OPTIMIZATION OF SINGLE AND MULTISTEP WIRE DRAWING PROCESSES WITH RESPECT TO MINIMIZATION OF THE FORMING ENERGY

Optimization of single and multistep wire drawing processes, based on the finite element analysis and nonlinear mathematical programming tec hniques, is considered. Since the investigated problem involves the op timal selection of the extrusion die angles and the correspondent redu ction rate sequence, it can be considered as one belonging to a class of optimum shape design problems. Characteristic to the considered pro blem is that the domain boundary, the shape of which is to be optimize d, is subject to the shape dependent forming loads. The minimization o f the objective function, which is related to the process energy consu mption, is sought by taking several technological and geometrical cons traints into account. The numerically evaluated examples demonstrate t hat by using the proposed optimization technique not only a substantia l cost reduction, but also a considerable improvement in the homogenei ty of plastic deformation through the cross-section oi the drawn wire can be achieved.