Empirical knowledge and the trial-and-error method are still common design approaches used in the extrusion industry. However, the service life of three-dimensional extrusion dies is generally unstable and extremely short, especially for high-strength aluminium extrusions, which clearly increases production cost and lowers efficiency. This paper proposes a method for establishing optimal die design for three-dimensional extrusions using the Taguchi method and the finite element method (FEM). Taguchi's orthogonal array is applied to plan the simulation of FEM. After Taguchi's response analysis, the influence of each factor on the die stress was understood and an optimum design was obtained.
LofJ.BlokhuisY.FEM simulations of the extrusion of complex thin-walled aluminium sections. J. Mater. Processing Technol., 2002, 122, 344–354.
3.
JoH. H.LeeS. K.LeeS. B.KimB. M.Prediction of welding pressure in the non-steady state porthole die extrusion of Al7003 tubes. Int. J. Mach. Tools Mf., 2002, 22, 753–759.
4.
JoH. H.JeongC. S.LeeS. K.KimB. M.Determination of welding pressure in the non-steady state porthole die extrusion of improved Al7003 hollow section tubes. J. Mater. Processing Technol., 2003, 139, 428–433.
5.
ZouL.XiaJ.WangX. Y.HuG.Optimization of die profile for improving die life in the hot extrusion process. J. Mater. Processing Technol., 2003, 142, 659–664.
6.
LiQ.SmithC. J.HarrisC.JollyM. R.Finite element modeling investigations upon the influence of pocket die design on metal flow in aluminium extrusion. Part I: Effect of pocket angle and volume on metal flow. J. Mater. Processing Technol., 2003, 135, 189–196.
7.
LiQ.SmithC. J.HarrisC.JollyM. R.Finite element modeling investigations upon the influence of pocket die design on metal flow in aluminium extrusion. Part II: Effect of pocket geometry configurations on metal flow. J. Mater. Processing Technol., 2003, 135, 197–203.
8.
DuanX.VelayX.SheppardT.Application of finite element method in the hot extrusion of aluminium alloys. Materi. Sci. Engng., 2004, A369, 66–75.
9.
LeeJ. M.KimB. M.KangC. G.Effect of chamber shapes of porthole die on elastic deformation and extrusion process in condenser tube extrusion. Mater. Des., 2004, 26, 327–336.
