A Review of Manufacturing Parameter Optimization and Component Design of Magnesium Alloys Using Numerical and Experimental Methods

Magnesium alloys are promising materials for lightweight engineering applications owing to their low density and favorable strength-to-weight ratio. However, their widespread industrial application remains challenging because of limited formability, a relatively narrow processing window, and strong sensitivity of mechanical behavior to processing conditions. In this study, an interdisciplinary framework is proposed for optimizing manufacturing parameters and component design of magnesium alloys by integrating numerical simulation, predictive modeling, experimental investigation, and design of experiments (DoE). Particular attention is given to metal forming processes, especially extrusion, in which billet temperature, ram speed, extrusion ratio, and friction conditions strongly influence forming load, material flow, exit temperature, microstructural evolution, and final mechanical properties. Three-dimensional finite element analysis (FEA) is employed to investigate the effects and interactions of the main processing parameters and to identify feasible processing regions prior to extensive experimental testing. The numerical results are subsequently validated through experimental measurements, while statistical and predictive methods are used to determine the most influential parameters and establish optimized processing conditions. This integrated methodology enables the reduction of experimental trials, improves the efficiency of process optimization, and provides a more comprehensive understanding of the relationships between processing conditions, deformation behavior, microstructure, and mechanical performance. The proposed framework can therefore serve as an effective tool for designing robust manufacturing processes for magnesium alloy components and facilitating their application in lightweight structural systems.

کلیدواژه ها:

process optimization ، functional design ، extrusion ، finite element method (FEM) ، design of experiments (DoE) ، mechanical properties ، microstructure.