Fracture Analysis of Copper Cathode and Function Optimization of the Cathode Stripping Machine (CSM)

Incorrect separation of the copper cathode from the stainless-steel cathode blank in the cathode separation machine (CSM) is a significant factor affecting production efficiency. This study investigates the conditions leading to improper cathode separation and explores ways to address this issue. Experimental observations show that the thickness of the cathode, the formation of nodules on the cathode, and the positioning of the flex mechanism in the (CSM) significantly influence the separation of cathodes from the cathode blanks. Once, twenty-four cathodes were randomly selected from the CSM output at Sarcheshmeh Copper Refinery (Rafsanjan, Iran). The thickness, crack width and length in the cathodes separated from the cathode blanks were measured. Subsequently, after model validation and simulation strategies, the cathode separation process, involving the application of impact by the flex, was simulated using the finite element method (FEM) with the cohesive zone model (CZM). In the FEM simulation, CZM was applied under the assumption of plane strain and considering fracture energy to predict the changes in the separation layers of the cathode from the cathode blank. Simulation results indicate that shifting the position of the flex increases the crack width and length of the cathode-cathode blanks separation. Finally, based on the simulation results, a mechanism to optimize the impact location for more efficient cathode separation was designed, and improved the machine for CSM in practice.