Extrusion is a crucial manufacturing process that requires state-of-the-art set-up and proper machinery. In the wire and cables industry, proper extrusion is vital to ensure the quality and durability of the product. One cannot overlook the importance of the high-quality wires and cables that are used across industrial circles and commercial settings. To ensure the quality of the product we need to ensure the process is rightly done from the very beginning of the manufacturing process that starts with a rubber extruder machine. Extrusion being an initial step in the process enhances the need for understanding the details related to this process.

What is meant by the process of Extrusion?

When we say extrusion, we refer to a manufacturing process where a base metal is forced through a pre-shaped die to create objects with a specific shape and profile. Under this process, a metal changes its shape and forms the die’s shape when it passes through it. There are different types of processes of extrusion.

What are the types of extrusion?

The process of extrusion, done with the help of high-performance machinery lines like rubber or Polyethlene extrusion lines, converts solid granules or other forms into homogeneous melt. This melt is pumped through a shaping die mounted in the crosshead alongside the tip at a steady, controlled rate. In the crosshead, the tip guides the cable and shaping die in order to give it the shape of the insulation depending upon the material. The most commonly used extrusion processes are listed below.

Cold Extrusion

Cold extrusion is a process appropriate for the slug form of metal. In this process, this type of metal is poured into the die’s feeder where the application of pressure is applied to join them together in order to create a solid object in a new shape. The process is generally done at room temperature. The metals that are generally extruded as per this process are Aluminum, Niobium, Copper, Steel, Tin, and Lead.

Hot Extrusion

This process is exactly the opposite of the previously explained method. Here, the use of a heating process is done to melt the metal at a high temperature. Once the metal is in the molten state, it is forced through a die for extrusion. The temperatures generally vary from 650 degrees Fahrenheit (magnesium) all the way to 1,300 degrees Fahrenheit (steel) totally depending upon the type of metal used in extrusion. Using the right temperature is crucial for this process of hot extrusion. In case the base metal isn’t heated to the appropriate temperature, the process of hot extrusion becomes a more accurate and effective way to reshape metal. The metals that are generally extruded as per this process are Magnesium, Steel, Copper, Nickel, Aluminum, etc.

Friction Extrusion

Another type of extrusion is friction extrusion. It is a modern extrusion process, which involves the automatic rotation of the metal slugs or billet according to the position of the die. The heat helps the metal in passing through the die more easily. This is an effective, efficient process that is gaining popularity among new-age manufacturers.

Micro Extrusion

In the end, we will talk about the latest type of extrusion. The name depicts the ability of this process to create small, micro-sized objects. Under the cross-section of the die supports extrusion of base metal measuring just 1 millimeter. It has gained the same level of recognition as friction extrusion, due to its extremely technical nature of creating such small dies that can withstand such pressure.

Conclusion

When it comes to cables, the characteristic of durability is ensured through the correct extrusion process. From the above information, you will now be able to find the best extrusion process that is appropriate per your specifications.