Optimization of single and multistep wire drawing processes with respect to minimization of the forming energy

Abstract

Optimization of single and multistep wire drawing processes, based on the finite element analysis and nonlinear mathematical programming techniques, is considered. Since the investigated problem involves the optimal selection of the extrusion die angles and the correspondent reduction rate sequence, it can be considered as one belonging to a class of optimum shape design problems. Characteristic to the considered problem is that the domain boundary, the shape of which is to be optimized, is subject to the shape dependent forming loads. The minimization of the objective function, which is related to the process energy consumption, is sought by taking several technological and geometrical constraints into account. The numerically evaluated examples demonstrate that by using the proposed optimization technique not only a substantial cost reduction, but also a considerable improvement in the homogeneity of plastic deformation through the cross-section of the drawn wire can be achieved.