Numerical study and genetic algorithm optimization of hot extrusion process to produce rectangular waveguides

Rectangular waveguide is one of the earliest types of transmission lines. Rectangular waveguide can be produced by hot extrusion process. In this paper, the hot extrusion process of CuZn5 rectangular waveguide was investigated by Finite Element Method (FEM). In addition, Genetic Algorithm (GA) was used to optimize the die geometry and process conditions to achieve the lowest magnitude of extrusion force. Die geometry was introduced in terms of die length and billet hole diameter under various frictional conditions. It was found that die length and billet hole diameter had contradictory effects on the extrusion force. The experimental study was also carried out to verify the accuracy of estimated results.