Extrusion Process: Definition, Working,

Types, Applications

Introduction
Mechanical engineers often rely on the Extrusion Process to shape objects with a consistent cross-
sectional area. This method involves pushing raw materials through a die to achieve the desired shape.
Notably, extrusion is particularly effective in transforming brittle materials into desired products, and
it can be utilized as a semi-continuous or continuous process for shaping both hot and cold materials.

What is Extrusion?
Extrusion is a metal-forming operation. In this operation, dies are used to change the shape of the
metal piece. External force is used to do this which is compressive in nature. Any type of complex
shape can be made quite easily through this operation.

Working Principle of Extrusion

The required amount of force in the case of the extrusion process is given by a plunger or piston to
produce the compressive force. The following is the working principle of the extrusion process:

At first, an ingot or a billet of a standard size is developed by the manufacturer.

Then the billet is heated at a higher temperature and it is stored for a long time at room
temperature to push it in the press.
The billet is pushed by the plunger mounted in the press towards the die by providing
compressive force.
High compressive force helps the material to achieve the desired form.
Lastly, the material is taken out from the press and after that, it needs to be passed through the
finishing process in order to enhance its mechanical properties.

Types of Extrusion
Extrusion can be broadly classified into two types:

Hot Extrusion
Cold Extrusion.

They are further categorized into the following categories:

Hot Extrusion

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 Forward Extrusion
Backward Extrusion

Cold Extrusion

Forward Extrusion
Hydrostatic Extrusion
Hooker Extrusion
Backward Extrusion Impact
Extrusion
Cold Extrusion Forging

Hot Extrusion

In Hot Extrusion, the workpiece or billet is heated above its recrystallization temperature. A ram
applies force to the filled container, allowing the heated workpiece to flow easily through the die and
be precisely reshaped. This process commonly utilizes materials such as Magnesium, Copper, Steel,
Aluminum, and Nickel.

Cold Extrusion

In this process, the workpiece is kept at the normal room temperature, or you can say below the
recrystallization temperature. To extrude any product through this process huge amount of force is required.

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Indirect Extrusion

In this process, the direction of the force applied by the ram and the direction of extruded metal is on
opposite side. This type of extrusion is also called as backward extrusion. The main advantage of this
mode of extrusion is that it reduces friction comparatively. Also by this process, we can extrude metal
of relatively less diameter.

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Direct extrusion

In this type of extrusion process, the direction of the ram and the direction of extruded metal are in
the same direction. This mode of extrusion is also called forward extrusion. The main advantage of
this process is that by using this type of process we can extrude longer
workpieces.

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Hydrostatic extrusion

In this type of extrusion, we use fluid to pressurize the billet. At first, a billet is loaded into the
container. We then need to fill the container with fluid generally castor oil. The container is then
closed except for one side of the container, which contains a ram and a piston. To keep the operation
smooth the shape of the billet is maintained conical so that it can easily pass through the die.

When we start the machine, the ram exerts a high amount of pressure on the fluid which is then
transferred to the billet. Due to high pressure fluid, plastic deformation takes place
inside the billet. It comes out from the other side of the die and gets the shape of the die. The main
advantage of this process is that a very less amount of friction force comes into action as there is no
contact between the container wall and the billet. Hydrostatic extrusion is usually performed at room
temperature.

Hooker Extrusion

This is quite a popular extrusion process, by which thin-walled seamless copper or aluminum tubes
are produced. At first, the billet or the blank is placed in the container. A punch exerts a force on the
workpiece and makes the workpiece into a cup shape. In the next step, the
longer length will punch again and make it a long cylinder-shaped product, and the
thickness, as usual, reduces as well.

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Impact Extrusion

In an Impact Extrusion, a punch is struck to the workpiece at a very high speed to produce an impact
load. It can be of any type namely forward, backward, or even both. It is generally done at room
temperature i.e. Cold Extrusion. If we need products like a cup, toothpaste cover, or any hollow
section we generally do Backward impact extrusion which is quite a popular impact extrusion
process.

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Cold Extrusion Forging

Cold Extrusion Forging is a backward extrusion process. The process of Cold Extrusion forging is
the same as that of Impact Extrusion. In this process, the movement of the punch or ram is a little bit
slower as compared to Impact Extrusion.

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Applications of Extrusion Process
The extrusion process is mainly used in the formation of hollow pipes and it can also be used in
the production industry. Apart from that, for making instant foods and snacks type products,
extrusion process is preferred by manufacturers. In the case of food processing, extrusion
process is used to heat the product and develop a liquid stage of the product. Also, in cooking,
the extrusion process is used nowadays which includes mixing, shearing, separation, cooling,
heating, etc. For removing the moisture from the products and also for encapsulating material,
the extrusion process is taken into account by the producers.
However, to develop ready-to-eat material cold extrusion process is used. As an example, pasta
is manufactured with the help of a cold extrusion process. These types of products are
incorporated with low moisture due to which the life cycle of products is increased and also it is
more convenient to serve the customers.
Pharmaceutical products are also developed with the help of the extrusion process.
Polymeric filters and nonporous goods are formed through the extrusion process. The making
process of drugs includes both hot as well as cold extrusion processes. To
increase the solubility of products and bioavailability, hot extrusion process is used. In this
process, a high amount of pressure, heat, and agitation is taken into account by manufacturers.

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 Apart from this, in structural work, the aluminum extrusion process is used. This process
includes doors, windows, etc. In an automotive industry, the extrusion process is also used to
form the desired type of material by using brittle materials.
Lastly, it can be said that the extrusion process is widely used to make plastic
materials.

Advantages of the Extrusion Process

Extrusion includes several advantages which are as follows:

 The extrusion process is widely used to create a complex profile of materials within the least
time as compared to other metal-forming processes.
 The extrusion process is very useful to work with brittle and ductile materials.
Mechanical properties which can be developed by the extrusion process are very precise
and enhances the life cycle of products.
 High production rates: Extrusion can produce large quantities of products at high speeds,
making it a cost-effective method for mass production.
 Consistent product quality: The extrusion process produces products with consistent
dimensions and high strength, which helps ensure quality and reduces the need for additional
inspection and testing.
 Versatility: Extrusion can be used to produce a wide range of products, including pipes, tubing,
sheets, and structural shapes, as well as food products, packaging materials, building products,
and automotive components.
 Flexibility: Extrusion can be customized for specific applications by adjusting the shape and
size of the die, the temperature, and the speed of the process.
 Energy efficiency: The extrusion process can be energy-efficient, especially when using
modern equipment, as the material is heated only once in the process and the energy used can
be recovered and reused.

Disadvantages of the Extrusion Process

Some disadvantages of extrusion processes are listed below:

The time consumption of this process is very high. The

set-up is costly.
The extrusion process demands a significant amount of compressive force,
necessitating careful fixation of the plunger in the press by the operator.

Conclusion:

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We can conclude by saying that it is a widely used manufacturing process. It is highly consistent and
has higher accuracy. The extrusion process is likely to continue to develop and used widely in the
future too.

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