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@Radu Rista -- A common method is to use a special die called a spider die. It uses a mandrel at the center to create the opening and arms that support the mandrel that the hot aluminum is forced over and then a collar that shapes the outer tube surface. Difficult to explain but there are lots of images on RUclips showing the process. I worked as an extrusion press operator for Harvey Aluminum to pay for college.
@wndyd95 The extrusion was done "hot" since it is well above the recrystallization temp for all aluminum alloys. The final drawing to straighten the long extruded pieces is done at room temp ("cold").
I have worked at one of these plants for 30 yrs.The ram or stem that you see is pushing the aluminum billet forward in to the container.The die is at the front of the container,The ram will push the aluminum thru the die at about 3500 lbs per square inch.The diameter of the billet vary's from 3.5 inches for very small parts up to 18 inches and length from 12" to 50". 18" diameter is about 1250cm,very big
The extruded bar at the end has a hole through the centre of it. How does the die produce that? The centre of the die would have supporting structures which should shear the aluminium in half. It the aluminium was molten I could see it reforming on the other side.
The dies have connectors in the middle. Kinda hard to explain in words here is a example. We run a die at my plant that is a square with a hollow hole in the middle of it. The back of the die were the billet pushes into it looks like a "X" with a circle in the middle of it. Useing a technique similar to that they can create metal we call hollows bc they have 1 or more open areas in the pieces.
Look up 'friction stir welding', where cold aluminum is literally swirled around by a hard peg that is spun, plunged into, and then dragged across between two aluminum plates. Aluminum, and in fact all metals, can be welded together with pressure and friction alone so long as the metal is fairly clean and the pressure is strong enough. Aluminum is simply the one common metal that is both weak and ductile enough that extruding it or friction stir welding it is feasible; I wouldn't want to stand anywhere near an extruder forcing white hot steel billets through a die. What would you even make it out of? Anyway, just google some images of aluminum extrusion dies and you'll see how they get those tubes to form.
Amazing that metals can be pushed through a die like they were cornmeal. Even with help from pre-heating, it still boggles the mind. The pressure must be tremendous. I wonder what the lifespan of a die like that could be.
Aluminum Extrusion Die are made of H13 Grade Steel, heat treated and nitride, the hardness reads 48 RC hardeness after is finish, the life of a extrusion die depends on the maintanace, type of die (it can be a solid die, hollow die, bridge die, etc,) and also the die has to be renitride after certain extruded lbs. to extend the die life. solid die use to have longer life but also depends on the shape of the extrusion die, hollow dies are usually more complicated to work and have a shorter life.
I think???? for hollow extrusions the blank already has a hole through which the inside shape is inserted,, thats the only way I can figure it out as they don't show it in any of the posts,
+Geoff Conroy I've been trying to get a clear explanation of how they extrude tubes for months, and it must be classified or a state secret or something. Like, what holds up the thing that pushes into the center of the rod to form the hole in the tube? All I can think is that Superman must position himself in front of the extrusion with the center-dye in his hand. From what I've seen there has to be a center mandril that goes right through the center of the solid rod then the big pusher forms the tube-wall around the mandrel, then the mandrel pulls out and, voila...sort of... I also saw one where they started with a squat-looking tube with a hole, then rolled it thinner and thinner. It's weird. It's as if they want to keep it a secret or something... I still don't get how it works...
the die has three different components, the mandrel, the cap and the backer, this three pieces are hold together with bolts. the dies has some ports to feed the aluminum and form the hollow part as well as the exterior part of the extrusion. look for aluminum extrusion hollow dies on you tube and probably you can understand or have a better idea how is made
There is a mandril or set of mandrils that are supported by the ram, and move independently of the ram. You know those toy clay extruders? They can extrude tubes of clay too, and they do it essentially the same way. imgur.com/a/LnTzpgk
it is beautiful to see it form like that with tremendous pressure,
how is the center hole made????
@Radu Rista -- A common method is to use a special die called a spider die. It uses a mandrel at the center to create the opening and arms that support the mandrel that the hot aluminum is forced over and then a collar that shapes the outer tube surface. Difficult to explain but there are lots of images on RUclips showing the process. I worked as an extrusion press operator for Harvey Aluminum to pay for college.
I think same as you! First i had many questions, but now, when i read all comments I learn a lot!!! :)
@wndyd95 The extrusion was done "hot" since it is well above the recrystallization temp for all aluminum alloys. The final drawing to straighten the long extruded pieces is done at room temp ("cold").
I have worked at one of these plants for 30 yrs.The ram or stem that you see is pushing the aluminum billet forward in to the container.The die is at the front of the container,The ram will push the aluminum thru the die at about 3500 lbs per square inch.The diameter of the billet vary's from 3.5 inches for very small parts up to 18 inches and length from 12" to 50". 18" diameter is about 1250cm,very big
Hey Gremlin G. I have some questions about this process and the business around it. Can we get in contact? Thanks! :)
There’s a company hiring in my area, what should I know before applying?
Ok now I know exactly what happens to the dies I build after we send them to our customers. Interesting!
good understanding about this process! Thanks
Very good and educational video!!! :D
The extruded bar at the end has a hole through the centre of it. How does the die produce that? The centre of the die would have supporting structures which should shear the aluminium in half. It the aluminium was molten I could see it reforming on the other side.
The dies have connectors in the middle. Kinda hard to explain in words here is a example. We run a die at my plant that is a square with a hollow hole in the middle of it. The back of the die were the billet pushes into it looks like a "X" with a circle in the middle of it. Useing a technique similar to that they can create metal we call hollows bc they have 1 or more open areas in the pieces.
QwertyTSecond they use more than one die
Debra Johnson they do not use 2 dies.
Look up 'friction stir welding', where cold aluminum is literally swirled around by a hard peg that is spun, plunged into, and then dragged across between two aluminum plates. Aluminum, and in fact all metals, can be welded together with pressure and friction alone so long as the metal is fairly clean and the pressure is strong enough. Aluminum is simply the one common metal that is both weak and ductile enough that extruding it or friction stir welding it is feasible; I wouldn't want to stand anywhere near an extruder forcing white hot steel billets through a die. What would you even make it out of?
Anyway, just google some images of aluminum extrusion dies and you'll see how they get those tubes to form.
Very good video and very good explanation. Thanks a lot.
How are made the holes in the profile? For example the hole in the last image?
Amazing that metals can be pushed through a die like they were cornmeal. Even with help from pre-heating, it still boggles the mind. The pressure must be tremendous. I wonder what the lifespan of a die like that could be.
My plant runs up to 3000 pound press
We have does that could last up too 100,000 kgs of aluminum
We have dies that are used regularly and are over 10yrs old. It's all about maintenance and care.
Aluminum Extrusion Die are made of H13 Grade Steel, heat treated and nitride, the hardness reads 48 RC hardeness after is finish, the life of a extrusion die depends on the maintanace, type of die (it can be a solid die, hollow die, bridge die, etc,) and also the die has to be renitride after certain extruded lbs. to extend the die life. solid die use to have longer life but also depends on the shape of the extrusion die, hollow dies are usually more complicated to work and have a shorter life.
aluminum is very malleable; think of forming aluminum foil.
great video, very educational
Cheers, this really helped with my homework!
@@cameronledoux95 extrusion of aluminium in engineering
Narrator sounds like Jamie Hyneman from Mythbusters
Thank you for this video, really i understood the processes how it be done.
very good video on extrusion. thank you
sir can i use this video for educational purpose on my youtube channel
I think???? for hollow extrusions the blank already has a hole through which the inside shape is inserted,, thats the only way I can figure it out as they don't show it in any of the posts,
Usually there is a fixed mandrill which shapes the inside hole. see this: ruclips.net/video/PT_mqlZwmXs/видео.html
+Geoff Conroy
I've been trying to get a clear explanation of how they extrude tubes for months, and it must be classified or a state secret or something. Like, what holds up the thing that pushes into the center of the rod to form the hole in the tube? All I can think is that Superman must position himself in front of the extrusion with the center-dye in his hand.
From what I've seen there has to be a center mandril that goes right through the center of the solid rod then the big pusher forms the tube-wall around the mandrel, then the mandrel pulls out and, voila...sort of... I also saw one where they started with a squat-looking tube with a hole, then rolled it thinner and thinner. It's weird. It's as if they want to keep it a secret or something... I still don't get how it works...
the die has three different components, the mandrel, the cap and the backer, this three pieces are hold together with bolts.
the dies has some ports to feed the aluminum and form the hollow part as well as the exterior part of the extrusion.
look for aluminum extrusion hollow dies on you tube and probably you can understand or have a better idea how is made
There is a mandril or set of mandrils that are supported by the ram, and move independently of the ram. You know those toy clay extruders? They can extrude tubes of clay too, and they do it essentially the same way. imgur.com/a/LnTzpgk
@@servandoaldaco4813 you mean the mandrel the cap and the feeder
good video on extrusion. good job!
Hope aluminum 3D printing soon
thank you for this video
how much would one of these machines cost? and where would they even purchase one of these machines
The press at my job cost roughly $500,000
900 °F = 482 °C
@eyescreamcake i was kinda wondering how this works 2
is this cold, hot or warm drawing?
The Wind Rises
900 Fahrehenheit = 480 Celsius. You're welcome :)
👍👍
*Aluminium
misumi
:D