Extrusion is one of the widely used metal forming processes. The extrusion process is carried out conventionally using a shear faced die, but shear faced dies have many practical problems such as a dead metal zone, more redundant work. In the present investigation, the evolution of uniform microstructure in extruded product with improved mechanical properties for quality products to get dimensional accuracy. A mathematically contoured non-linear converging die has been designed for extrusion of square section from round billet. CAD models of die profile have also been developed. The experiments have been conducted to verify the proposed theoretical model. The extrusion test rigs have been fabricated to carry out extrusion through mathematically contoured dies.