Table Of ContentHYDROSTATIC EXTRUSION
Theory and Applications
HYDROSTATIC EXTRUSION
Theory and Applications
Edited by
N. INOUE
Science University of Tokyo, Tokyo, Japan
and
M. NISHIHARA
Kobe Steel Ltd, Kobe, Japan
ELSEVIER APPLIED SCIENCE PUBLISHERS
LONDON and NEW YORK
ELSEVIER APPLIED SCIENCE PUBLISHERS LTD
Crown House, Linton Road, Barking, Essex IG11 8JU, England
Sale Distribution in the USA and Canada
ELSEVIER SCIENCE PUBLISHING CO., INC.
52 Vanderbilt Avenue, New York, NY 10017, USA
WITH 20 TABLES AND 266 ILLUSTRATIONS
©
ELSEVIER APPLIED SCIENCE PUBLISHERS LTD 1985
Softcover reprint ofthe hardcover 1st edition 1985
British Library Cataloguing in Publication Data
Hydrostatic extrusion: theory and applications.
1. Hydrostatic extrusion
I. Inoue, N. II. Nishihara, M.
621.8'9 TS255
Library of Congress Cataloging in Publication Data
Hydrostatic extrusion
1. Hydrostatic extrusion. I. Inoue, Nobuo,
1919- II. Nishihara, M. (Masao), 1920-
TS255.H94 1985 671.3'4 85-15884
ISBN-13: 978-94-010-8696-7 e-ISBN-13: 978-94-009-4954-6
001: 10.1007/978-94-009-4954-6
The selection and presentation of material and the opinions expressed in
this publication are the sole responsibility of the authors concerned.
All rights reserved. No part of this publication may be reproduced, stored
in a retrieval system, or transmitted in any form or by any means,
electronic, mechanical, photocopying, recording. or otherwise. without
the prior written permission of the publisher.
v
Preface
This book is intended to be a reference text on hydrostatic extru
sion, a multidisciplinary technology involving the forming process of
materials, tribology, high pressure engineering and so forth.
Until now only one book bearing the title of hydrostatic extrusion,
by Prof. Alexander and Dr. Lengyel, has been published since 1971.
Although there are chapters on hydrostatic extrusion in such books as
THE MECHANICAL BEHAVIOUR OF MATERIALS UNDER PRESSURE edited by Dr. Pugh,
METAL FORMING by Prof. Avitzur and HIGH PRESSURE TECHNOLOGY by Drs. Spain
and Paauwe, it is regrettable that no up~to-date reference books on hydro
static extrusion are available.
As is well known, hydrostatic extrusion is a nearly-ideal lubricated
extrusion. Its advantages have been demonstrated by laboratory research
in the past two decades, yet many manufacturers, however, still hesitate
to adopt the technology in their plants. Their hesitation is certainly
due to the lack of exact information on the process and its equipment
and also to 'their unfamiliarity with the actual method of operation.
In order to provide a useful introduction to the subject for engi
neers who work in industries which plan to employ this technique and
also to give exact and reliable information on the durability and perform-
ance of production facilities, as well as the capabilities of the process
and the properties of extruded products, we decided to publish this book.
Starting with theories and computational methods, the processes
of cold, warm and hot hydrostatic extrusion are described by experts
in their respective fields. Then follows a chapter devoted to industrial
hydrostatic extrusion plant equipment and the book concludes with an
up-to-date account of hydrostatic extrusion of new materials, such as
composites, special alloys, fine wires, or polymers.
Nobuo Inoue
Masao Nishihara
VII
CONTENTS
PREFACE v
xi
LIST OF CONTRIBUTORS
CHAPTER 1 INTRODUCTION
N. Inoue
CHAPTER 2 THEORY OF HYDROSTATIC EXTRUSION 7
Section FUNDAMENTALS OF HYDROSTATIC EXTRUSION 7
K. Osakada and P. B. Mellor
1. Introduction 7
2. Flow Stress and Extrusion Pressure 8
3. Geometrical Factors Affecting Extrusion Pressure 11
4. Ductile Fracture 16
5. Property of Product 17
Section 2 MECHANICS OF HYDROSTATIC EXTRUSION 21
K. Osakada and P. B. Mellor 21
1. Analytical Methods for Extrusion 21
2. Stress and Strain 22
3. Upper Bound Method 26
4. Rigid-Plastic Finite Element Method 29
5. Elastic-Plastic Finite Element Method 36
Section 3 LUBRICATION IN HYDROSTATIC EXTRUSION 41
W. R. D. Wilson
1. Introduction 41
2. Inlet Zone-Liquid Lubricants 46
3. Inlet Zone-Solid Lubricants 54
4. Steady Lubrication 62
5. Unsteady Lubrication 65
6. Lubricant Selection 68
Section 4 DYNAMICS OF HYDROSTATIC EXTRUSION 72
T. Matsushita
1. Introduction 72
2. Dynamics of Billet Motion 74
Vlll
3. Dynamics of Press Ram Motion 90
4. Conclusions 95
CHAPTER 3 COLD AND WARM HYDROSTATIC EXTRUSION PROCESS 97
S. Mitsugi and M. Seido
Section INTRODUCTION 97
Section 2 MAIN FEATURES OF HYDROSTATIC EXTRUSION 98
Section 3 METHODS OF COLD AND WARM EXTRUSION 100
1. Extrusion Process 100
2. Industrial Method for Hydrostatic Extrusion 100
3. Applications 104
Section 4 EXTRUSION PRESSURE 105
1. Aluminium and Aluminium Alloys 106
2. Copper and Copper Alloys 109
3. Steels 111
4. Special Metals and Alloy 113
5. Clad Composite Metals 113
Section 5 PROCESS PARAMETERS 113
1. Lubrication 113
2. Die Design 118
3. Billet Nose Geometry 123
4. Extrusion Temperature 125
Section 6 PROPERTIES OF PRODUCT 130
1. Surface Quality 130
2. Dimension 131
3. Microstructure 133
4. Mechanical Properties 135
CHAPTER 4 HOT HYDROSTATIC EXTRUSION PROCESS 139
M. Nishihara
Section 1 INTRODUCTION 139
Section 2 METHOD OF HOT HYDROSTATIC EXTRUSION 141
1. Process of Hot Hydrostatic Extrusion 141
2. Pressure Medium 142
Section 3 THERMAL PROBLEMS IN HOT HYDROSTATIC EXTRUSION 145
1. Temperature Rise of Product 145
2. Die and Mandrel for High Temperature Use 147
Section 4 PRESSURE REQUIREMENT FOR HOT HYDROSTATIC EXTRUSION 150
IX
Section 5 QUALITY OF EXTRUDED PRODUCTS 158
Section 6 PRODUCTION PROCESS USING HOT HYDROSTATIC EXTRUSION 161
CHAPTER 5 PLANT EQUIPMENT FOR HYDROSTATIC EXTRUSION 164
Section EXTRUSION PRESS AND AUXILIARY EQUIPMENT 164
M. Yamaguchi
1. Introduction 164
2. Basic Type of Hydrostatic Extrusion Press 165
3. Movement of Hydrostatic Extrusion Press 170
4. Structure of Hydrostatic Extrusion Press 173
5. Main Parts and Tools for Hydrostatic Extrusion Press 179
6. Auxiliary Equipment 190
7. Conclusions 193
Section 2 TOOLING FOR HYDROSTATIC EXTRUSION 194
Y. Yamaguchi
1. Introduction 194
2. Materials for Tools 194
3. High Pressure Container 203
4. Stem 217
5. Die and Mandrel 220
Section 3 HYDROSTATIC EXTRUSION PLANTS IN INDUSTRY 225
A. Kobayashi
1. Introduction 225
2. General Description of 4,000 Tonf Hydrostatic Extrusion Press 225
3. Auxiliary Equipment 232
4. Solid-Rod Extrusion with 4,000 Tonf Press 235
5. Pipe Extrusion with 4,000 Tonf Extrusion Press 241
6. Conclusion 248
CHAPTER 6 HYDROSTATIC EXTRUSION OF VARIOUS MATERIALS 249
Section CLAD COMPOSITE METALS 249
M. Seido and S. Mitsugi
1. Introduction 249
2. Method of Billet Making and Extrusion 249
3. Extrusion Pressure 251
4. Conditions for Sound Extrusion 254
5. Thickness Distribution of Clad Layers 263
6. Clad Composite Products 275
x
Section 2 SELECTED HYDROSTATIC EXTRUSION METHODS AND EXTRUDED
MATERIALS 284
R. J. Fiorentino
1. Introduction 284
2. Thick-Film Hydrostatic Extrusion Process 284
3. Hydrostatic Extrusion of Brittle Materials 305
4. Extrusion with a Step-Bore Container 316
Section 3 FINE WIRES 323
K. Osakada
1. Introduction 323
2. Equipment 323
3. Extrusion Pressure in Cold Hydrostatic Extrusion 325
4. Warm Hydrostatic Extrusion 330
5. Concluding Remarks 331
Section 4 POLYMERS 333
N. Inoue
1. Introduction 333
2. Plastic Deformation of Polymers 336
3. Effects of Hydrostatic Pressure 337
4. Mechanics of Hydrostatic Extrusion 340
5. Lubrication 345
6. Process Variables 346
7. Properties of Product 351
8. Conclusions 359
AUTHOR INDEX 363
SUBJECT INDEX 369
Xl
LIST OF CONTRIBUTORS
R. J. Fi orenti no, Program Manager, Meta lworki ng Section, Engi neeri ng and
Manufacturi ng Technology Department, Battelle Columbus Laboratori es,
505 King Avenue, Columbus, Ohio, U. S. A. 43201
N. Inoue, Professor, Department of Mechanical Engineering, Faculty of Engi
neering, Science University of Tokyo, 1 - 3 Kagurazaka, Shinjuku-ku,
Tokyo, JAPAN 162
A. Kobayashi, Assistant Manager, Toyoura Works, Hitachi Cable, Ltd., 1500
Kawajiri-cho, Hitachi, JAPAN 319-14
T. Matsushita, Senior Researcher, Central Research Laboratory, Kobe Steel,
Ltd., 1 - 3 - 18 Wakinohama-cho, Chuo-ku, Kobe, JAPAN 651
P. B. Mellor, Professor, Department of Mechanical Engineering, University
of Bradford, Bradford, West Yorkshire, BD7 lDP, U. K.
S. Mi tsugi, Seni or Researcher, Metals Research Laboratory, Hitachi Cable,
Ltd., 3 - 1 - 1 Sukegawa-cho, Hitachi, JAPAN 317
M. Ni shi hara, Advi ser, Kobe Stee 1, Ltd., 1 - 3 - 18 Waki nohama-cho, Chuo
ku, JAPAN 651
K. Osakada, Professor, School of Mechanical Engineering, Faculty of Engi
neering, Hiroshima University, Shitami, Saijo, Higashi-hiroshima,
JAPAN 724
M. Seido, Senior Researcher, Metals Research Laboratory, Hitachi Cable,
Ltd., 3550 Kidamari-cho, Tsuchiura, JAPAN 300
W. R. D. Wilson, Professor, Department of Mechanical and Nuclear Engi
neering, Northwestern University, The Technological Institute,
Evanston, I 11 i noi s, U. S. A. 60201
M. Yamaguchi, General Manager, Mechanical Engineering Research Laboratory,
Kobe Steel, Ltd., 1 - 3 - 18 Wakinohama-cho, Chuo-ku, Kobe, JAPAN
651
Y. Yamaguchi, Chief Researcher, Central Research Laboratory, Kobe Steel,
Ltd., 1 - 3 - 18 Wakinohama-cho, Chuo-ku, Kobe, JAPAN 651
CHAPTER 1
INTRODUCTION
N. INOUE
SCIENCE UNIVERSITY OF TOKYO
The idea of employing hydrostatic pressure for metalworking was con
ceived as early as in the nineteenth century and a British patent was
granted to Robertson in 1893 [1]. Experimental proofs of the pressure-in
duced ductility in metals and other materials, however, were not obtained
until Bridgman made an extensive study of subject along with metalworking
under pressure and published the result in the form of a monograph [2] in
1949. He invented a high-pressure seal, now called the 'Bridgman Seal',
which was so effective that he found himself in a uniquely advantageous
position to do high-pressure work. He spent the rest of his life studying
the fascinating world of high pressure and left a mountain of research
papers on the subject, which were later compiled in the form of a seven
volume monograph entitled COLLECTED EXPERIMENTAL PAPERS OF P. W. BRIDGMAN
and published by Harvard University Press in 1964 [3]. An extremely versa
tile high-pressure unit bearing his name has long been manufactured by the
Harwood Engineering Company of Newhall, with the assistance of Abbot,
former Research Assistant of Bridgman, and has benefited countless re
searchers in the high-pressure field. A similar type of press was also pro
duced by the Pressure Technology Corporation of America, headed by
Bobrowsky.
In Great Britain, on the other hand, systematic work on the hydro
static extrusion of metals and alloys was started by Pugh at the National
Engineering Laboratory in Glasgow. He and his collaborators developed the
technique of hydrostatic extrusion to such an extent that it is now es
tablished as a useful industrial process. In the Soviet Union high
pressure study was started by Vereshchagin at the High Pressure Laboratory
of the Academy of Sciences and reports on hydrostatic extrusion began
to appear in 1957 [4]. For a historical review of high-pressure work the
reader is referred to an excellent paper by Vodar and Kieffer of the High
Pressure Laboratory, C.N.R.S., Bellevue, France, included in the book, THE
