Multi-Goal Virtual Optimization of Industrial Extrusion Dies

In the design of complex extrusion dies, a number of different and potentially conflicting goals are involved in the process optimization such as profile tolerances, mechanical properties, aesthetic surfaces, and die life. The aim of the present work was to carry out a multi-objective virtual optimization of industrial porthole dies for the maximization of profile quality (seam welds strength), of the production rate (flow balance and ram speed), and of die strength. Two industrial profiles were investigated, a thick round tube and a more complex industrial case of a hollow rectangular profile. In the first case, the gain achieved by the optimal design was compared with the experimental evidence of an already optimized configuration, showing an additional increase in terms of welding strength and flow balance. For the rectangular profile, the most significant improvements were attained not only for the seam weld quality, but also for the die strength, if compared to the performances of a starting configuration.