Data Analysis And Theoretical Simulation Of Continuous Casting And Rolling Copper Rod And Its Optimization Of Deep Processing Production Line

Copper has remarkable advantages such as high thermal conductivity,good ductility,and good electrical conductivity,and is widely used in the fields of electric power,military industry,communications,and transportation.Continuous casting and rolling is the representative production method for copper rods and wire and cable.However,the technical processing theory is weak and the level of intelligent control is low.In this paper,based on the full analysis of the on-site working conditions of SCR copper rod continuous casting and rolling production line,from the perspective of the whole production line,the factors affecting the quality of copper rod products are systematically studied by means of simulation and effective optimization measures are proposed,while the drawing process of copper rod deep processing line is combined with the simulation model to optimize the drawing process is studied,the main research content is as follows:According to the theoretical basis of copper rod melting and casting principle and wire rod continuous casting technology,the key processes and control parameters of the SCR3000 continuous casting and rolling production line,such as raw material composition control,shaft furnace melting,five-wheel continuous casting machine continuous casting and ten-stand continuous rolling,were analyzed and the relevant process data generated in each link or process were systematically mined.The impact of raw material components on the quality of copper rod products,etc.was analyzed,and the key technical points for producing high-quality bright copper rods from complex copper raw materials were proposed to test the raw materials and establish files,and to optimize the ratio of different raw materials according to the characteristics of the elemental ratios of different batches of raw materials;key process control points such as combustion system and casting system were analyzed,and control optimization measures were proposed;for the collection of rolling mill at each station in the continuous rolling system Data analysis,process optimization control points are given.Through on-site data collection and management work,a large amount of quantitative data in SCR3000 continuous casting,rolling and deep processing line is obtained,which provides data support for the establishment of theoretical models of key processes.ANSYS finite element analysis software is applied to construct a heat-force coupled finite element model based on heat transfer theory and solidification theory to simulate and analyze the relationship between macrostructure formation and microstructure evolution of copper billet casting in the crystallization cavity of continuous casting,and based on the simulation results to objectively and realistically show the formation process of solidification organization of billet casting,explain the formation mechanism of defects such as porosity and inclusions in copper billet casting,and provide quality control The key issues are analyzed and optimized.The finite element model of hot rolling deformation of copper rod is constructed by DEFORM software,and the variation of stress field,strain field,temperature field and damage field of each pass is analyzed.According to the constructed model using numerical simulation analysis,the amount of plastic deformation and plastic damage mode of copper billets are determined,and the reasons for the adhesion of copper billets and rolls are explored.At the same time,the rolling state change behavior and the rolling microstructure evolution law corresponding to each process parameter are studied,and specific continuous rolling process improvement measures are proposed in conjunction with the production reality.The correctness of the improved process parameters was verified through tests to improve the quality of the finished copper rod products.According to the characteristics and theoretical basis of the drawing deep processing production line,the finite element analysis model of the drawing process of copper rod deep processing is constructed based on DEFORM software,and the field working conditions are simulated and analyzed,the key issues of the drawing process are proposed,the optimum values of the stress and strain fields of the die structure design are obtained,the corresponding improvement measures are proposed,and the results are verified by the analysis of typical broken wire morphology and simulation results.Combined with the actual production,the optimization improvement measures from raw material quality,equipment mold structure,drawing process parameters,lubricants and other key aspects are proposed,and the best process parameters are verified and determined by means of experiments to reduce the wire breakage rate.