<p>The selection of process parameters is crucial for optimizing the extrusion process to ensure high-quality products with minimal defects. Extrusion, a widely used metal-forming process, involves forcing a billet through a die to achieve the desired shape. Various parameters, including die geometry, extrusion ratio, die angle, ram speed and material properties, influences the metal flow and process efficiency. Among these, die angle, coefficient of friction and ram speed significantly affect extrusion force, material damage and displacement. The present study investigates the effect of these key process parameters on extrusion responses using finite element simulation in DEFORM-3D software, with AA 2024 alloy as the billet material. A total of 27 simulations were conducted based on an L₂₇ orthogonal array to systematically analyze the effects of input parameters on extrusion force, material damage and displacement. Multi-objective optimization was carried out using Grey Relational Analysis (GRA), with equal weightage given to all three responses. The optimized combination of 30° die angle, 4.8&#xa0;mm/min ram speed and 0.1 coefficient of friction resulted in 38.9% reduction in extrusion force, 90% reduction in material damage and 73% improvement in displacement compared to the least favorable condition. These enhancements have strong industrial relevance, especially in aerospace and automotive sectors where dimensional accuracy, formability and mechanical integrity are critical. The optimized process not only improves product quality and material utilization but also reduces energy consumption and manufacturing cost. The study demonstrates that finite element-based simulations can effectively minimize experimental efforts while delivering reliable process optimization, thereby supporting sustainable and efficient cold extrusion practices.</p>