基于ProCast铝合金电机壳挤压铸造工艺设计

Squeeze Casting Process Design of Aluminum Alloy Motor Housing Based on ProCast

针对使用常规铸造工艺制造的新能源汽车电机壳出现缩松缩孔、气密性合格率低的问题,应用数值模拟技术对电机壳的挤压铸造工艺进行研究。通过对铸造充型、凝固过程进行模拟仿真,验证工艺设计的合理性,并结合单一变量法研究浇注温度、模具温度、比压等工艺参数对缩松缩孔的影响。最终确定最佳工艺参数为浇注温度680℃,模具温度280℃,比压110 MPa、压射速度0.1 m/s、保压30 s。在此参数下结合局部加压装置可以消除铸件的缩松缩孔,得到的铸件性能优良,气密性合格率达到88%。

Aiming at the problem of shrinkage and low pass rate of gas tightness of new energy automobile motor housing produced by conventional casting process, the squeeze casting process of motor housing casting was studied by using numerical simulation technology. The rationality of the process design was verified through the simulation of casting＇s filling and solidification process, and the effects of pouring temperature, mold temperature and specific pressure on the shrinkage were studied by using single variable method. Finally, the best process parameters were determined, which were pouring temperature of 680 ℃, mold temperature of 280 ℃, specific pressure of 110 MPa , injection speed of 0.1 m/s, and holding pressure with 30 s. Under the parameters combined with local pressure device, the casting shrinkage was eliminated. The casting had good properties, and the pass rate of gas tightness reached 88%.