Optimal die design for three-dimensional porthole extrusion using the Taguchi method

Abstract: 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