Research On Energy Consumption Modeling And Optimization Of Aluminum Profile Extrusion Process Based On Genetic Algorithms

Aluminum extrusion is a high energy-consuming industry,which is the key industry of energy saving and emission reduction in China.Energy consumption cost has become an important obstacle to the development and upgrading of enterprises such as aluminum processing.Energy efficiency optimization of aluminum profile production process and production process has attracted more and more attention of aluminum profile industry in the world.Existing research on extrusion energy consumption of aluminum profiles mainly focuses on energy consumption of extrusion process or extrusion deformation,and seldom studies the influence of die structure on energy consumption of extrusion process.Aiming at the influence of die structure on energy consumption in extrusion process,this thesis took rectangular hollow aluminum profile extrusion as an example.Firstly,the energy consumption model of extrusion process was established,and then the relevant parameters of extrusion process were obtained by numerical simulation.Combining the two parameters,studied the influence of three groups of die structure parameters on energy consumption in extrusion process,including welding chamber depth,working band length and angle of welding angle.Finally,based on genetic algorithm,a multi-objective optimization model of die structure parameters was established,and the optimal combination of die structure parameters was obtained,and a comparative analysis was made.The main contents of this paper are as follows:(1)Energy consumption analysis and modeling.The characteristics of metal flow in extrusion process were studied,and the energy transfer form and the distribution of transformation were analyzed.According to the analysis,the energy consumption in extrusion process of aluminum profiles was mainly metal plastic deformation energy consumption,friction energy consumption and heat exchange energy consumption,and the related energy consumption models were established.Finally,the energy consumption of extrusion process is related to the extrusion process parameters,die structure parameters,profile style and material characteristics.(2)Establishment of finite element analysis model.The finite analysis model of rectangular hollow aluminum profile was established by using HyperXtrude software based on ALE finite element method.After that,the die structure parameters were analyzed,and three groups of main parameters such as welding chamber depth,welding angle and working band length were selected.Combined with finite element simulation and energy consumption model,the influence of these three groups of parameters on energy consumption in extrusion process was studied.(3)Establishment of multi-objective optimization model.Taking rectangular hollow aluminum profile as an example,a multi-objective optimization model of die structure parameters,energy consumption in extrusion process and profile quality was established based on genetic algorithm,aiming at uniform profile cross-section velocity distribution(profile quality)and minimum energy consumption in extrusion process.The optimum combination of die parameters was found by optimizing the die structure parameters.The comparison analysis showed that the speed difference rate of profile section was reduced by 30%,and the energy consumption of extrusion process was reduced by 10%.It has certain guiding significance for the selection of die parameters in profile extrusion production.