The theoretical and experimental method of optimization the aluminium billet’s contact surface during extrusion have been presented in this paper. The theoretical assumption, based on welding criteria, have been confirmed by experimental researches. The technique of measurement has been shown as well. Experiments are made using plasticine as a substiute material. Some kind of different variants have been investigated. The theory and experiments have been provided to optimize the modeling shape and may help in design and technology. The theory has been tested experimentally using a plasticine as a substitute material and a plexiglass die such that the velocity fields at the surfaces could be observed and measured during plastic flow, allowing the empirical coefficients in the mathematical formulation to be estimated. On the basis of the theory and experiments an optimal billet’s contact surface was proposed.
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