Numerical Simulation Research On The Temperature And Stress Field Of The Anode Copper Mold During Mouldingdie Casting

In order to meet the Isaac electrolysis needs of the NO.9 and NO.10 which new build, Yunnan Copper Limited Company re-designed anode plate mold, which called copper mold. First of all, six ordinary casting experiments carried out using the existing equipment and technology, and several copper molds were produced.This copper mold takes on the following feature:working face is not smooth enough, loosing densification and bubbles and cracks are easy to generate.Except the ordinary casting, the mouldingdie casting method has applied in the manufacture of anode copper mold, which can reduce the bubbles and cracks on the surface and decrease the surface roughness.The upper die and die-axis connect into a overall body, after the liquid copper was poured into the mould and the upper die was pressed into the mould, so the time which the upper die contact the high temperature liquid copper is very short, and avoid the erosion of liquid copper. These will longer the life of the upper die.With reference to the die-casting equipment of foreign corporation, Yunnan Copper Limited Company developed a large semi-open mouldingdie casting method to produce pure copper moldcombining with their actual production condition. The aim is to improve the quality and lifespan of the copper mold.Numerical simulation of casting process is the frontier of academic development, which has entered the stage of practical engineering. Numerical simulation of stress field in the solidification process can help engineers to predict a variety of possible defects including its size, location and occur time in the design stage of casting effectively to optimize the casting process, ensure the casting quality, shorten production cycle and reduce production costs.Large semi-open mouldingdie casting process was simulated by the numerical simulation method, then temperature field of copper mold and mouldingdie casting mold and distribution of stress field was studied and the defect was analyzed and forecasted, which would provide a scientific basis for the actual production.The paper illustrated research generality of the temperature field and stress field of numerical simulation technology in the casting and the basic methods of numerical simulation. The mathematical model of the transient temperature field and thermal elastic-plastic stress field in the solidification process was established because the article analyzed the finite element theory about thermal analysis and stress calculation in the numerical simulation The paper introduced large semi-open copper mold pressure casting for the study object, selected large-scale finite element software ANSYS, established a three-dimensional finite element model through the reasonable simulation assumptions, set the initial and boundary conditions, successed in application load, carried on the numerical simulation of three-dimensional temperature field and stress field to copper mold castings and mouldingdie casting.The results of simulation calculation reflected splendidly the cooling process of three-dimensional temperature field of the copper mold and mouldingdie casting and stress field and the dynamic changes of temperature and stress field, analyzed results of temperature and stress field in detail, predicted the copper mold and mouldingdie casting solidification defects inculding cooling, cracks and deformation in the casting process, improved properly mouldingdie casting for possible occur defects and combined final simulation analysis results after technology process was improved and the actual production.