Optimal design of extrusion dies using hp-adaptive finite element model

Extrusion die design is still an art and depends heavily on previous experience and several in-plant trial and error processes to manufacture a single die, of particular importance is the shape of the die passages. In this paper we present an algorithm for optimal design of extrusion dies using an A/j-adaptive finite element model and shape optimization based on an efficient response surface methodology, /zp-adaptive finite element analysis is used to obtain accurate flow solutions. Starting with an initial guess for the die geometry, we iteratively solve the fluid flow and optimization problems to produce a die design that satisfies the objective function and constraints. Results for a two- and three-dimensional extrusion problem are presented to show the robustness of the approach and its effectiveness in simplifying the method of die design. The advantage of this approach is that, in addition to removing the guesswork from mesh generation, it eliminates the time consuming trial and error experiments in extrusion die design. The present research also highlights another use of the response surface methodology in multidisciplinary design optimization.

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