AA Seminor Under Special Study
ON“ Analysis of Hot Isothermal Copper Extrusion for Multi-
Channel” Submitted in partial fulfillment of the requirement for the award of degree of
MASTER OF TECHNOLOGYIN
Mechanical Engineering Department(Production & Industrial Engineering)
BY Brijesh Kumar Patel
(14MTMEPIE011)Submitted to
Er. Raul Davis
SHEPHEARD SCHOOLOF ENGINEERING AND TECHNOLOGYSAM HIGGINBOTTOM INSTITUTE OF AGRICULTURE,
TECHNOLOGY AND SCIENCESDeemed-to-be-University
(FORMERLY ALLAHABAD AGRICULTURAL INSTITUTE)NAINI, ALLAHABAD-211007
Extrusion ProcessA compression forming process in which the work metal is forced to flow through a die opening to produce a desired cross-sectional shape.
Example of Extrusion Parts
Railings for Sliding Doors
Window Frames
Aluminum Ladders
Extrusions can be cut into desired
lengths, allowing for discreet parts such to
be produced as Gears, and Brackets
Multi Channel ProfileResearch focused on extrusion of two multi-
channel tube profile of different ratio. One tube is 11- channel profile and the other a 2- channel design.
Fig 1. 2- Channel profile Fig2. 11 – Channel Profile
By these process 2-channel and multi channel product are produced which are shown in fig. The temperature are required for the copper extrusion is 750 oC to 900 oC.
Fig (1) 2- channel Product Fig (2)11- channel Product
Extrusion ProcessHot extrusion :
Keeping the processing temperature to above the re-crystalline temperature. Reducing the ram force, increasing the ram speed, and reduction of grain flow characteristics. Controlling the cooling is a problem. Glass may be used as a lubricant.
Cold extrusion :Often used to produce discrete parts. Increase strength due to strain hardening, close tolerances, improved surface finish, absence of oxide layer and high production rates.
Types of Extrusion1.Direct Extrusion
The ram forces the work billet metal to move forward to pass through the die opening.
Friction increases the extrusion force.
Types of ExtrusionIndirect Extrusion:Metal is forced to flow through the die in an opposite direction to the ram’s motion.
Lower extrusion force as the work billet metal is not moving relative to the container wall.
Hydrostatic ExtrusionThe chamber, which is larger than the billet, is
filled with a fluid. The fluid is compressed with the ram and pushes the billet forward.
Benefit: no friction to overcome along sides of chamber.
Die DesignMain types of die designs:
1) Square dies: Used in extruding nonferrous metals- Develops dead metal zones that form the
dies angle2) Solid or Hollow Dies: Used in extruding tubing
products- The ram is fitted with a mandrel that pierces a hole in the billet-Wall thickness is limited to 1 mm for aluminum. 3mm for stainless steels, 5mm to stainless steels
Die MaterialsHot Worked dies Steels
are used for hot extrusion
Coatings such as zirconia used to extend die life• Not suitable for dies
used for complex shapes because of the sever stress gradients that develop in the die.
Lubricants Lubrication Is important in hot extrusions
because of major effects on:a) Material flowb) Surface finish on extrusionc) Product qualityd) Extrusion forces
Metal flow
- A common technique in investigating a flow is to section the round billet in half
- Dead-Metal Zone – The corner of the material stays stationary. Bright finishes result due to material flowing past the die angle
- Fig a – flow patterns attained with low friction- Fig b – flow patterns attained with high friction- Fig c – flow pattern attained with high friction or cooling of the
billets outer regions in the chamber
Extrusion Defects
a) Centre-burst: internal crack due to excessive tensile stress at the centre possibly because of high die angle, low extrusion ratio.
b) Piping: sink hole at the end of billet under direct extrusion.
c) Surface cracking: High part temperature due to low extrusion speed and high strain rates.
Extrusion Analysis
Extrusion ratio =
MaterialsCommon metals used in extraction
process:AluminumCopperSteelsStainless steelsMagnesiumLead
Advantage of Cold & Hot ExtrusionCold Extrusion:
Better mechanical properties due to work-hardening.
Good dimensional tolerances & surface finish.No need to heat billet.Competitive production rates & costs.
Hot Extrusion:Larger variety of materials.Less forces required.Better material flow.
Referances [1] Bauser, M., Sauer, G., and Siegert, K. (2006). Extrusion. Materials Park, OH: ASM
International. pp. 203-241, pp. 544-545. [2] International Copper Association. (2012). Semi-finished antimicrobial copper products.
Retrieved from http://www.antimicrobialcopper.com/uk/find-products-andpartners/ find-antimicrobial-copper-semi-finished-products.aspx
[3] (n.d.). Direct extrusion.[Web Drawing]. Retrieved from http://www.roymech.co.uk/Useful_Tables/Manufacturing/Extruding.html
[4] Kraft, F. (2011). “Extrusion of thin-wall multi-channel copper profiles”, presented at Materials Science & Technology 2011 Conference and Exhibition sponsored by ACERS,AIST, ASM, TMS and NACE.
[5] Kraft, F. (2011). Apparatus and Method for Extruding Micro-Channel Tubes, European Patent, number 2104577, August 3, 2011.
[6] Vaitkus, V. (2008). A process for the direct hot extrusion of hollow copper profiles. (Master's thesis, Ohio University). pp. 13-24, pp. 48-62.
[7] Kraft, F. (2012) Micro-Channel Tubes and Apparatus and Method for Forming Micro-Channel Tubes. U.S. Patent, number 8191393 B2, June 5, 2012.
[8] ATI All vac. “ATI 720 alloy".(n.d.). Retrieved from http://www.alleghenytechnologies.com/aerospace/docs/aerospacedatasheets/ATI7Nickel.pdf
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