This research addresses modeling and optimization of the process parameters for extrusion operation. To model the process, a set of data has been used to evaluate the effects of various parameter settings in extruding 2A12TA aluminum alloy. The set of data used in this paper was achieved by ABAQUS finite element package instead of carrying out the experiments. The process variables considered here include die angle, coefficient of friction and the ratio of reduction of area. Extrusion pressure, as one of the most important output characteristics, has been evaluated based on different parameter settings. The Taguchi method and regression modeling are used in order to establish the relationships between input and output parameters. The adequacy of the model is evaluated using analysis of variance (ANOVA) technique. The pairwise effects of process parameters settings on process response outputs are also shown graphically. The objective is to determine proper levels of process parameters in order to obtain a certain level of extrusion pressure and save time as well as cost, using regression model instead of running FE simulations.

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