Paper Titles
Preface
Mechanical Evaluation of 6060 Aluminum Alloy under Elevated Extrusion Ram Speed Using Liquid Nitrogen Die Cooling
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An Experimental Investigation of the Effect of Compression Calibration on the Ductility of AA6061 Extrusions
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Numerical Investigation of Round Profile Production: A Fem-Based Comparison between Friction Stir Extrusion and Conventional Extrusion
p.25
Compensating Property Fluctuations in Cold Extrusion Using Adaptive Dies
p.35
Lightweight Battery Housings from Thin-Walled, Large-Scale Aluminum Profiles by Hot Extrusion
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Calibrating a Lode-Parameter-Dependent Damage Evolution Equation to Cold Extrusion Experiments
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Effect of Chemical Composition on Hot Extrudability and Tribological Behavior of 7000 Series Aluminum Alloys
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Using Tungsten Inert Gas Welding Equipment to Locally Heat Tubes and Achieve Inhomogeneous Thickness in Tube Sinking Processes
p.83

Compensating Property Fluctuations in Cold Extrusion Using Adaptive Dies

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Abstract:

This study investigates an adaptive die concept for cold extrusion that actively modulates radial preload during the main forming and ejection phases. A Gaussian process regression (GPR) surrogate, trained on fewer than 400 finite-element simulations, provides a highly data-efficient model capable of accurately predicting geometric tolerances, residual stresses, and process forces. Experimental spot measurements validate the physical trends captured by the surrogate, demonstrating reliable reproduction of the underlying mechanical interactions. The results show that increased preload during forming enables micrometer-level calibration of final diameters, while higher preload during ejection promotes beneficial compressive residual stresses at the cost of elevated ejector forces. A part-to-part control strategy effectively improves accuracy by independently steering two target properties through separate preload adjustments. Furthermore, a reinforcement learning-based controller, enhanced by flow stress estimates derived from hardness measurements, reduces variance and compensates for stochastic fluctuations in material and friction conditions. Overall, the adaptive die system, combined with surrogate-and RL-based control provides a robust foundation for achieving high dimensional precision and stable product properties under future variability scenarios, such as green steel and sustainable lubrication systems.

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Periodical:

Key Engineering Materials (Volume 1048)

Pages:

35-50

DOI:

https://doi.org/10.4028/p-gzNY4X

Citation:

Cite this paper

Online since:

April 2026

Authors:

Christian Siedbürger*, Peter Groche

Keywords:

Adaptive Tooling, Adjustable Dies, AI Surrogate, Cold Extrusion, Dimensional Accuracy

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Creative Commons CC BY 4.0

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* - Corresponding Author

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