Lightweighting Study of Rotary Kiln Cylinder Structure Based on Response Surface

Abstract

To achieve the lightweight design of the rotary kiln cylinder, reduce its manufacturing costs, and improve its mechanical properties, the maximum stress and deformation were determined through a static and thermal structural analysis of the rotary kiln equipment. Employing the Box-Behnken response surface method, an optimization of the rotary kiln cylinder structure was performed, with the aim of minimizing the cylinder mass and deformation, while considering constraints such as cylinder thickness and yield strength. A multi-objective optimization mathematical model was established, and three sets of Pareto solutions were obtained using a multi-objective genetic algorithm. The optimized design of thickness structure was determined for the stall section, transition section, and cylinder section of the rotary kiln. The finite element method was utilized to simulate the optimized solutions and verify their validity and accuracy. The results showed that the rotary kiln cylinder mass was reduced by 13.8%, and the maximum deformation under static structural conditions was reduced by 4.6%, while maintaining the strength requirement of the structural stiffness. The relevant geometric parameters of the optimal solution were verified by finite element numerical tests, and the optimized cylinder mass, maximum stress and deformation under static structural conditions, and maximum deformation and stress under thermal structural coupling were in good agreement with the numerical test results, with a deviation of less than 2%. Additionally, this study realized the lightweight design of the rotary kiln cylinder and provided useful references for the thickness design of the rotary kiln cylinder.