CN112658228B - Low-pressure casting process of motor casing of new energy automobile - Google Patents
Low-pressure casting process of motor casing of new energy automobile Download PDFInfo
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- CN112658228B CN112658228B CN202011602769.2A CN202011602769A CN112658228B CN 112658228 B CN112658228 B CN 112658228B CN 202011602769 A CN202011602769 A CN 202011602769A CN 112658228 B CN112658228 B CN 112658228B
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Abstract
The invention discloses a low-pressure casting process of a motor shell of a new energy automobile, which comprises the following steps: cleaning a mold, placing a sand core, and closing the mold; pressurizing the aluminum liquid in the heat preservation furnace for 120mbar/10s to ensure that the aluminum liquid rises to the bottom of the pouring gate 1; continuously pressurizing the aluminum liquid in the heat preservation furnace for 120mbar/16s and pressurizing to 240mbar to ensure that the mold cavity 3 is slowly filled with the aluminum liquid; continuously pressurizing the aluminum liquid by 360mbar/10s after the mold cavity is filled with the aluminum liquid, pressurizing to 600mbar and continuously maintaining pressure for 319 +/-20 s; after pressure maintaining, the aluminum liquid pressure is discharged, and the casting is left to be cooled for 290 +/-20 s, so that the temperature of the surface of the casting is reduced to 300-350 ℃; and opening the die to obtain a qualified casting. The invention uses a low-pressure casting process, and is matched with the inorganic sand core to be preset in the die, so that the motor shell product is integrally formed, the production output is effectively improved, the cost of the die and a welding tool is saved, and the defect of low material strength of a welding area can be avoided.
Description
Technical Field
The invention relates to a low-pressure casting process of a motor shell of a new energy automobile.
Background
Generally, a cooling water channel is required in the motor shell, an outer barrel and an inner wall are respectively cast and formed, and then the motor shell is assembled through a friction stir welding process. The process is complicated, the cost is high and the strength of the material in the welding area is low, so that the risk of cracks or water seepage is generated.
Moreover, because the middle of the motor shell is provided with a water channel for cooling, if the inside of the shell is loose or has air holes, water can permeate into the inside of the motor, so that the motor is burnt and damaged, and even safety accidents occur. The internal quality of the motor housing is very critical and does not allow any leakage. The porosity requirement belongs to the highest standard in the same category of castings (the porosity is less than or equal to 5 percent). Through analysis, the defect is mainly caused by shrinkage cavity because the size of a sprue designed by an original mold is too small, and the aluminum liquid can not be solidified in sequence by the conventional cooling process, so that the shrinkage cavity is generated by forming hot junction in the product. The width a of the existing pouring gate is 28mm, the width b of the inlet of the pouring gate 2 is 36mm, the height c of the outlet of the pouring gate is 34mm, the size value of a is close to the wall thickness of a product by 19.5 +/-0.7 mm, when a motor shell body is solidified in the pressure holding stage, the position a begins to solidify, the fluidity of molten aluminum is reduced, and the shrinkage cavity is generated due to unsmooth feeding of the product body, so that the casting qualification rate is only 20%, the defect cannot be identified on X-ray equipment, and the CT scanning detection is required to be carried out for 100%, and the cost consumption is huge.
In the casting process, the width of the sand core of the water channel cavity of the motor shell is only 7mm, an inward waist structure is arranged in the middle of the sand core, and the middle of the sand core is inclined outwards by 1.5 degrees. In the casting process, the sand core is soaked and wrapped by aluminum liquid at the high temperature of 700 ℃, so that the sand core is easy to deform and bend, and the wall thickness of the inner wall of the motor shell is unqualified. This size detection also requires a CT scan to detect the thickness of the inner wall by X-ray, which is costly.
Disclosure of Invention
The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. It should be understood that this summary is not an exhaustive overview of the invention. It is not intended to determine the key or critical elements of the present invention, nor is it intended to limit the scope of the present invention. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later.
The invention aims to provide a low-pressure casting process of a motor shell of a new energy automobile, which aims to solve the problems in the background technology.
In order to achieve the purpose, the invention provides the following technical scheme: a low-pressure casting process of a motor shell of a new energy automobile comprises the following processing steps:
A. cleaning a mold, placing a sand core, and closing the mold;
B. pressurizing the aluminum liquid in the heat preservation furnace for 120mbar/10s to ensure that the aluminum liquid rises to the bottom of the pouring gate;
C. continuously pressurizing the aluminum liquid in the heat preservation furnace for 120mbar/16s and pressurizing to 240mbar, so that the aluminum liquid slowly passes through the pouring channel to fill the die cavity;
D. continuously pressurizing the aluminum liquid by 360mbar/10s after the mold cavity is filled with the aluminum liquid, pressurizing to 600mbar and continuously maintaining pressure for 319 +/-20 s;
E. after pressure maintaining, the aluminum liquid pressure is discharged, and the casting is left to be cooled for 290 +/-20 s, so that the temperature of the surface of the casting is reduced to 300-350 ℃;
F. and opening the die to obtain a qualified casting.
The invention is further improved in that: in the step B, the temperature of the aluminum liquid is more than 700 ℃.
The invention is further improved in that: and E, when the water is cooled to 240s, starting water cooling, and after 30s, closing the water cooling, wherein the water flow during the water cooling is 3 +/-1L.
The invention is further improved in that: the sprue is connected with the pouring gate, the width of the pouring gate is 44.5mm, the width of the pouring gate at the inlet is 47.5mm, and the height of the pouring gate at the outlet is 50 mm.
The invention is further improved in that: the die cavity in the die is formed by a cavity between the outer side slide block and the insert, the radius of a transition angle at the bottom of the insert is 30mm, and the outer wall of the insert inclines by 5 degrees.
The invention has the beneficial effects that: the invention has the advantages of high casting utilization rate, easy sequential solidification, less internal defects, less gas and sundries involved, capability of using sand cores, easy realization of automation, capability of performing multiple operations and multiple procedures, and wide application range of casting materials.
According to the invention, the inward waist-closing structure is arranged at the middle position of the water channel cavity of the motor shell, the inclination of the middle part is outward 1.5 degrees, and the proper reverse deformation amount is established by optimizing the waist-closing angle of the sand core, so that the wall thickness of the inner wall of the motor shell can meet the requirement of a drawing by 100%, the qualified output is effectively improved, the CT scanning detection cost is saved, and the cost is greatly saved.
The invention adopts the designed product to enter the sprue, the quality qualification rate of the interior of the motor shell reaches more than 90 percent, and the existing defects can be distinguished by X-ray, thereby saving the CT scanning detection cost and greatly saving the cost.
Description of the drawings:
FIG. 1 is a schematic structural view of a motor casing;
FIG. 2 is a schematic view of a portion of the structure at the gate of the mold;
reference numbers in the figures: 1-sprue, 2-runner, 3-mould cavity, 4-outside slide block, 5-insert, width in a-runner, width at inlet of b-runner, height at outlet of c-runner and 6-motor shell.
The specific implementation mode is as follows:
in order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below, and it is obvious that the described embodiments are a part of the embodiments of the present invention, but not all of the embodiments. Elements and features described in one embodiment of the invention may be combined with elements and features shown in one or more other embodiments. It should be noted that the illustration omits illustration and description of components and processes not relevant to the present invention that are known to those of ordinary skill in the art for clarity purposes. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without any inventive step, are within the scope of the present invention.
In order to make the technical advantages of the embodiments more apparent, the following detailed description of the present invention is provided with reference to the accompanying drawings.
In the description of the present invention, it should be noted that, unless explicitly stated or limited otherwise, the terms "disposed," "mounted," "connected," and "transmitting" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; the two components can be connected mechanically or electrically, directly or through an intermediate medium, or the two components can be communicated with each other. The transmission may be of gas pressure or of electrical data information. The specific meaning of the above terms in the present invention can be understood in terms of specific situations by those of ordinary skill in the art.
In the following detailed description of the embodiments, features of the embodiments may be combined with each other.
The implementation scheme provided by the implementation method is a low-pressure casting process of the motor shell of the new energy automobile, and the processing steps are as follows: cleaning a mold, placing a sand core, and closing the mold; pressurizing the aluminum liquid in the heat preservation furnace for 120mbar/10s to ensure that the aluminum liquid rises to the bottom of the pouring gate 1; continuously pressurizing the aluminum liquid of the heat preservation furnace for 120mbar/16s and pressurizing to 240mbar, so that the aluminum liquid slowly passes through the pouring channel 2 to fill the mold cavity 3, and through multiple mold flow analysis and practice verification, the mold filling rate can effectively avoid the entrainment of gas and impurities; after the mold cavity is filled with the aluminum liquid, continuously pressurizing the aluminum liquid by 360mbar/10s, pressurizing to 600mbar and continuously maintaining pressure for 319 +/-20 s, so that good feeding can be obtained when the aluminum liquid is solidified, and finally a casting with compact structure and porosity of less than 5% is obtained; after pressure maintaining, the aluminum liquid pressure is discharged, the casting is left to be cooled for 290 +/-20 s, the temperature of the surface of the casting is reduced to 300-350 ℃, the casting obtains higher hardness, and deformation is prevented when the mold is opened and ejected; when the water is cooled to 240S, starting water cooling, and after 30S, closing the water cooling, wherein the water flow during the water cooling is 3 +/-1L; and opening the die to obtain a qualified casting.
The invention uses a low-pressure casting process, and is matched with the inorganic sand core to be preset in the die, so that the motor shell product is integrally formed, the production output is effectively improved, the cost of the die and a welding tool is saved, and the defect of low material strength of a welding area can be avoided.
In the second stage of the low-pressure casting process, the molten aluminum is slowly filled in the cavity at a height of 120mbar/16s (about 30 mm/s), the temperature of the molten aluminum is above 700 ℃, and the yield strength of the sand core is reduced at high temperature; in the third stage of the die casting process, the pressure is suddenly increased to 600mbar, and the area of the sand core waistline is impacted, so that the sand core generates certain deformation, and the wall thickness of a product is influenced. According to the invention, the proper reverse deformation amount is established by optimizing the waist-retracting angle of the sand core, so that the wall thickness of the inner wall of the motor shell can meet the requirement of a drawing by 100%, the qualified output is effectively improved, the CT scanning detection cost is saved, and the cost is greatly saved.
Gate 1 connects runner 2, with a width a of 44.5mm in runner 2, a width b of 47.5mm at the inlet of runner 2, and a height c of 50mm at the outlet of runner 2. When the product body is solidified in the pressure maintaining stage, the integral temperature of the molten aluminum of the sprue is higher than that of the original sprue, the fluidity is good, and the feeding of the product body is easily completed.
A mold cavity 3 in the mold is formed by a cavity between the outer side sliding block 4 and the insert 5, the radius R of a transition angle at the bottom of the insert 5 is 30mm, and the outer wall of the insert 5 inclines by 5 degrees, so that feeding is smoother when aluminum liquid is filled and solidified. According to the invention, the quality qualification rate in the motor shell reaches more than 90% by redesigning the product inlet gate, and the existing defects can be identified by X-ray, so that the CT scanning detection cost can be saved, and the cost is greatly saved.
Finally, it should be noted that: although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, devices, means, methods, or steps.
Claims (1)
1. The low-pressure casting process of the motor casing of the new energy automobile is characterized by comprising the following steps of: the pouring gate (1) is connected with a pouring gate (2), the width (a) of the pouring gate (2) is 44.5mm, the width (b) of the pouring gate (2) at an inlet is 47.5mm, and the height (c) of the pouring gate (2) at an outlet is 50 mm;
a mold cavity (3) in the mold is formed by a cavity between an outer side slide block (4) and an insert (5), the radius (R) of a transition angle at the bottom of the insert (5) is 30mm, and the outer wall of the insert (5) inclines by 5 degrees;
the motor shell processing steps are as follows:
A. cleaning a mold, placing a sand core, and closing the mold;
B. pressurizing the aluminum liquid in the heat preservation furnace for 120mbar/10s to ensure that the aluminum liquid rises to the bottom of the pouring gate (1), wherein the temperature of the aluminum liquid is more than 700 ℃;
C. continuously pressurizing the aluminum liquid of the heat preservation furnace for 120mbar/16s and pressurizing to 240mbar, so that the aluminum liquid slowly passes through the pouring channel (2) and fills the mold cavity (3);
D. after the mold cavity (3) is filled with the aluminum liquid, continuously pressurizing the aluminum liquid at 360mbar/10s, pressurizing to 600mbar and continuously maintaining the pressure for 319 +/-20 s;
E. after pressure maintaining, the pressure of aluminum liquid is discharged, the casting is left to be cooled for 290 +/-20 s, the temperature of the surface of the casting is reduced to 300-350 ℃, water cooling is started when the surface of the casting is cooled to 240s, the water cooling is stopped after 30s, and the water flow during the water cooling is 3 +/-1L;
F. and opening the die to obtain a qualified casting.
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| CN202011602769.2A CN112658228B (en) | 2020-12-30 | 2020-12-30 | Low-pressure casting process of motor casing of new energy automobile |
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| CN112658228B true CN112658228B (en) | 2022-04-15 |
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