. The process involves the use of a press, which applies high amounts of pressure to the metal being worked on. The pressure is used to stamp the metal into the desired shape and size. Stamping can be used to create complex shapes and precise designs, making it a popular technique for many applications.
Extrusion is a manufacturing method that involves pushing heated materials through a die in order to produce a continuous length of the desired cross-sectional shape. This technique can be used on a variety of materials, including metals, plastics, and ceramics. Extrusion involves heating the material to a molten state and then forcing it through a die. The result is a product that has a uniform cross-section, making it an ideal method for creating tubes, pipes, and structural components.
Differences between Stamping and Extrusion
Although they have some similarities, stamping and extrusion are fundamentally different. Here are some of the key differences between the two techniques:
• Design Complexity: Stamping is great for creating detailed and intricate designs due to the precision and accuracy of the die. Extrusion, however, is better suited for designs that are relatively simple and uniform.
• Cost: Stamping is more expensive than extrusion due to the cost of creating and maintaining the die. It is only practical for small to medium-sized production runs. Extrusion is more affordable, making it the better choice for larger production runs.
• Material selection: Stamping is ideal for thicker materials, such as metals, whereas extrusion can be used for a broader range of materials, including plastics and rubbers.
• Production Volume: If you need to produce large quantities of parts or products, extrusion is the better option because it enables mass production. Stamping, however, is more suitable for small production runs.
In conclusion, the difference between stamping and extrusion boils down to the intricacy of the design, the material required, the cost and production volume. Both are extremely useful manufacturing techniques, but one may be better suited to your needs than the other, depending on the requirements of your project.
When to Choose Stamping
Stamping is a preferred option when it comes to creating smaller parts with intricate details. The technique is ideal for producing parts that require high precision since it can cut metals in exact shapes and sizes. This makes it perfect for items like latches, clips, and door handles.
When to Choose Extrusion
Extrusion is best used for creating products with a uniform cross-section, such as tubes and pipes. This technique is ideal for creating larger components that require strength and durability, such as building frames or automotive parts.Look for custom extrusion molding services to better complete your project.
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