Optimization of aluminum extrusion die using finite element analysis and experimental validation

In this thesis study, the design of dies used in the aluminum extrusion process was analyzed and improved using the finite element software Inspire Extrude Metal. In the analyses conducted for three different aluminum alloys and profile types, three main parameters were considered: temperature, material flow rate, and strain. Based on the analysis results, the extrusion die designs were optimized according to these parameters, aiming to ensure homogeneous material flow, reduce potential defects, and increase die life. The high correlation between the simulation results and the final product demonstrated the validity of the analyses performed using the finite element method. This study provides significant contributions to improving die design in the aluminum extrusion process through numerical methods, enhancing production quality, energy efficiency, and cost-effectiveness.