| In the current development of nonferrous industries,copper products occupy an essential position in many industries,such as power cable,home appliances,and real estate.By 2018,the refined copper consumption in China accounts for about 50% of the world market.A large amount of the refined copper depends on imports,which seriously restricts the development of China’s copper industry and various basic industries.To date,most of the refining methods in China are electrolytic methods,which use electrolytic refining processes to produce refined copper.The design of copper anode plates is one of the most important steps in the overall refining processes.Previously,due to the economic constraints,most copper smelting enterprises used the disc casting machines and small plate production processes.In the past decade,some domestic copper smelting companies,such as Guixi Copper,imported the advanced large plate production technologies and processes,and made certain progress internationally.As a new equipment,the copper vertical mold casting machine has been proved to be applicable by theoretical research and market research.Its production efficiency is more than three times higher than the existing equipment.However,the usage of copper vertical mold casting machine is still in experimental stage.Therefore,this project put forward the topic of "analysis of the influence of copper vertical mold casting cooling on the microstructure performance of the anode plate and the research on the fracture mechanism of the lug plate".We took the copper vertical die casting process for the production of copper anode plate as the research object,and the vertical die casting machine design as the main line.The aim was to improve the quality and yield of refined copper.With the aid of the three-dimensional fluid mass transfer theory and the plastic deformation theory in metal solidification process,we systematically studied the cooling curve and principle of copper vertical mold casting process and established the mathematical models of three kinds of cooling channel design for casting machines,namely hollow type,single cycle and double cycle water cooling systems,respectively.The flow state and the velocity were simulated by ANSYS software.Based on the design of the water-cooling system,we analyzed the steady-state temperature field,transient temperature field and thermal stress.Then,the numerical simulation of the anode plate casting process was carried out by Anycasting software.The solidification time and casting defects were also analyzed by cloud images.Results showed:1)The double-turn water cooling system has a better cooling effect.According to the numerical simulation results,the water flow of the doublerotating water-cooling system is more stable,the flow rate is uniform,and there is no dead water zone,which is the same as the practical application effect.2)The design mode of the water cooling system,the temperature of the cooling water and the temperature of the casting have a significant influence on the casting temperature and time,and basically show a positive correlation.Therefore,in a reasonable interval,the cooling water temperature and the casting temperature should be reduced as much as possible to save time.,quality improvement.3)Funnel type auxiliary gate is better.According to the numerical simulation results,the funnel-type auxiliary gate can improve the quality of the copper anode plate,reduce defects and looseness,and reduce the vibration of the copper liquid in the mold when casting the copper liquid,and improve the service life of the vertical mold casting machine.In conclusion,the relevant conclusions of this study can provide a corresponding design reference for copper smelting enterprises,improve the quality of refined copper,and provide theoretical basis for the vertical mold casting machine manufacturers in the process of equipment development,development and design. |
