The Extrusion Force Calculator helps engineers and manufacturers determine the required force to push a material through a die during the extrusion process. This is important for metalworking, polymer extrusion, and even food manufacturing. The calculator is used to estimate the amount of mechanical or hydraulic energy needed to shape materials into continuous profiles. By knowing the extrusion force, users can select the right equipment and optimize operating conditions to reduce wear, energy consumption, and production cost.
This tool simplifies complex force estimations, especially when dealing with different material properties, billet shapes, and extrusion ratios. It is a vital resource in material science, production design, and mechanical engineering.
formula of Extrusion Force Calculator
Extrusion Force (F) = σ × A
Where:
F = Extrusion force in newtons (N)
σ = Flow stress of the material (in pascals or N/m²)
A = Cross-sectional area of the billet (in m²)
Expanded Formula for Cylindrical Billets:
F = σ × (π × D²) / 4
Where:
D = Diameter of the billet (in meters)
If using the extrusion ratio:
F = σ × A × ln(R)
Where:
R = Extrusion ratio = A₀ / A_f
A₀ = Original cross-sectional area
A_f = Final cross-sectional area after extrusion
ln = Natural logarithm
These formulas help estimate the pushing force depending on the material strength, geometry, and how much the shape is being reduced.
Common Conversion & Reference Table
| Term | Typical Range or Note | Units |
|---|---|---|
| Flow Stress (σ) | 50 MPa – 800 MPa (depending on material) | Pa or N/m² |
| Billet Diameter (D) | 0.01 m – 0.3 m | meters |
| Extrusion Ratio (R) | 1 – 100 | unitless |
| Cross-Sectional Area (A) | (π × D²) / 4 for round billets | m² |
| Natural Logarithm (ln R) | Calculated using scientific calculator | unitless |
This table helps when approximating or double-checking input values for typical materials and shapes.
Example of Extrusion Force Calculator
Let’s assume you're extruding a cylindrical aluminum billet:
- Flow stress (σ) = 300 MPa = 300,000,000 Pa
- Diameter (D) = 0.1 m
First, calculate the area:
A = (π × D²) / 4 = (π × 0.1²) / 4 = (π × 0.01) / 4 ≈ 0.00785 m²
Now apply the main formula:
F = σ × A = 300,000,000 × 0.00785 ≈ 2,355,000 N
So the required extrusion force is approximately 2.36 MN (MegaNewtons).
If there’s an extrusion ratio involved, say R = 10:
ln(R) = ln(10) ≈ 2.302
F = σ × A × ln(R) = 300,000,000 × 0.00785 × 2.302 ≈ 5,422,000 N
That increases the force to around 5.42 MN due to the tighter final shape.
Most Common FAQs
This calculator fits within mechanical and manufacturing engineering tools. It's mainly used in forming, shaping, and materials processing.
The extrusion ratio shows how much the material’s cross-section is reduced. A higher ratio means more force is needed to compress and reshape the material through a smaller die opening.
No, flow stress changes based on the material type, temperature, and strain rate. Metals like aluminum and copper have much lower flow stress than steels or titanium alloys.