Process optimization diagram based on FEM simulation for extrusion of AZ31 profile

The ram speed and the billet temperature are the primary process variables that determine the quality of the extruded magnesium profile and the productivity of the extrusion operation. The optimization of the extrusion process concerns the interplay between these two variables in relation to the extrudate temperature and the peak extrusion pressure. The 3D computer simulations were performed to determine the effects of the ram speed and the billet temperature on the extrudate temperature and the peak extrusion pressure, thereby providing guidelines for the process optimization and minimizing the number of trial extrusion runs needed for the process optimization. A case study on the extrusion of an AZ31 X-shaped profile was conducted. The correlations between the process variables and the response from the deformed material, extrudate temperature and peak extrusion pressure, were established from the 3D FEM simulations and verified by the experiment. The research opens up a way to rational selection of the process variables for ensured quality and maximum productivity of the magnesium extrusion.