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The design variable progressive optimization method based on RSA was proposed and applied to optimize the shape of 2-piece aluminum beverage bottle bottoms. On the basis of sensitivity analyses, the most effective dimensions are selected as design variables in the first stage design optimization, while the dimensions with relatively small influences are optimized in the secondary stage. In the design optimization of the bottom, the column strength was maximized, the bulge strength was restricted to fall into a range, and the maximum bottom growth and the axial displacement of sidewall constrained.
