Ural Federal University named after the first President of Russia B. N. Yeltsin, Ekaterinburg, Russia

O. M. Ogorodnikova, Assistant Professor of a Chair “Electronic Engineering”, Head of Technological Center of Computer Engineering, e-mail: O.M.Ogorodnikova@bk.ru

Laboratoty of Foundry, “Ural Institute of Metals” JSC, Ekaterinburg, Russia

D. G. Ryabov, Researcher
V. S. Radya, Head of Laboratory

The urgency of this work is conditioned by the need to introduce modern CAD/CAE/CAM technologies into daily projection practice of metallurgy. The significance of computer methods to simulate and to investigate the digital models of the projected products is increasing in researcher world. By means of Computeraided Engineering Software we analyzed the cast molds used in Sredneuralsky Copper Smelter to produce the blister copper ingots. For this purpose the boundary conditions of heat transfer were formulated and verified by temperature measurements for the interface surfaces “mold – ingot”, “mold – environment”, “ingot – environment”. According to the verified model of nonstationary heat transfer the temperature fields in the mold during the crystallization of blister copper were computed. The algorithm of combined analysis of temperature fields and stress-strain states was created. On the layered finite-element mesh the computation model was realized to estimate the distortion and cracking of molds in operating regime. On the stage of stress and fracture analysis the previously calculated non-uniform temperature fields were applied to the mold as thermal loads to compute the internal stresses and residual strains. The results of computer simulations were used to optimize the design of the mold. The pilot batch of optimized molds was produced and tested in the plant conditions. The increase of the mold resistance by 15% was revealed during the production testing. More over, the distortion of walls and bottom didn’t propagate after 200 fillings. Thus, the computer simulation of the cast mold under thermal loading due to solidification of blister copper ingot is an effective tool to improve the technological processes.

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