TOOL DESIGN OPTIMIZATION IN EXTRUSION PROCESSES

Tool design optimization in steady-state extrusion processes, based on the finite element discretization and nonlinear mathematical programm ing techniques, is considered in this paper. In order to perform the o ptimization the die geometry is adequately parameterized, according to the polynomial representation. By imposing real technological and geo metry constraints the optimal tool design is effected by extremizing t he actual optimization objectives. In particular, the minimization of the forming energy consumption and the maximization of the possible ar ea reduction are considered. The results, obtained numerically by assu ming the Lagrange incremental elastic-plastic finite element formulati on in modelling the material flow and the considered optimization appr oach, are compared to the known theoretical solutions, in cases where such solutions are available. It is demonstrated that the discussed ap proach is quite effective. (C) 1998 Elsevier Science Ltd and Civil-Com p Ltd. All rights reserved.