The purpose of this study was to simulate the metal extrusion processes via three-dimensional physical modeling technique. Plasticine was utilized as the modeling material, while plexiglass was incorporated in the design and fabrication of a labscale extrusion apparatus. The extrusion setup was designed to accommodate dies of different semi-cone angle while also making it possible to change the extrusion ratio R = A0/Af. Cylindrical billets were prepared utilizing alternating layers of two colors of plasticine. Extrusion of cylindrical billets was conducted at three different reduction ratios and three different die angles for each reduction ratio. Dissection of the extruded billets along a centroidal plane revealed the internal deformation patterns which were subsequently utilized for determining the effect of the die angle and extrusion ratio on the state of strain in the final product as well as the required extrusion loads.

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