Simulation-driven evaluation and selection of analog rice extrusion die geometry using design of experiments and finite element analysis

Analog rice extrusion dies must resist the applied extrusion load while maintaining low deformation, yet their structural geometry is rarely evaluated systematically before fabrication. This study aims to quantify the effects of edge fillet diameter and die-hole thickness on maximum von Mises stress and total deformation, and to identify the best-performing configuration within a predefined design space. Nine die configurations were generated using a 3² full factorial design with fillet diameters of 1, 2, and 3 mm and hole thicknesses of 10, 12, and 14 mm. Each configuration underwent one deterministic static finite element analysis in Altair SimLab under identical material properties, boundary conditions, mesh settings, and a 7117 N design load. The die material was Aluminum Alloy 6061-T6. Maximum stress ranged from 22.757 to 43.979 MPa, while deformation ranged from 0.008 to 0.016 mm. Across the evaluated levels, increasing both variables reduced the two structural responses, with hole thickness showing the larger main effect. Exploratory main-effects ANOVA and response models supported the observed trends, although inferential results were interpreted cautiously because the simulations were not independently replicated. The 3 mm fillet and 14 mm hole thickness configuration produced the lowest simulated stress and deformation among the nine cases. It is therefore reported as the best-performing tested configuration rather than a globally optimised design. The workflow supports pre-fabrication screening of analog rice extrusion dies and identifies priorities for subsequent experimental and thermo-mechanical validation.