Metal template powerpoint

METAL

Transcript: IAED 381 PRODUCT DETAILING SPRING SEMESTER 2011-2012 INSTRUCTOR SERPIL ALTAY METAL OUTLINE INTRODUCTION HISTORY THE EXTRUSION PROCESS HOT EXTRUSION COLD EXTRUSION WARM EXTRUSION EQUIPMENTS TYPES OF EXTRUSION DIRECT EXTRUSION INDIRECT EXTRUSION HYDROSTATIC EXTRUSION EXTRUSION DEFECTS THE DRAWING PROCESS DRAWING DEFECTS METAL DESIGN REFERENCES PREPARED BY: ZELAL AYTİN ECE YILDIRIM BERİL NAZ ZIRH EXTRUSION: Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section. TWO MAIN ADVANTAGES OF THIS PROCESS Ability to create very complex cross-sections Work materials that are brittle The material only encounters compressive and shear stresses. Forms finished parts with an excellent surface finish. Extrusion may be continuous (theoretically producing indefinitely long material) or semi-continuous (producing many pieces). The extrusion process can be done with the material hot or cold. In 1797, Joseph Bramah patented the first extrusion process for making lead pipe. It involved preheating the metal and then forcing it through a die via a hand driven plunger. The process wasn't developed until 1820 when Thomas Burr constructed the first hydraulic powered press. At this time the process was called squirting. In 1894, Alexander Dick expanded the extrusion process to copper and brass alloys THE EXTRUSION PROCESS By heating the stock material Loaded into the container in the press Dummy block is placed Presses on the material One of the main advantages of the extrusion process is that this ratio can be very large while still producing quality parts. HOT EXTRUSION Hot working process Done above the material's recrystallization temperature Keep the material from work hardening Make it easier to push the material through the die The extrusion process is generally economical when producing between several kilograms (pounds) and many tons, depending on the material being extruded. There is a crossover point where roll forming becomes more economical. The biggest disadvantage of this process is its cost for machinery and its upkeep. Lack of oxidation Higher strength due to cold working Closer tolerances Good surface finish Fast extrusion speeds if the material is subject to hot shortness It is usually used to achieve the proper balance of required forces, ductility and final extrusion properties 1.Movement of the extrusion with relation to the ram. If the die is held stationary and the ram moves towards it then its called "direct extrusion". If the ram is held stationary and the die moves towards the ram its called "indirect extrusion". 2.The position of the press, either vertical or horizontal. 3.The type of drive, either hydraulic or mechanical. 4.The type of load applied, either conventional (variable) or hydrostatic. It works by placing the billet in a heavy walled container. The billet is pushed through the die by a ram or screw. There is a reusable dummy block between the ram and the billet to keep them separated. The major disadvantage of this process is that the force required to extrude the billet is greater than that needed in the indirect extrusion process because of the frictional forces introduced by the need for the billet to travel the entire length of the container. The billet and container move together while the die is stationary. The die is held in place by a "stem" which has to be longer than the container length. The maximum length of the extrusion is ultimately dictated by the column strength of the stem. Advantages A 25 to 30% reduction of friction, which allows for extruding larger billets, increasing speed, and an increased ability to extrude smaller cross-sections There is less of a tendency for extrusions to crack because there is no heat formed from friction The container liner will last longer due to less wear The billet is used more uniformly so extrusion defects and coarse grained peripherals zones are less likely. Disadvantages Impurities and defects on the surface of the billet affect the surface of the extrusion. These defects ruin the piece if it needs to be anolized or the aesthetics are important. In order to get around this the billets may be wire brushed, machined or chemically cleaned before being used. This process isn't as versatile as direct extrusions because the cross-sectional area is limited by the maximum size of the stem. The billet is completely surrounded by a pressurized liquid, except where the billet contacts the die. The fluid can be pressurized two ways 1.Constant-rate extrusion: A ram or plunger is used to pressurize the fluid inside the container. 2.Constant-pressure extrusion: A pump is used, possibly with a pressure intensifier, to pressurize the fluid, which is then pumped to the container. Advantages No friction between the container and the billet reduces force requirements. This ultimately allows for faster speeds, higher reduction ratios, and lower billet temperatures.

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