Aluminum alloy motor shell low pressure sand casting process design

Taking a 140 kW aluminum alloy water-cooled motor shell as the research object, the typical casting process scheme of motor shell using low-pressure sand molding process is discussed, and the simulation software is used to evaluate the feasibility of the process scheme. The results show that the produced motor shell fully meets the requirements of the relevant technical conditions.

In recent years, under the demand of energy saving and environmental protection, the R&D focus of automobile manufacturers is shifting from traditional fuel vehicles to new energy vehicles. Aluminum alloy motor shell, as the core casting of powertrain for new energy vehicles, has a complex structure and is difficult to cast. The sealing of the side wall of the water-cooled motor shell around the cooling water jacket is an important technical requirement of the product and also the biggest casting difficulty of the product. At the same time, the shrinkage of the upper and lower end surfaces of the motor shell and the side wall is also a casting defect that needs to be avoided in the process development. With the rapid development of computer technology in the field of casting, casting defects can be predicted and process feasibility can be assessed through casting process simulation analysis simulation. 

In this paper, we take a 140 kW motor shell as the research object, study the casting process design of aluminum alloy motor shell of low-pressure sand molding process, carry out the simulation analysis of the casting process with the help of MAGMA simulation, and carry out the casting process analysis of the optimization scheme and process evaluation.