Abstract
Due to the intricate die design, the metal flow and stress distribution in the metal extrusion process are quite complex. This study successfully used the commercial finite element code Deform-3D to simulate the stress distribution in the direct hot extrusion of Al-AA7075 rods. The outcomes demonstrate that the ideal die angle reduces the effective stress intensity. The best die angle for the least effective stress is angle 15°, and the best die angle for the least maximum stress is angle 30°. Moreover, the least load is found at an angle of 15°; the load decreases with an increase in the diameter. Further more, careful design of the extrusion dies profile can therefore control and reduce the stresses, which cause a main defect in product structure, supported that it can be used to minimize the amount of in-homogeneity imparted in to the product, and therefore control the product quality.
