Non-symmetric Hollow Extrusion of High Strength 7075 Aluminum Alloy

A hollow extrusion process by varying pocket geometry in welding chamber and bearing length to obtain a uniform material flow is studied. Finite element analysis and Taguchi method are used to obtain a better porthole type extrusion die design. The research results show that the billet has the best uniform material flow and minimum dead metal zone in Double arc type, and the ramp load shows that R of 40 mm is smaller than 45 mm. In addition, unequal bearing length makes metal flow more uniform. Finally, extrusion die with port-hole die structure has been manufactured and a successful extruding process has been conducted which proves the better design using the double arc pocket and unequal bearing length.