Precise punch forming process for anode carbon block

Abstract

The invention belongs to the technical field of anode carbon block punch forming, and particularly relates to an anode carbon block precision punch forming process which comprises the following steps: raw material pretreatment and intelligent mixing: petroleum coke and pitch coke are selected as aggregates, coal pitch is selected as a binder, and the aggregates are subjected to size grading screening and matched according to a preset proportion; an intelligent mixing system is adopted to mix the raw materials, the proportion, the temperature and the humidity of each component in the mixture are monitored in real time, and the addition amount and the mixing speed of each component are automatically adjusted; carrying out preheating treatment on the mixture; in the raw material pretreatment stage, the aggregate is subjected to surface modification treatment, for example, a silane coupling agent is used as a modifier, so that a coating with activity is formed on the surface of the aggregate, the bonding strength of the aggregate and a binder is greatly improved, and the bonding strength is improved by 30% compared with that of an unmodified aggregate through detection. By means of the improvement, the internal structure of the anode carbon block is more compact in the subsequent stamping, roasting and other processes, and internal defects are reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of anode carbon block stamping and forming, and in particular to a precision stamping and forming process for an anode carbon block. Background Art

[0002] In the electrolytic aluminum industry, anode carbon blocks are key components of electrolytic cells. Their performance and quality play a vital role in the efficiency, cost, and product quality of electrolytic aluminum production. High-quality anode carbon blocks not only improve current efficiency and reduce energy consumption, but also reduce anode carbon block consumption, extend the service life of the electrolytic cell, and thus reduce the overall cost of electrolytic aluminum production.

[0003] However, in the traditional anode carbon block preparation process, the treatment of aggregates is usually relatively simple, and there is a lack of effective surface modification methods. This results in insufficient bonding strength between the aggregate and the binder, which can easily lead to loose internal structures and internal defects in the anode carbon blocks during subsequent stamping and roasting processes. For example, in the electrolytic aluminum production process, defects inside the anode carbon blocks can lead to uneven current distribution, reduce current efficiency, increase the resistivity of the anode carbon blocks, and increase power consumption. In addition, insufficient bonding strength can also make the anode carbon blocks prone to falling off and pulverization during use, shortening the service life of the anode carbon blocks.

[0004] Furthermore, traditional stamping processes often use single pressure and time parameters for stamping, making it impossible to adjust in real time based on the state of the paste and changes in the stamping process. This not only leads to low stamping efficiency, but also makes it difficult to ensure the uniformity of the density and internal quality of the anode carbon blocks. In actual production, due to inaccurate control of stamping pressure and time, problems such as uneven density, internal pores, and cracks in the anode carbon blocks often occur. These problems can seriously affect the performance of the anode carbon blocks, reducing their compressive strength and thermal shock resistance, making them susceptible to damage during the electrolytic aluminum production process and increasing production costs. At the same time, traditional stamping die design also has certain limitations. The mold material has poor wear resistance and fatigue resistance, and is prone to wear and deformation during long-term use, resulting in a decrease in mold precision and affecting the molding quality of the anode carbon blocks. Moreover, the mold lacks adaptive adjustment capabilities and cannot automatically adjust its shape and size according to different stamping conditions, further limiting the improvement of the anode carbon block quality.

[0005] Finally, in the demoulding process, traditional demoulding methods often make it difficult to accurately control the demoulding force and demoulding speed, which can easily cause the anode carbon blocks to be damaged during the demoulding process and reduce the yield rate; in terms of post-processing, the control of the roasting and cooling processes is not precise enough. The heating rate and holding time of the traditional roasting process are difficult to accurately adjust according to the characteristics of the paste, resulting in the volatile matter in the paste not being fully volatilized and the internal structure of the anode carbon block being uneven. During the cooling process, improper control of the cooling rate will cause greater stress inside the anode carbon block, reducing its thermal shock resistance, resulting in problems such as cracking during use. These problems cause the performance indicators of the anode carbon block after post-processing to fluctuate widely and have poor quality stability, making it difficult to meet the high quality and high stability requirements of electrolytic aluminum production for anode carbon blocks. To this end, we provide a precision stamping process for anode carbon blocks. Summary of the Invention

[0006] In order to solve the above problems, the present invention proposes a precision stamping process for an anode carbon block, so as to more accurately solve the problems raised in the above background technology.

[0007] The present invention is achieved through the following technical solutions: The invention proposes a precision stamping process for anode carbon blocks, comprising the following steps: Raw material pretreatment and intelligent mixing: Petroleum coke and asphalt coke are selected as aggregates, and coal tar is used as a binder. The aggregates are screened by particle size classification and mixed according to preset proportions. An intelligent mixing system is used to mix the raw materials, monitoring the proportions, temperature, and humidity of the components in the mixture in real time, and automatically adjusting the addition amount and mixing speed of each component. The mixture is preheated to a temperature 70-80°C higher than the softening point of the binder and controlled at 180-190°C. During the preheating process, the aggregate surface is modified to form an active coating on the aggregate surface. Innovative mold design and preparation: A new precision stamping mold is designed, consisting of an upper mold, a lower mold, and side molds. The mold is made of high-strength, wear-resistant materials. Multiple adaptive adjustment columns are installed inside the mold. These columns are made of intelligent materials and can automatically adjust their shape and size according to pressure and temperature changes during the stamping process. A microporous structure is set inside the mold, and gas diversion grooves connected to the microporous structure are set on the side mold and lower mold of the mold. The mold adopts a modular design, and each component can be disassembled and quickly replaced. Multi-stage stamping and intelligent control: The mixed paste is injected into the mold, and a multi-stage stamping process is adopted. The stamping process is divided into initial pre-pressing, intermediate pressurization and final forming stages. The pressure and time of each stage are precisely controlled according to the specifications and requirements of the anode carbon block. An intelligent control system is used to monitor and control the stamping process in real time. Sensors are used to obtain parameters such as pressure, displacement and temperature during the stamping process in real time, and the pressure, speed and stroke of the stamping machine are automatically adjusted. Dynamic vibration-assisted forming technology is combined in the stamping process. A vibration motor is installed at the bottom of the mold to dynamically adjust the vibration frequency and amplitude according to the stamping stage and the properties of the paste. Demolding and post-processing optimization: Use an intelligent demoulding system for demoulding, and automatically adjust the demoulding force and demoulding speed according to the shape and size of the anode carbon block; the surface of the green carbon block after demoulding is treated and strengthened, and the surface of the green carbon block is roughened by sandblasting or chemical etching, and a layer of silicon carbide protective coating is applied to the surface of the green carbon block; the green carbon block is precisely roasted, using a staged heating roasting process, and slowly cooled after roasting. The cooling rate is accurately adjusted by controlling the flow and temperature of the cooling medium.

[0008] Furthermore, in the raw material pretreatment and intelligent mixing steps, the surface modifier used for surface modification of the aggregate is an organic compound containing active functional groups, which can chemically react with the aggregate surface during the preheating process to form an active coating.

[0009] Furthermore, in the innovative mold design and preparation steps, the high-strength and wear-resistant material used in the mold is chromium-molybdenum alloy steel, which has a hardness of not less than HRC50 and has good fatigue resistance.

[0010] Furthermore, in the innovative mold design and preparation steps, the number of adaptively adjustable columns set inside the mold is 4-8, the initial shape of the columns is a cylinder or a prism, and the cross-sectional area gradually decreases from the upper bottom surface to the lower bottom surface.

[0011] Furthermore, in the innovative design and preparation steps of the mold, the micropore diameter of the microporous structure is 0.3-1 mm, the distribution density is 10-25 per square centimeter, and the micropores are evenly or unevenly distributed inside the mold. When unevenly distributed, the design is optimized according to the shape and stress conditions of the anode carbon block.

[0012] Furthermore, in the multi-stage stamping and intelligent control steps, the initial pre-pressing pressure is 4-6 MPa, and the pre-pressing time is 10-15 seconds; the intermediate pressurizing pressure gradually increases to 13-18 MPa, and the pressurizing time is 20-30 seconds; the final forming pressure is 18-22 MPa, and the pressing time is 30-40 seconds; in the dynamic vibration-assisted forming technology, the vibration frequency is 45-55 Hz, and the amplitude is 1-2 mm.

[0013] Furthermore, in the multi-stage stamping and intelligent control steps, the sensors used by the intelligent control system include pressure sensors, displacement sensors and temperature sensors. The accuracy of the pressure sensor is not less than ±0.1MPa, the accuracy of the displacement sensor is not less than ±0.01mm, and the accuracy of the temperature sensor is not less than ±1°C.

[0014] Furthermore, in the demoulding and post-processing optimization steps, the demoulding force control accuracy of the hydraulic or pneumatic device used by the intelligent demoulding system is not less than ±5%, and the demoulding speed control accuracy is not less than ±10%.

[0015] Furthermore, in the demolding and post-processing optimization steps, in the precise calcination process, the staged temperature increase calcination process is specifically as follows: first, the temperature is increased to 750-800°C at a rate of 40-50°C per hour, and the holding time is 2-4 hours; then, the temperature is increased to 1150-1250°C at a rate of 25-30°C per hour, and the holding time is 20-26 hours.

[0016] Furthermore, in the demoulding and post-processing optimization steps, the cooling rate of the slow cooling is 15-20°C per hour. After cooling to room temperature, the volume density of the anode carbon block is not less than 1.55g / cm³, and the resistivity is not higher than 60μΩ·m.

[0017] Beneficial effects of the present invention: The present invention performs surface modification on the aggregate during the raw material pretreatment stage, such as using a silane coupling agent as a modifier, so that an active coating is formed on the surface of the aggregate, which greatly improves the bonding strength between the aggregate and the binder. Testing shows that the bonding strength is 30% higher than that of the unmodified state. This improvement makes the internal structure of the anode carbon block tighter during subsequent stamping, roasting and other processes, and reduces the occurrence of internal defects. During the stamping process, a combination of multi-stage stamping and intelligent control is adopted, combined with dynamic vibration-assisted forming technology, so that the density uniformity of the anode carbon block is improved by 25% compared with the traditional process, and the internal defect rate is reduced by 30%. The final formed anode carbon block has a volume density of 1.58g / cm³, a resistivity of 55μΩ·m, and a compressive strength of 35MPa. These performance indicators meet or exceed the advanced level of the industry, and can better meet the high requirements of electrolytic aluminum production for anode carbon blocks, thereby improving the efficiency and quality of electrolytic aluminum production.

[0018] The present invention ensures the stability and efficiency of the stamping process by enabling the intelligent control system to monitor and adjust stamping parameters in real time during the stamping process. The multi-stage stamping process precisely controls pressure and time according to the different stamping stages, reducing unnecessary energy consumption and time waste, and shortening the stamping cycle by 15%-20%. At the same time, the new precision stamping die is made of high-strength, wear-resistant materials (such as chromium-molybdenum alloy steel), and is equipped with adaptively adjustable columns and microporous structures inside, which improves the wear resistance and fatigue resistance of the die. After actual use tests, the die can still maintain high precision and stability after 1,000 consecutive stamping cycles, with the die wear less than 0.1mm, and the service life is extended by more than 30% compared to traditional dies. This not only reduces the cost of die replacement, but also reduces the production interruption time caused by die replacement, thereby improving overall production efficiency.

[0019] The present invention uses an intelligent demoulding system to automatically adjust the demoulding force and demoulding speed according to the shape and size of the anode carbon block, avoiding the problem of damage to the anode carbon block caused by excessive or insufficient demoulding force in the traditional demoulding method, and the demoulding success rate reaches more than 99%. In terms of surface treatment, the surface of the raw carbon block is roughened by sandblasting or chemical etching, and a silicon carbide protective coating is applied to enhance the surface performance and corrosion resistance of the anode carbon block. The precise roasting treatment adopts a staged heating process to fully volatilize the volatile matter in the paste, fully sinter the anode carbon block, and make the internal structure more uniform. The slow cooling process reduces the internal stress of the anode carbon block and improves its thermal shock resistance by precisely controlling the cooling rate. According to testing, the performance indicators of the anode carbon block after post-treatment have a small fluctuation range, high quality stability, and the yield rate is about 20% higher than that of the traditional process, which has brought significant economic benefits to the enterprise. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 The figure is a schematic diagram of the stamping process flow of an embodiment of the present invention. DETAILED DESCRIPTION

[0021] In order to more clearly and completely illustrate the technical solution of the present invention, the present invention will be further described below with reference to the accompanying drawings.

[0022] like Figure 1 As shown, an embodiment of the present invention provides a precision stamping process for anode carbon blocks: Raw material pretreatment and intelligent mixing: Petroleum coke and asphalt coke are selected as aggregates. Vibrating screens are used for particle size classification. Petroleum coke and asphalt coke are screened to select particles within different size ranges (e.g., 0-5mm, 5-10mm, 10-15mm, etc.) and mixed according to preset proportions (e.g., 70% petroleum coke, 30% asphalt coke). An intelligent mixing system is employed, equipped with a high-precision electronic scale and sensors to monitor the proportions, temperature, and humidity of the mixture in real time. If the monitored proportion of a component deviates by more than ±1%, the system automatically adjusts the addition of that component. When the temperature falls below the set range (180-190°C), the system accelerates the heating rate. When the humidity is too high, the system activates ventilation to reduce the humidity. The mixing speed is automatically adjusted within a range of 20-50 rpm based on real-time monitoring data. The mixture is preheated at 185°C. During the preheating process, an organic compound containing active functional groups (such as a silane coupling agent) is added to the mixture as a surface modifier. The mixture reacts at 185°C for 30 minutes, forming an active coating on the aggregate surface. Testing shows that the modified aggregate surface activity is significantly increased, and the bond strength with the binder is 30% higher than that of the unmodified aggregate.

[0023] Innovative Mold Design and Preparation: A new precision stamping mold was designed. Made of chromium-molybdenum alloy steel with a hardness of HRC52 and excellent fatigue resistance, the mold consists of an upper mold, a lower mold, and side molds. Six adaptively adjustable cylinders, made of shape-memory alloy, are installed within the mold. These cylinders have an initial cylindrical shape, with a cross-sectional area that gradually decreases from the upper base to the lower base. A microporous structure is incorporated within the mold, with a diameter of 0.5 mm and a density of 15 per square centimeter. The micropores are evenly distributed throughout the mold. Gas flow channels, 2 mm wide and 1 mm deep, are installed in the side and lower molds, connecting to the microporous structure. The channel design utilizes a modular design, with bolted components for quick disassembly and replacement. Field testing has shown that the mold maintains high precision and stability after 1,000 consecutive stamping cycles, with wear of less than 0.1 mm.

[0024] Multi-stage stamping and intelligent control: The kneaded paste is injected into the mold using a multi-stage stamping process. The initial pre-pressing pressure is 5 MPa, and the pre-pressing time is 12 seconds. The intermediate pressure is gradually increased to 15 MPa, and the pressing time is 25 seconds. The final pressing pressure is 20 MPa, and the pressing time is 35 seconds. An intelligent control system is used, equipped with pressure sensors, displacement sensors, and temperature sensors. The pressure sensor has an accuracy of ±0.05 MPa, the displacement sensor has an accuracy of ±0.005 mm, and the temperature sensor has an accuracy of ±0.5°C. These sensors capture real-time parameters such as pressure, displacement, and temperature during the stamping process. If the pressure deviates from the set value by ±0.2 MPa, the system automatically adjusts the press pressure; if the displacement deviation exceeds ±0.02 mm, the system adjusts the press stroke; and if the temperature exceeds the set range by ±2°C, the system adjusts the heating or cooling device. Dynamic vibration-assisted forming technology is incorporated into the stamping process. A vibration motor is installed at the bottom of the mold, with a vibration frequency of 50 Hz and an amplitude of 1.5 mm. After testing, it was found that the density uniformity of the anode carbon blocks formed by this process was 25% higher than that of the traditional process, and the internal defect rate was reduced by 30%.

[0025] Demolding and post-processing optimization: An intelligent demolding system is used for demolding. This system utilizes a hydraulic mechanism and high-precision pressure and displacement sensors to control the demolding force and speed. The demolding force and speed are controlled with an accuracy of ±3% and ±8%. The system automatically adjusts the demolding force to 80 kN and the demolding speed to 2 mm / s based on the shape and size of the anode carbon blocks. After demolding, the green carbon blocks undergo surface treatment by sandblasting with 60-mesh quartz sand for 5 minutes to roughen the surface. A protective silicon carbide coating with a thickness of 0.2 mm is then applied to the green carbon blocks. The green carbon blocks undergo precision calcination using a step-by-step heating process: the temperature is first increased at a rate of 45°C per hour to 780°C, held for 3 hours, and then increased at a rate of 28°C per hour to 1200°C, held for 24 hours. After calcination, the blocks are slowly cooled at a rate of 18°C ​​per hour to room temperature. After testing, the volume density of the anode carbon block after post-treatment is 1.58g / cm³, and the resistivity is 55μΩ·m. The performance indicators have reached the advanced level in the industry.

[0026] Furthermore, during the raw material pretreatment and intelligent mixing steps, a silane coupling agent (KH550) was used to modify the aggregate surface. During the preheating process, the silane coupling agent was added to the mixture at a rate of 1% by weight of the aggregate and reacted at 185°C for 30 minutes. Fourier transform infrared spectroscopy revealed that the silane coupling agent had been successfully grafted onto the aggregate surface, forming a reactive coating. Actual performance testing showed that the bond strength between the modified aggregate and the binder was 30% higher than that of the unmodified aggregate, and the compressive strength of the anode carbon blocks was also increased by 20%.

[0027] Furthermore, during the innovative mold design and preparation steps, the mold was constructed from chromium-molybdenum alloy steel (grade 35CrMo). After quenching and tempering, its hardness reached HRC52. Using a Rockwell hardness tester, five measurements were taken at different locations, and the average hardness deviation was within ±1 HRC. This mold exhibits excellent fatigue resistance. Fatigue testing under simulated production conditions revealed that after 10,000 stamping cycles, the mold showed no cracks or deformation and continued to function properly, ensuring the quality of the anode carbon blocks.

[0028] Furthermore, during the innovative mold design and preparation steps, six adaptively adjustable cylinders were installed inside the mold, made of a shape memory alloy (NiTi alloy). The cylinders initially had a cylindrical shape with a diameter of 10 mm and a height of 20 mm. Their cross-sectional area gradually decreased from the upper base to the lower base, with the upper base diameter being 10 mm and the lower base diameter being 8 mm. During the stamping process, when pressure and temperature change, the cylinders automatically adjust their shape and size within 5 seconds to accommodate varying stamping conditions. Actual use tests have shown that the adaptive adjustment function of these cylinders effectively improves the molding accuracy of the anode carbon blocks, keeping the dimensional deviation of the anode carbon blocks within ±0.1 mm.

[0029] Furthermore, in the innovative design and preparation steps of the mold, the micropores of the microporous structure have a diameter of 0.5 mm and are processed inside the mold by laser drilling technology. The micropore distribution density is 15 per square centimeter, and the pore spacing is 2.5 mm in a uniform distribution manner. The micropores are evenly distributed inside the mold, which is conducive to the uniform discharge of gas in the paste. During the stamping process, the gas is discharged out of the mold through the gas guide groove. After actual use testing, the design of the microporous structure and gas guide groove effectively reduced the pore defects inside the anode carbon block, reducing the porosity of the anode carbon block by 20%.

[0030] Furthermore, in the multi-stage stamping and intelligent control steps, the initial pre-pressing pressure is 5MPa, which is monitored in real time by a pressure sensor. The pressure fluctuation range is controlled within ±0.1MPa, and the pre-pressing time is 12 seconds to ensure the initial forming of the paste. The intermediate pressurization pressure gradually increases from 5MPa to 15MPa, and the pressurization time is 25 seconds. The pressure increase rate is uniform, ensuring further compaction of the paste. The final molding pressure is 20MPa, and the pressing time is 35 seconds, so that the anode carbon block reaches the required density and strength. In the dynamic vibration-assisted molding technology, the vibration frequency is 50Hz, which is monitored in real time by a frequency meter, and the frequency deviation does not exceed ±1Hz; the amplitude is 1.5mm, which is monitored by a displacement sensor, and the amplitude deviation does not exceed ±0.1mm. After testing, the density uniformity of the anode carbon block formed by this process is 25% higher than that of the traditional process, the internal defect rate is reduced by 30%, and the compressive strength of the anode carbon block reaches 35MPa.

[0031] Furthermore, during the multi-stage stamping and intelligent control steps, the intelligent control system utilizes sensors including a pressure sensor (model PT124G-111), a displacement sensor (model KTR-25), and a temperature sensor (model PT100). The pressure sensor has an accuracy of ±0.05 MPa, and in actual use, the pressure measurement error does not exceed ±0.03 MPa. The displacement sensor has an accuracy of ±0.005 mm, and the displacement measurement error does not exceed ±0.003 mm. The temperature sensor has an accuracy of ±0.5°C, and the temperature measurement error does not exceed ±0.3°C. These high-precision sensors provide real-time information on parameters such as pressure, displacement, and temperature during the stamping process. If the pressure deviates from the set value by ±0.2 MPa, the system automatically adjusts the press pressure within 0.5 seconds. If the displacement deviation exceeds ±0.02 mm, the system adjusts the press stroke within 0.3 seconds. If the temperature exceeds the set range by ±2°C, the system adjusts the heating or cooling device within 1 second. This intelligent control system effectively ensures the stability of the stamping process and the quality of the anode carbon blocks.

[0032] Furthermore, in the demoulding and post-processing optimization steps, the hydraulic device used in the intelligent demoulding system controls the demoulding force and demoulding speed through high-precision pressure sensors and displacement sensors. The pressure sensor monitors the demoulding force in real time. When the demoulding force deviates from the set value of 80kN±4kN, the system automatically adjusts the pressure of the hydraulic system within 0.2 seconds, so that the demoulding force control accuracy reaches ±3%. The displacement sensor monitors the demoulding speed in real time. When the demoulding speed deviates from the set value of 2mm / s±0.2mm / s, the system adjusts the flow of the hydraulic system within 0.1 seconds, so that the demoulding speed control accuracy reaches ±8%. After actual use testing, the intelligent demoulding system can smoothly and quickly remove the anode carbon block from the mold, avoiding damage to the anode carbon block, and the demoulding success rate has reached more than 99%.

[0033] Furthermore, during the demolding and post-processing optimization steps, a staged temperature increase process was used for precise calcination. The temperature was first raised to 780°C at a rate of 45°C per hour. The temperature was monitored in real time by thermocouples, with a temperature deviation of no more than ±2°C. The temperature was then maintained at 780°C for three hours to fully evaporate the volatile matter in the paste. The temperature was then raised to 1200°C at a rate of 28°C per hour, with a temperature deviation of no more than ±3°C. The temperature was maintained at 1200°C for 24 hours to fully sinter the anode carbon blocks. Testing showed that the anode carbon blocks treated with this calcination process had a uniform internal structure and a reasonable grain size. The volume density of the anode carbon blocks reached 1.58g / cm³, and the resistivity was 55μΩ·m. These performance indicators met the requirements for electrolytic aluminum production.

[0034] Furthermore, in the demoulding and post-processing optimization steps, the cooling rate of slow cooling is 18°C ​​per hour, and precise control is achieved by adjusting the flow rate and temperature of the cooling medium. The cooling medium is nitrogen, and the flow rate and temperature of the nitrogen are monitored in real time by a flow meter and a temperature sensor. When the cooling rate deviates from the set value by ±1°C / h, the system automatically adjusts the flow rate and temperature of the nitrogen within 0.5 seconds. After cooling to room temperature, the anode carbon block is subjected to performance testing. After testing, the volume density of the anode carbon block is 1.58g / cm³ and the resistivity is 55μΩ·m, both of which meet the indicators specified in claim 10. Compared with the anode carbon block treated with the traditional cooling process, the anode carbon block treated with the slow cooling process has smaller internal stress and its thermal shock resistance is improved by 15%.

[0035] Finally, it should be noted that while the basic concepts have been described above, it should be apparent to those skilled in the art that the detailed disclosure is provided merely as an example and does not constitute a limitation of this specification. Although not explicitly stated herein, those skilled in the art may make various modifications, improvements, and revisions to this specification. Such modifications, improvements, and revisions are suggested throughout this specification and remain within the spirit and scope of the exemplary embodiments of this specification. Furthermore, this specification uses specific terms to describe the embodiments of this specification. For example, terms such as "one embodiment," "an embodiment," and / or "some embodiments" refer to a particular feature, structure, or characteristic associated with at least one embodiment of this specification. Therefore, it should be emphasized and noted that references to "one embodiment," "an embodiment," or "an alternative embodiment" two or more times in different places in this specification do not necessarily refer to the same embodiment. Furthermore, certain features, structures, or characteristics of one or more embodiments of this specification may be appropriately combined. Furthermore, unless expressly provided in the claims, the order of the processing elements and sequences, the use of alphanumeric characters, or other designations described in this specification are not intended to limit the order of the processes and methods of this specification.

[0036] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art will be able to modify the technical solutions described in the aforementioned embodiments or substitute equivalents for some of the technical features. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. A precision stamping process for anode carbon blocks, characterized in that: The following steps are involved: Raw material pretreatment and intelligent mixing: Petroleum coke and asphalt coke are selected as aggregates, and coal tar is used as a binder. The aggregates are screened by particle size classification and mixed according to preset proportions. An intelligent mixing system is used to mix the raw materials, monitoring the proportions, temperature, and humidity of the components in the mixture in real time, and automatically adjusting the addition amount and mixing speed of each component. The mixture is preheated to a temperature 70-80°C higher than the softening point of the binder and controlled at 180-190°C. During the preheating process, the aggregate surface is modified to form an active coating on the aggregate surface. Innovative mold design and preparation: A new precision stamping mold is designed, consisting of an upper mold, a lower mold, and side molds. The mold is made of high-strength, wear-resistant materials. Multiple adaptive adjustment columns are installed inside the mold. These columns are made of intelligent materials and can automatically adjust their shape and size according to pressure and temperature changes during the stamping process. A microporous structure is set inside the mold, and gas diversion grooves connected to the microporous structure are set on the side mold and lower mold of the mold. The mold adopts a modular design, and each component can be disassembled and quickly replaced. Multi-stage stamping and intelligent control: The mixed paste is injected into the mold, and a multi-stage stamping process is adopted. The stamping process is divided into initial pre-pressing, intermediate pressurization and final forming stages. The pressure and time of each stage are precisely controlled according to the specifications and requirements of the anode carbon block. An intelligent control system is used to monitor and control the stamping process in real time. Sensors are used to obtain parameters such as pressure, displacement and temperature during the stamping process in real time, and the pressure, speed and stroke of the stamping machine are automatically adjusted. Dynamic vibration-assisted forming technology is combined in the stamping process. A vibration motor is installed at the bottom of the mold to dynamically adjust the vibration frequency and amplitude according to the stamping stage and the properties of the paste. Demolding and post-processing optimization: Use an intelligent demoulding system for demoulding, and automatically adjust the demoulding force and demoulding speed according to the shape and size of the anode carbon block; the surface of the green carbon block after demoulding is treated and strengthened, and the surface of the green carbon block is roughened by sandblasting or chemical etching, and a layer of silicon carbide protective coating is applied to the surface of the green carbon block; the green carbon block is precisely roasted, using a staged heating roasting process, and slowly cooled after roasting. The cooling rate is accurately adjusted by controlling the flow and temperature of the cooling medium.

2. The anode carbon block precision stamping process according to claim 1, characterized in that: In the raw material pretreatment and intelligent mixing steps, the surface modifier used for surface modification of the aggregate is an organic compound containing active functional groups, which can chemically react with the aggregate surface during the preheating process to form an active coating.

3. The anode carbon block precision stamping process according to claim 1, characterized in that: In the innovative mold design and preparation steps, the high-strength and wear-resistant material used in the mold is chromium-molybdenum alloy steel, which has a hardness of not less than HRC50 and has good fatigue resistance.

4. The anode carbon block precision stamping process according to claim 1, characterized in that: In the innovative mold design and preparation steps, the number of adaptively adjusted columns set inside the mold is 4-8, the initial shape of the columns is a cylinder or a prism, and the cross-sectional area gradually decreases from the upper bottom surface to the lower bottom surface.

5. The anode carbon block precision stamping process according to claim 1, characterized in that: In the innovative design and preparation steps of the mold, the micropore diameter of the microporous structure is 0.3-1 mm, the distribution density is 10-25 per square centimeter, and the micropores are evenly or unevenly distributed inside the mold. When unevenly distributed, the design is optimized according to the shape and stress conditions of the anode carbon block.

6. The anode carbon block precision stamping process according to claim 1, characterized in that: In the multi-stage stamping and intelligent control steps, the initial pre-pressing pressure is 4-6 MPa, and the pre-pressing time is 10-15 seconds; the intermediate pressurizing pressure gradually increases to 13-18 MPa, and the pressurizing time is 20-30 seconds; the final forming pressure is 18-22 MPa, and the pressing time is 30-40 seconds; in the dynamic vibration-assisted forming technology, the vibration frequency is 45-55 Hz, and the amplitude is 1-2 mm.

7. The anode carbon block precision stamping process according to claim 1, characterized in that: In the multi-stage stamping and intelligent control steps, the sensors used in the intelligent control system include pressure sensors, displacement sensors and temperature sensors. The accuracy of the pressure sensor is not less than ±0.1MPa, the accuracy of the displacement sensor is not less than ±0.01mm, and the accuracy of the temperature sensor is not less than ±1°C.

8. The anode carbon block precision stamping process according to claim 1, characterized in that: In the demoulding and post-processing optimization steps, the demoulding force control accuracy of the hydraulic or pneumatic device used in the intelligent demoulding system is not less than ±5%, and the demoulding speed control accuracy is not less than ±10%.

9. The anode carbon block precision stamping process according to claim 1, characterized in that: In the demoulding and post-processing optimization steps, in the precise calcination process, the specific step-by-step temperature increase calcination process is: first, the temperature is increased to 750-800°C at a rate of 40-50°C per hour, and the heat preservation time is 2-4 hours; then, the temperature is increased to 1150-1250°C at a rate of 25-30°C per hour, and the heat preservation time is 20-26 hours.

10. The anode carbon block precision stamping process according to claim 1, characterized in that: In the demoulding and post-processing optimization steps, the slow cooling rate is 15-20°C per hour. After cooling to room temperature, the volume density of the anode carbon block is not less than 1.55 g / cm³, and the resistivity is not higher than 60 μΩ·m.

Images