A finite element model incorporating Archards wear model was successfully develop to simulate aluminum die
extrusion process. Stress distribution and the amount of wear were calculated. The exit temperature, maximum load
on ram during breakthrough stage, and dead metal zones were simulated. The results are in good agreement with
experimental data. Wear simulations showed that the coated tooling had a higher resistance to temperature and wear
than uncoated one. The results generated from the simulation would help predict the service life of the components,
and can be used to optimize the right amount of thickness needed for the coating to improve die life.