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Numerical simulation and multiobjective optimization of fluid–structure interaction in aluminum extrusion

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Abstract

Although much technological advancement has been implemented in the aluminum extrusion industry, there are still considerable expenses as tests of different process parameters or new die geometries are carried out. To reduce the amount of trial-and-error testing, it is important to understand the process variation as each parameter or piece of equipment changes. Therefore, this work performed and analyzed the numerical simulation of aluminum extrusion using the finite element method through the COMSOL® Multiphysics software. A visco-plastic modeling approach was used, where the solid, aluminum, is treated as a high viscosity fluid. Furthermore, in order to optimize the process parameters and understand the physical behavior of the problem, a metamodel was built using a quadratic response surface model and, from this, a mono and multiobjective optimization was performed using the Lichtenberg algorithm metaheuristic. The multiobjective optimization with the metamodel resulted in errors of 0 to 2% in relation to the actual response.

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Availability of data and materials

The data in this manuscript is available from the corresponding author on reasonable request.

Code availability

Not applicable.

Abbreviations

CAE:

Computer-aided engineering

DOE:

Design of experiments

FEM:

Finite element method

FVM:

Finite volume method

MEP:

Multiport extrusion

ALE:

Arbitration Lagrangian–Eulerian

CVD:

Chemical vapor deposition

SPRING:

Multiobjective Lichtenberg algorithm

RSM:

Response surface methodology

TOPSIS:

Technique for Order Preference by Similarity to Ideal Solution

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Funding

This study is financially supported by the Brazilian agency CNPq (Conselho Nacional de Desenvolvimento Cientifico e Tecnológico), CAPES (Coordenação de Aperfeiçoamento de Pessoal de Nível Superior) and FAPEMIG (Fundação de Amparo à Pesquisa do Estado de Minas Gerais—APQ-00385–18).

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Authors and Affiliations

  1. Mechanical Engineering Institute, Universidade Federal de Itajubá, Itajubá, Brazil

    Danilo Pazeto, João Luiz Junho Pereira & Guilherme Ferreira Gomes

Authors
  1. Danilo Pazeto
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  2. João Luiz Junho Pereira
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  3. Guilherme Ferreira Gomes
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All authors contributed to the conceptual idea, methodology and results of the manuscript.

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Correspondence to Guilherme Ferreira Gomes.

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Pazeto, D., Pereira, J.L.J. & Gomes, G.F. Numerical simulation and multiobjective optimization of fluid–structure interaction in aluminum extrusion. Int J Adv Manuf Technol 124, 545–566 (2023). https://doi.org/10.1007/s00170-022-10543-2

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