Effect of Processing Parameters on the Strain Inhomogeneity and Processing Load in Vortex Extrusion of Al–Mg–Si Alloy

Vortex extrusion (VE), a single pass severe plastic deformation technique, can impose a high amount of effective strain obtained from simultaneously twisting and reduction in area on the processed material. In this study, a hybrid investigation based on finite element analysis (FEA) and response surface methodology (RSM) was carried out to investigate the effect of geometrical parameters involved in VE die design on the strain inhomogeneity and processing load in vortex extrusion of Al–Mg–Si alloy. The analysis of variance (ANOVA) was used for verifying the effect of input variables and the significance of mathematical modeling. Developed mathematical model from RSM was verified using results obtained from the experiment. Results showed that increasing the twist angle increases the effective strain inhomogeneity. Twist angle (\(\varphi\)), reduction in area (RA), and interaction of twist angle and reduction in area (\(\varphi \times RA\)) were determined as the most effective parameters affecting strain inhomogeneity, while the processing parameters of\(\varphi\), RA, and the interactions of \(\varphi \times RA\), \(\varphi \times \varphi\) and \(RA\times RA\) are the most effective parameters on the load of VE process.