Virtual tryout and optimization of the extrusion process using a shape variables generator integrated in the CAE pre-processing environment

CAE tools usage to evaluate process performances it has became a matter of fact in cases like: metal forming, foundry, casting and forging. Like in these applications, also for the extrusion processes CAE tools usage has became a convenient opportunity, not only to verify the designed process but also to tune it in a virtual way. In this specific application, it has been evaluated the chance to use an optimization tool in combination with a process solver. The chance to optimize the extrusion process has been investigated using shape design variables for the tool process design, in order to obtain the best extruded profile quality. The applied procedure has shown strength points like: the full integration between the preprocessor and the shape variables generator, without any need to exchange data with the CAD environment during the optimization and weak points, such has the reduced freedom for the shape variation, due to the risk of an excessive distortion of the finite elements which describe the process.