Introduction to Extrusion Process
Definition
Extrusion is a manufacturing process in which a material (typically metal, plastic, or food) is
forced through a die to create a continuous shape with a uniform cross-section. This process
is widely used for producing pipes, tubes, sheets, and complex profiles in various industries.
Working Principle
The extrusion process involves:
1. Feeding the Raw Material – The material, in the form of granules, billets, or
powders, is loaded into the extruder.
2. Heating (if required) – In hot extrusion, the material is heated to reduce resistance
and enhance flow.
3. Applying Pressure – A mechanical or hydraulic press pushes the material through a
die.
4. Shaping – The material takes the shape of the die opening as it exits the extruder.
5. Cooling and Cutting – The extruded product is cooled (if necessary) and cut into
desired lengths.
Types of Extrusion
1. Based on Temperature:
o Hot Extrusion – Performed at high temperatures to reduce material
resistance. Used for metals like aluminum and copper.
o Cold Extrusion – Performed at room temperature to increase strength and
reduce oxidation. Common for steel and aluminum parts.
2. Based on Direction of Material Flow:
o Direct (Forward) Extrusion – The material is pushed in the same direction as
the applied force.
o Indirect (Backward) Extrusion – The die moves while the
material remains
o stationary, reducing friction.
3. Based on Material Type:
o Metal Extrusion – Used in the automotive and construction industries.
o Plastic Extrusion – Produces pipes, films, and sheets.
o Food Extrusion – Common in snack, pasta, and cereal production.
2. Comparison of Hot and Cold Extrusion
Parameter Hot Extrusion Cold Extrusion
Temperature High Room temperature
Material Flow Easier due to reduced More difficult but produces stronger
resistance parts
Surface Finish Rougher due to oxidation Better surface finish
Mechanical Lower strength Higher strength due to strain
Properties hardening
Applications Aluminium, copper tubes Automotive parts, gears
3. Materials Used in Extrusion
1. Metals – Aluminium, copper, steel, titanium.
2. Plastics – Polyethylene (PE), Polypropylene (PP), Polyvinyl chloride (PVC).
3. Composites – Fiber-reinforced materials for aerospace and automotive applications.
4. Food – Wheat flour, rice, soy, corn starch.
4. Machinery and Equipment for Extrusion
Key Components
1. Hopper – Feeds raw material into the extruder.
2. Screw (in plastic extrusion) – Pushes material forward while heating it.
3. Barrel – Houses the screw and provides heating.
4. Die – Shapes the extruded material.
5. Cooling System – Uses air or water to cool the product.
6. Cutting Mechanism – Cuts the extruded product into required lengths.
5. Process Parameters in Extrusion
Key Factors Affecting Quality
1. Temperature – Too high can degrade material; too low can cause poor flow.
2. Pressure – Determines material flow rate and product uniformity.
3. Screw Speed (in plastic extrusion) – Affects mixing and output rate.
4. Die Design – Determines final shape and surface quality.
6. Extrusion in the Automotive Industry
Used for engine components, structural parts, and trims.
Aluminium extrusions make vehicles lighter and more fuel-efficient.
Cold extrusion is used for gear blanks, shafts, and fasteners.
7. Extrusion in the Construction Industry
Aluminium window and door frames
Plastic pipes and conduits for electrical and plumbing applications
Metal beams and channels used in structural applications.
8. Extrusion in the Food Industry
Snack foods (chips, puffed cereals, pasta)
Pet food production
Meat alternatives like textured vegetable protein (TVP)
