Aiming to the serious earing defect at the wide edge of aluminum controller housing formed in the extrusion process, the forming process of initial trial for the controller housing was simulated by DEFORM-3D.From the shape and dimension the final part, the simulation results showed a good agreement with the actual experiment results, and the earing phenomena was properly simulated.Base on the simulation results, it is easy to find that the non uniform velocity of metal flow is the main cause leading to the earing defect.According to the above analyses, a novel process scheme which tries to improve the status of material flow by using a punch with a group of resistance ribs was put forward.For further study, the orthogonal experiment method was adopted to optimize the novel process.The width of the rib d, the thickness of the rib t, the length of the longest rib L and the inclination angle α were selected as the design variables, and the height difference Ah along the top edge of the controller housing extrusion which could reflect the earing phenomena was determined as the optimized objective, and the optimized scheme was obtained finally.Compared with the initial trial process, the optimized scheme could reduce the height difference from 14.09 mm to 3.32 mm and the earing defects have been obviously improved.This optimization will provide the following implementation of the improved process with specific tool design parameters.