F - Extrusion and Shearing

Question 1

A manufacturing method that is used to produce long lengths of stock material. It is mainly performed on non-ferrous materials.

Answer 1

EXTRUSION

Question 2

What material are the vast majority of EXTRUSIONS done on?

Answer 2

Aluminum Alloys

Question 3

A hydraulic ram pushes on the billet from the rear. Since the billet is constrained by an enclosing container (cylinder) its only exit is via a die at the front, which can be any shape.

Answer 3

DIRECT EXTRUSION

Question 4

Utilizes a container with a solid back end. The die is pushed back into the container by forces applied at the front.

Answer 4

INDIRECT EXTRUSION

Question 5

A solid circular bar stock of around 2 feet in length.

Answer 5

BILLET

Question 6

How are SOLID EXTRUSIONS of standard cross-sections usually created?

Answer 6

DIRECT EXTRUSION

Question 7

A solid extrusion, but hollow; more complex

Answer 7

HOLLOW EXTRUSION

Question 8

Another word for final shape

Answer 8

PROFILE

Question 9

A type of hollow extrusion with a round or square cross-section.

Answer 9

EXTRUDED TUBE STOCK

Question 10

A mandrel must be suspended in the die opening in order to extrude hollow parts. The shape and position of the mandrel will correspond to the hole running through the extruded part.

Answer 10

MANDREL

Question 11

Thin “webs” bridge the gap between the die walls and the mandrel.

Answer 11

SPIDER DIE

Question 12

They divide the main metal flow into separate streams through “porthole” openings in the die, before recombining them as they flow past the mandrel.

Answer 12

PORTHOLE DIE

Question 13

Extrusions made with multiple cells or holes.

Answer 13

MULTI-CELLED EXTRUSIONS

Question 14

A process that allows the extrusion of steel at temperatures above the recrystallization point. These temps are needed to convert from cast to wrought structure.

Answer 14

HOT EXTRUSION

Question 15

What are other EXTRUSION PROCESSES used to create discrete components instead of long-length products?

Answer 15

COLD EXTRUSION and IMPACT EXTRUSION

Question 16

A die is used to extrude the metal up the outside of a descending punch. it always stays constrained within the die.

Answer 16

COLD EXTRUSION

Question 17

A die is used to extrude the metal up the outside of a descending punch. the metal hugs the punch as it rises unrestrained above the confines of the die.

Answer 17

IMPACT EXTRUSION

Question 18

A process used to create very long lengths of product with a small diameter. The diameter of the wire rod is reduced through a series of dies.

Answer 18

WIRE DRAWING

Question 19

A process to cut large pieces of material into more manageable-sized pieces. Uses a fracturing approach where bending stresses are induced and raised to the point of metal failure.

Answer 19

SHEARING

Question 20

occurs at the upper edge as a result of plastic (permanent) deformation.

Answer 20

ROLLOVER/DROOP

Question 21

The ugliest portion of the cut. It has a rough crystalline appearance and dominates the sheared face.

Answer 21

SLIP PLANE

Question 22

is present at the lower edge which represents a hazard during handling since it can be jagged and sharp.

Answer 22

BURR

Question 23

A secondary process used to clean up the edge that has been sheared.

Answer 23

SHAVING

Question 24

A method of SHEARING that applies to cutting around an enclosed shape, such as a hole.

Answer 24

PUNCHING