Finite Element Simulation of Alloyed Steel (20MnCr5) in Extrusion Process Using Deform 3D Software

This study focuses on optimizing input process parameters for the extrusion of alloyed steel (20MnCr5) using finite element simulation via DEFORM-3D software and the Taguchi method. The selection of appropriate process parameters is critical to minimize extrusion force, particularly when different material sets are involved. The research examines key parameters such as billet material properties, workpiece geometry, die angle, coefficient of friction, logarithmic strain, ram speed, and die length. Through DEFORM 3D simulation, the minimum extrusion force is predicted, and optimal process parameters are identified using Taguchi analysis. The regression analysis identified optimal conditions with a coefficient of friction at 0.08, die angle at 20°, and ram velocity at 1.5 mm/s, resulting in an extrusion force of 556291KN. ANOVA results indicate that die angle is the most influential factor, contributing 43.45% to the variation in extrusion force. Using an L27 (3^3) orthogonal array, the experiments were analyzed via MINITAB software. The analysis of extrusion speed's effect on temperature revealed a maximum die temperature of 600°C and billet temperature of 1030°C at ram speeds between 1-2 mm/s. Additionally, the temperature-stress relationship indicated the highest stress value of 1000 MPa at 20°C with 0.7% strain, while the lowest stress of 90 MPa occurred at 1050°C with 0% strain. The findings demonstrate the significant impact of optimized parameters on reducing extrusion force, enhancing process efficiency.