Sheet-Metal Forming ProcessesExtrusion and Drawing of MetalsDefinitionsExtruded itemsDrawing ProductsTypes of Extruding ProcessPropertiesFurnaceMetalsTypical Horizontal Hydraulic Extrusion PressSlide 11Die Slide, Tooling AssemblyProfileDiesDies ContinuedSlide 16Extrusion PrinciplesBenifitsCharacteristics of Sheet-Metal Forming ProcessesShearingPowerPoint PresentationMiscellaneous cutting methodsSlide 23Characteristics of MetalsSlide 25Examples of sheet metal partsBendingBending MechanismSpring-backPress Brake FormingFour- Slide MachineRoll Bending/ FormingTube Bending and FormingSlide 34Stretch FormingRubber Forming?Additional OperationsDeep DrawingSlide 39Slide 40Spinning and FormingWhat is Spinning?AdvantagesTypesConventional SpinningConventional- MandrelConventional- ToolsSheer SpinningSlide 49Slide 50Slide 51TubeFormingSuperplasticSlide 55DisadvantagesDiffusion Bonding/SuperplasticSlide 58Diffusion BondingExplosiveSlide 61Magnetic-PulseSlide 63Peen FormingSlide 65Slide 66Laser FormingSlide 68During PassAfter PassResultMicroformingElectrohydraulicSlide 74Sheet Metal Forming TechniquesCost Optimization With BlankingProducing Better BlanksStamping, Drawing, PressingDesign to Increase Bend PrecisionExamples of Metal Failures in FormingEquipment for Sheet Metal FormingFactors for Press SelectionMore Factors for Press SelectionExample of Blanking MachineOther Examples of Metal forming machineryEconomics of Sheet-Forming OperationsEquipment CostsConclusionWorks citedWorks cited continuedSheet-Metal Forming ProcessesGroup 9 PresentationScott Currie Jared AdamsTaylor GrishamYien- Sheng AoJoe ButnerExtrusion and Drawing of MetalsDefinitionsExtrusion is defined as the process of shaping material, such as aluminum, by forcing it to flow through a shaped opening in a die. Extruded material emerges as an elongated piece with the same profile as the die opening.  Drawing is defined as the process of shaping material, such as aluminum, by pulling the material through a shaped opening in a die (draw die). This process of drawing is not to be confused with the drawing process related to the forming of sheet metalsExtruded itemsRailings for sliding doorsWindow framesTubing having various cross-sectionsAluminum laddersNumerous structural and architectural shapesDrawing ProductsRods and wires:Including : Rods for shaftsMachine and structural componentsElectrical wiringCablesTension-loaded structural membersWelding electrodesSpringsPaper clipsSpokes for bicycle wheelsStringed musical instrumentsDirect (forward) extrusionIndirect (reverse, inverted, or backwards) extrusionHydrostatic extrusionDirect Extrusion Operation Types of Extruding ProcessProperties Extrusion process actually increases the properties of metals, because it allows the creation of a final end product that is stronger and more resilient than components that must be assembled. It allows for the fabrication of products to various specifications and sizes, while being flexible enough to allow for design alterations.Log tableFurnaceThe extrusion process starts with the furnace, where aluminum billets are heated to the necessary point of malleability. The aluminum or aluminum alloy is heated to temperatures ranging 750 to 900 degrees Fahrenheit, at which temperatures it acts as a malleable solid.MetalsCommon metals used in extraction process:AluminumCopperSteelsStainless steelsMagnesiumLeadOther metal alloys can be extruded with various levels of difficultyTypical Horizontal Hydraulic Extrusion PressTypical Horizontal Hydraulic Extrusion PressAt this point, aluminum is a soft solid that can be pressed through dies, using scaleable amounts of pressure - a process called extrusion.An extrusion press utilizes a hydraulic ram that applies between 100 to 15,000 tons or more of pressure. The extrusion press container chamber, which holds the billet, is made of steel.Die Slide, Tooling AssemblyPhotos showing a new length of extrudate, just emerging from the press (left) and the production of a profile in progress (right).ProfileThe aperture in the die represents the final product. The aluminum is pressed through the chamber and through the die to create the final, shaped profile.DiesA solid die, as shown here, produces shapes without any enclosed voids and/or semihollow conditionsThis process allows designers and engineers freedom to create products in complex and intricate shapes, since the end product can be extruded as a final piece instead of requiring multiple ones that must be assembled.Dies ContinuedThe extrusion process also creates a natural finish - a thin layer of aluminum oxide - that forms on the surface of the metal as a result of the process. This naturally resilient and attractive finish can be improved with additional beautifying and weather-resistant finishes.•A semihollow die also produces shapes without enclosed voids; however, unlike a solid die, it produces shapes with a tongue ratio of 3:1 or greater.Dies ContinuedComplex shapes may emerge from the extrusion press as slowly as one foot per minute. Simpler shapes can emerge as quickly as 200 feet per minute.•A hollow die produces shapes with one or more enclosed voids. The die shown here, when used together with a mandrel and other support tooling, produces a profile with six voids.Flow through a dieExtrusion PrinciplesThe force required for extrusion depends on:The strength of the billet materialThe extrusion ratio Ao/Af Friction between the billet and the chamber and die surfaceThe geometric variables in extrusion are:The die angleThe ratio of the cross-sectional area of the billet to that of the extruded product, Ao/Af The temperature of the billetThe speed at which the ram travelsThe type of lubricationBenifitsA benefit to extrusions and Drawing process would be that large deformations can take place without fracture, because the material is under high triaxial compression during the process.Since the die geometry remains constant throughout the process extruded products have a constant cross-sectionCharacteristics of Sheet-Metal Forming ProcessesDrawing - shallow or deep parts with relatively simply shapes.Explosive – Large sheets with relatively simple shapes.Magnetic Pulse – Shallow forming, bulging, and embossing operations on relatively low-strength sheetsPeen – Shallow contours