Process Parameter Optimization of Hydrostatic Extrusion Using Metaheuristic

Abstract

Friction at die work piece interface can be reduced by the presence of lubricant in the entry zone. As the metal–metal contact in the deformation zone is avoided, the deformation force is reduced and at the same time the product quality and die life are improved. So the prediction of minimum film thickness and its control through process variables is gaining interest in the industry. Two multi-objective nonlinear optimization problems are formulated in this study, one using the minimum thermal thickness and billet temperature at the work zone. And the other optimization problem is formulated by including the minimum isothermal thickness at entry zone and the billet temperature at the work zone. These two multi-objective optimization problems have been solved using particle swarm optimization algorithm (PSO). The key process variables are identified by coefficient of variance (COV) analysis. A sensitivity analysis on the process variables is performed to prioritize the process variables. A design procedure is explored to demonstrate the industrial application of this analysis.