A novel comprehensive approach for multi-objective optimization of the aluminum extrusion process

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