Investigation and optimization of extrusion process parameters with finite element analysis and Taguchi method

Extrusion method is commonly used for metal forming applications to produce profiles with different shapes. Many parameters effect to the product quality in extrusion process. Investigation and optimization of these parameters can be reduced the producing time, labor and energy cost. The aim of this study is to investigate the effect of process parameters on extrusion load and profile exit temperature for extrusion method. For this purpose, the finite element simulations were performed at the different initial temperatures of billet, die and container, and speed of different ram. The number of finite element simulation were arranged by Taguchi method, so that 9 simulations are performed instead of 81. Before performing all finite element simulations using DEFORM 2D, one of them was performed and compared with the results in literature. The results showed good agreement with the results in literature. After that all 9 simulations were performed and an ANOVA was applied to the results. With this approach, effect of each parameters was determined on maximum extrusion load and temperature.