Multi Response Optimization of Cold Extrusion Parameters on AA 2024 Alloy Using TOPSIS

Aluminum alloys have significant application in several main industries owing to their ease of formability and cost-effectiveness. However, in order to improve their effectiveness more, material processing techniques must be constantly improved. Extrusion is one of the classic manufacturing techniques that provide effective shape and forming of Aluminum alloys in recent years. Proper selection and control of extrusion parameters show a vital role in achieving product quality. Die angle (DA), punch speed (PS) and lubricant coefficient (LUB) are the main process parameters that affect the extrusion process. Extrusion force, displacement and time are the critical component in the extrusion process which are greatly influenced by the metal flow and consequently affect the product’s quality. Hence, the present work employs finite element simulations (DEFORM-3D) of AA 2024 alloy during the cold extrusion. The results revealed that, as process parameters are raised, both extrusion force and displacement increase leading to a reduction in processing time. The simulations are run according to the L₂₇ orthogonal array. A multi-response optimisation is also carried out using TOPSIS while taking extrusion force, time and displacement into equal consideration. The optimal levels of input process parameters setting as die angle 30°, punch speed 4.8 mm/min and lubricant coefficient 0.06.