砂型3D打印技术在电驱桥主减壳开发中的应用

Application of Sand Mold 3D Printing Technology in the Development of Main Reducer Housing Casting

20002型电驱桥前主减速器壳体是一款将减速器壳体、中间箱体、轴承座等部件采用集成化设计而成的薄壁复杂铸件。产品具有轮廓起伏大、热节分散的结构特点,存在较大的冷隔、缩孔和气孔倾向。新品研制过程中,通过设计阶梯式多流道浇注系统以及3D打印的全组芯工艺,结合数值模拟优化,改善了产品充型末端的温度分布,提高了孤立热节的补缩效果,获得了内部组织致密、轮廓清晰、表观光洁的壳体铸件,实现了新品样件的快速交付。

The front main reducer housing of the 20002 electric drive axle is a thin-walled complex casting that integrates components such as the reducer housing,intermediate box,and bearing seat.The product has the structural characteristics of large contour undulations and dispersed hot spots,with significant tendencies towards cold shut,shrinkage,and porosity.In the process of new product development,by designing a stepped multi channel pouring system and a 3D printed full core assembly process,combined with numerical simulation optimization,the temperature distribution at the end of product filling was improved,and the shrinkage effect of isolated heat joints was enhanced.A shell casting with dense internal structure,clear contour,and smooth appearance was obtained,achieving rapid delivery of new product samples.