Die shape optimal design in cold and hot extrusion

A process optimal design methodology applicable to cold and hot forming is presented, on the basis of an integrated thermo-mechanical finite element process model and a derivative-based optimization scheme. The process model, the formulation for process optimal design, and the schemes for the evaluation of the design sensitivity considering the effect of strain-hardening and heat transfer are described in detail. The capability of the proposed approach is demonstrated through applications to die shape optimal design in cold and hot extrusion.