Optimum Shape Design of Axisymmetric Extrusion Die by using Hybrid Meta-Heuristic Optimization (ICACO)

The present study investigates the optimal design of the die shape in the metal forming process using extrusion. Due to the large deformations that occur during the forming process and the resulting entry into the plastic deformation zone, the finite element method is used to analyze the problem in this area, and the modeling is performed in the Eulerian system. The objective function of this study is to minimize the total energy required for deformation in the extrusion process. The design variable is the die shape, and spline curves with multiple control points are used to generate the die shape. Due to the nonlinear nature of the forming problem, the complexity, and the large amount of computation required during the analysis, a powerful combination of two metaheuristic optimization methods, the Imperialist Competitive Algorithm and Ant Colony Algorithm (ICACO), has been inspired for the optimal design of the die shape. To validate the obtained results for the die geometry, they are compared with the results presented in previous studies, The error was less than 2%, showing a good agreement. The results obtained have led to a significant reduction in the total energy consumption during deformation by approximately 12% compared to the conventional linear mode.