Study On Defect Monitoring Technology Of Precision Copper Casting And Rolling Process

During the casting and rolling process of the precision copper,it is challenging to avoid defects.If the defects can be monitored in real time,the stability and controllability of the process and product quality can be greatly improved,and the foundation for the real-time control of defects can be established.On-line monitoring of solidification microstructure and geometrical defects is of great significance to copper casting and rolling production and is one of the key problems to reduce cost and increase efficiency in copper casting and rolling production.This paper takes TP2 copper tube as an example,takes numerical simulation as the basic research method,combines off-line calculation with online calculation,and conducts a series of research on the defect monitoring technology of precision copper casting and rolling process.In order to fully understand the key physical processes of copper tube horizontal continuous casting,an off-line numerical model of the flow and heat transfer processes of copper tube horizontal continuous casting was established.The characteristics of fluid flow and temperature distribution in horizontal continuous casting of copper tube were analyzed according to the results of the model calculation.The graphite model temperature measurement experiment was carried out in the production site,and the parameters of the current model were checked according to the results of the temperature measurement experiment,which realized the high coincidence between the calculated results of the model and the measured data.In order to predict the solidification structure of copper tube billet,an off-line numerical model of the solidification process of horizontal continuous casting was established.Since the accuracy of solidification structure calculation depends on heat transfer calculation,the accuracy of heat transfer calculation of current model is verified according to the calculation results of flow and heat transfer model.In order to make sure that the current model can accurately calculate the solidification structure of the copper tube billet,the accuracy of the solidification structure calculation of the current model is verified according to the actual solidification structure of the copper tube billet.A finite-difference model of steady-state heat transfer in the continuous horizontal casting of copper tube is established,and the corresponding online calculation program is developed.The online calculation program provides the software basis for online prediction of solidification structure of copper tube billet.In order to ensure that the online calculation program can accurately calculate the steady temperature field of copper tube horizontal continuous casting,the accuracy of heat transfer calculation of the current program was verified according to the calculation results of the flow and heat transfer model.In order to predict the deformation evolution of the geometrical defects of copper tube billet before the spinning rolling process,an off-line numerical model for deformation and heat transfer of copper tube in three-roll rolling was established.Based on the model calculation results,the deformation and temperature distribution characteristics of three-roll rolling of copper tube are analyzed.Based on the current model,the deformation evolution characteristics of the internal defects of copper tube billet were analyzed,and the prototype program for online prediction of the deformation size of the copper tube billet geometric defects was developed based on the particle tracing method.