Effect of diegeometry on extrusion process

Using of magnesium has been widespread in many sector such as construction, aerospace and automotive due to its high mechanical properties and lower weight. One of the methods of application of magnesium and its alloys is extrusion process. Extrusion is a plastic forming method in which a metal block, called billet or workpiece, is allowed to flow through a mold cavity with a smaller cross section through the pressure. With this method, both profiles that solid section and profiles that hollow and complex section can be produced. In order to improve the quality of the profiles obtained in the extrusion process, the effect of many parameters was investigated. The material flow, which is one of the main factors, is important because of the material is in a homogeneous structure and accordingly has a smooth geometry. The die geometry needs to be optimized to control the metal flow in the extrusion dies. If the die design is not suitable, it is likely that there will be buckling or folding in the extruded product. However, the stress on the die and critical rises in the outlet temperature in the profile can cause the die and product to become dysfunctional. In this study, extrusion rate and die entry angle which are important parameters in die geometry, are taken into consideration. After the experimental study, DEFORM 3D software finite element analysis was performed by modeling the extrusion process that this experimental study was made. The validity of the finite element model was tested by comparing the experimental study result and analysis result. After creating a valid finite element model, extrusion rate and die entry angle are changed and new finite element simulations are performed and the results are examined. Data obtained by finite element analysis were modeled using GEP (Gene Expression Programming). With these GEP models, the relationship between extrusion rate and die entry angle (input parameters), extrusion force (output parameters) is revealed.