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The minimum amount of radius required to avoid any defect and problems depends on the extrudability of the material, as the material is more extrudable it can flow in corners with less radius. For example, for
Aluminium, Magnesium and Copper alloys the minimum radius required for corners and edges is
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For an extruded part a material should be selected from the top side of the series given above i.e. from
Aluminium and Magnesium side but without changing the functionality because high extrudability properties also mean less strength. So as explained above, considering this guideline while designing
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For best dimensional control (when component requirements are exacting), a secondary drawing operation is added after the extrusion of most metals. Although such an operation is entirely feasible, it does entail additional tooling, handling, and cost. Therefore, the designer should specify liberal
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Manufacturing of a complex cross-section is difficult and expensive, it involves tooling cost as a die of that cross section has to be manufactured. There are some standard shapes available from extrusion shops and metal supplier, a designer can choose any of these shapes if it serves his purpose.
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Although extrusion can produce very intricate shaped profiles but it is beneficial to limit irregularities of shape as much as the function of the part permits. This is because metal flows less readily into narrow and intricate sections that leads to defects in parts. Besides, these the irregular
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This point generally applies when the quantity of parts required is small. So generally when you put an order for extruded parts there is customarily a minimum weight for each order of a special cross section. For example, the minimum quantity may be 1000 kg for carbon steel, 500 kg for
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Symmetrical cross sections are always preferred to nonsymmetrical cross sections because it contains unbalances stresses which lead to warpage in the part and causes damage to the tools. Sometimes if a part cannot be converted into symmetric shape then two of them are clubbed together to form a
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In steel extrusions, the depth of an indentation should be no greater than its width at its narrowest point. This is necessary to provide sufficient strength in the tongue portion of the extruding die. In copper alloys, magnesium, and aluminum, the depth of an indentation may be greater since
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Having a radius at edges and corners advantageous because metals does not flows easily into the corners, so keeping round corners and edges eliminates any type of defect that may arise due to sharp corners and edges. These are the common problems faced while extruding a sharp corner:;
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friendly, in simple terms design that can be manufactured easily and cheaply. DFM guidelines define a set of rules for a person designing a product to ease the manufacturing process, reduce cost and time. For example, if a hole is to be
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process to form parts with constant cross-section along its length. This process uses a metal billet or ingot which is inserted in a chamber. One side of this contains a die to produce the desired cross section and the other side a
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It is often acceptable to have a different range of thicknesses however, a profile with uniform metal thickness is easy to extrude. In many cases, uniform metal thickness reduces the die stresses and improves
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Extrusion profiles with holes are very difficult to produce because they can not be just produced by a simple die, so it should be practiced to reduce the number of holes as much as possible.
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In hollow sections the section walls should be as balanced as much as the design function permits because die strain and extrusion distortion tend to occur with unbalanced cross sections.
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All the transitions in cross section should be as smooth as possible because sudden changes in cross sections are difficult to produce because metal does not readily flow there.
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With steels and other less extrudable materials, holes in nonsymmetrical shapes should be avoided because they lead to unsymmetrical stresses which cause warpage in the part.
335:, if the designer specifies a standard hole size then it reduces the cost because the drill bits of unusual sizes are not readily available they have to be custom made.
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stainless, and 80 kg for aluminum. The net result is that the most economical operation takes place at moderately low production quantities or higher.
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James Bralla (1999) 'CHAPTER 3.1 METAL EXTRUSIONS', in (ed.) Design for
Manufacturability Handbook. : McGraw Hill Professional, pp. 3.3-3.14.
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ram is present to push the metal billet or ingot. Metal flows around the profile of the die and after solidification takes the desired shape.
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Nowadays, quite a wide variety of metals are currently extruded commercially, the most common are (in order of decreasing extrudability):
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Less smooth flow of material through the die, leading to increased dimensional variations and surface irregularities in the extruded part
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George E. Dieter, Howard A. Kuhn, S. Lee
Semiatin (2003) 'Extrusion', in (ed.) Handbook of Workability and Process Design, pp. 291-292.
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If long, thin sections have a critical flatness requirement, variations from flatness are reduced if ribs are added to the section.
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The corners should be made in round shape instead of flat because it strengthens tongue and facilitates easy flow of metals.
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Extrusion process can be done with the material hot or cold, but most of the metals are heated before the process, if high
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This saves the tooling cost associated with manufacturing a complex die for the profile and simplifies the manufacturing.
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0.75 mm whereas for ferrous metals for corners 1.5 mm and for edges 3 mm minimum radius is required.
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sections lead to unbalanced stresses in dies and on the part too which cause distortion and other quality problems.
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that states a
Knowledge editor's personal feelings or presents an original argument about a topic.
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Comparison of
Maximum Indentation Depth possible for Steel, Copper, Aluminium and Magnesium Alloy
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leads to ease in the manufacturing process of the parts which in turn leads to cost savings.
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enough tolerances, if possible, so that secondary drawing operations are not required.
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Good And Bad
Practices while designing the cross section in Extrusion Process
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Less strength in the extruded part owing to stress concentrations
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Increased tool wear and increased possibility of tool breakage
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symmetric shape and they are cut off in two after extrusion.
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personal reflection, personal essay, or argumentative essay
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396:Common Commercially Available extrusion profiles
208:"DFM Guidelines for Hot Metal Extrusion Process"
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319:are required then the material is not heated.
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293:Schematic Diagram of Metal Extrusion Process
50:Learn how and when to remove these messages
355:and Copper alloys, low-carbon and medium-
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