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Numerical analysis

Multi-Objective Optimization Design and Verification of Extrusion Die Structure for TC4 Titanium Alloy Y-Shaped Profiles

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— 1 min read

A team of researchers at the School of Mechanical & Electrical Engineering, led by Wangqing Wu, has successfully optimized the design of extrusion die structures for TC4 titanium alloy Y-shaped profiles used in the aerospace field. The study employed a high-precision Hansel-Spittel constitutive model to simulate the material's flow behavior and a multi-objective optimization algorithm to optimize the die structural parameters. The results demonstrated a significant reduction in the relative exit velocity difference, maximum surface temperature difference, and extrusion force of the profile.

Key Takeaways:

  • The research focused on the multi-objective optimization design of extrusion die structures for TC4 titanium alloy Y-shaped profiles used in the aerospace field.
  • A high-precision Hansel-Spittel constitutive model of TC4 titanium alloy was established to provide a basis for numerical simulation analysis.
  • The model was verified by the correlation coefficient (R = 0.9910) and the average absolute relative error (AARE = 8.90%), demonstrating its capability to accurately characterize the material's flow behavior.
  • A second-order response surface model was developed based on the Box-Behnken experimental design to relate die structural parameters to optimization objectives.
  • The optimal die structure was obtained using the NSGA-II genetic algorithm, resulting in a 96.6% reduction in the relative exit velocity difference, a 7.44% decrease in the maximum surface temperature difference, and a 4% reduction in extrusion force.
  • The optimized die structure was manufactured and subjected to actual hot extrusion experiments, demonstrating observable quality enhancement of the profile.

Statistics:

  • The research achieved a 96.6% reduction in the relative exit velocity difference of the profile.
  • The maximum surface temperature difference decreased by 7.44%.
  • The extrusion force was reduced by 4%.
  • The correlation coefficient (R) was 0.9910.
  • The average absolute relative error (AARE) was 8.90%.

Sources:

  • Multi-objective Optimization Design and Verification of Extrusion Die Structure for Tc4 Titanium Alloy Y-section Profile. Journal of Materials Research and Technology, 2025;39:1585-1598.
  • VerticalNews. Researchers detail new data in Technology - Materials Research. November 4, 2025.
  • Wangqing Wu, et al. Target Materials Research. Mathematics Week. November 4, 2025; p 3788.

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