Accurate material modeling is critical for reliable finite element simulation of aluminum extrusion processes. This work presents the development and industrial validation of a strain-compensated Arrhenius constitutive model for AA7075 aluminum alloy applied to porthole die extrusion. Isothermal compression experiments were performed using a Gleeble 3500 system at 450–500°C and 0.1–1.0 s−1. Material constants were determined as sixth-order polynomial functions of strain, yielding a model with R = 0.997 and AARE = 1.50%. The constitutive relations were incorporated into the QForm software to simulate the extrusion of a complex curtain wall profile through a six-porthole die. Factory trials on a 2100-ton press confirmed the model’s reliability, with predicted forces deviating by only 1.11% from measured values, compared to 19.16% using default database parameters. TS-GHX1 tool steel with gas nitriding treatment was employed to address die failure issues associated with conventional H13 steel, demonstrating 6–8% reduction in peak die stresses and successful extrusion of the target profile.
Nguyen et al. (Wed,) studied this question.