In this paper, finite volume method (FVM) is adopted to simulate complex irregular aluminum profile extrusion process. The basic theory of FVM, the materials model, friction model, and a computer aided optimization (CAO) model based on orthographic experiments, artificial neural network (ANN) and genetic algorithm (GA) are presented. A complex aluminum profile extrusion is simulated and optimized. The results show FVM simulation is a good way for the description of material flow, and mesh distortion could be avoided effectively. Optimal values of multi parameters are also obtained. Experiment shows good fit among the simulation, optimization and the experimental results.