Metal extrusion is currently very beneficial for producing workpieces with long dimensions or when a uniform cross section area is required. Design of extrusion dies, which results to the shape, geometry and size of the workpiece, is the main factor for quality, productivity and durability of the products. Besides improving the bearing length, a die pocket is a good solution to effectively control the velocity of material flow into the die hole. Therefore, this study aimed to evaluate the structures of die pockets that influence the material flow in the extrusion process. Thus, the finite element method (FEM) was used to determine the parameters that affect the strength of the extrusion die due to the maximum stresses which occurred on the die and pocket. From this study, it was found that the circular shaped pocket with 31degrees pocket angle, 22 mm pocket die thickness and made of titanium alloy provided the maximum strengths and safety factors. This result from the simulations can sufficiently predict the risk of damages on the extrusion die and pocket for further extension of the tool’s life cycle.
