v
TABLE OF CONTENTS
Abstrak i
Abstract ii
Acknowledgement iii
Dedication iv
Table of Contents v
List of Tables x
List of Figures xi
1.0 INTRODUCTION
1
1.1 Introduction
1 1.2
Problem Statement 1
1.3 Objective
2 1.4
Scope 2
1.5 Parts of The Extrusion Process
3 1.5.1
Die Assembly 4
2.0 LITERARTURE REVIEW
6
2.1 Introduction
6 2.2
Overview of Extrusion 6
2.3 History of Extrusion
8 2.4
Extrusion Process 10
2.4.1 Basic Principles Of Extrusion
10 2.4.2
Types of Extrusion 11
2.4.3.1 Direct Extrusion
11 2.4.3.2
Indirect Extrusion 12
2.4.3.3 Impact extrusion
12 2.4.3
Advantages of Extrusion 13
2.4.4 Limitations of Extrusion
13 2.5
Types of Equipment Used 14
List Abbreviations x
i
v
vi 2.6
Standard Extrusion Shape 15
2.7 The Extrusion Product
15 2.8
Heat Treatment Process 16
2.8.1 Solution Heat Treatment and Age Hardening
16 2.8.2
Solution Heat Treating 17
2.8.3 Aging
19 2.9
Selection Material Workpieces 20
2.9.1 Guidelines For Alloy Selection
21 2.10
Die Design 22
2.10.1 Dimensions and Shapes of Extrusions
22 2.10.2
Dimensional Tolerances 22
2.10.3 Considerations in Die Design
23 2.10.4
Tolerances 23
2.10.5 Angular Dimensions
24 2.11
Theory Of Calculation For Extrusion Process 24
2.11.1 Extrusion Force
24 2.11.2
Extrusion ratio 25
2.11.3 Material Reduction
27 2.12
Theory of Plasticity 29
2.12.1 Applications of the Theory of Plasticity
30 2.12.2
Stress-Strain Behavior 30
2.13 Theory of elasticity
32 2.14
Finite Element Methods FEM 33
2.15 Finite element analysis FEA
34 2.15.1
Explicit Dynamic 35
2.15.2 DEFORM 3D
36 2.15.2.1 Analyzing Manufacturing Processes
37
3.0 METHODOLOGY
38
3.1 Introduction
38 3.2
Flow Chart 38
3.3 Project Details
39 3.3.1
Data mining 39
3.3.1.1 Material Information
39
vii 3.3.1.2
Die Design Information 41
3.4 Literature Review
42 3.5
Develop Design 42
3.5.1 Design Sketch
43 3.5.2
Comparison 43
3.5.3 CAD Design
44 3.5.4
Design Considerations 44
3.6 Finite Element Model
44 3.7
Boundary Condition 45
3.8 Simulation
45 3.8.1
Finite Element Analysis Stages 45
3.8.1.1 Pre-Processing
47 3.8.1.2
Simulation 47
3.8.1.3 Post-Processing
47 3.8.2
Analyze the Result 48
4.0 DETAIL DESIGN
48
4.1 Introduction
48 4.2
Design of Extrusion Die 48
4.3 Detail Design
51 4.4
Die Land Plate 52
4.5 Pre-land Plate
53 4.6
Transition Plate 54
4.7 Die Adapter Plate
56 4.8
Extruder Mounting Plate 57
4.9 Heater Band
58 4.10
Adding the standard component 59
5.0 ANALYSIS PROCEDURE
