Complex Water-cooled Motor Shell Casting Process Design And Mould Manufacturing

Along with the social development, the state increasingly strict with engine emissions, increasing the demand for the new energy engine; and the development of new energy engine parts is receiving more and more attention. The motor shell is used for new energy models in a large key parts. Its Geometry structure is complex, with circulating water chamber inside the shell wall, requiring good mechanics performance and air tightness. Complex shell parts casting foundry industry has been the focus of the difficulty. Currently sand mold casting is the most widely used in foundry enterprises, its advantage lies in the mature technology, low cost, but the casting blank allowance is big, with kinds of casting defects; Lost Foam Casting (LFC) parts have a precision size,due to its without core, no draft Angle, the characteristics of less machining allowance. But LFC also has limitations, such as EPS foam shape in the process of combustion, pyrolysis of the C atoms to the metal surface infiltration, caused the casting surface carbon inclusion defects. Moreover, the strength of the EPS foam is lower than the sand core, which is easliy to be extrused deformation in the process of modelling and vibrating, even collapse box. The following explores how to combine the two casting method and solve complex casting technology difficult problem of motor shell partsThis paper optimize the design parameters and process parameters of the dissolved mold casting based on CAD/CAE technology, using the lost-channel sand core combination of casting process to develop GH motor shell.we have designed two pairs of LFC mold and a pair of cold core box mold, using CAM module of UG to the mold processing programming, after debugging with a foam mold and core assembly produce casting, then we can produce something accord with the casting product design requirements. The following shows all the research results:(1)The combination of the mould and sand mould casting process is a kind of practical casting process method, With foamed EPS material particles making the lost foam pattern to express GH motor shell shape, with metal mould making channel to express the closed circulating water chamber cold sand core, then bubble the lost foam pattern and waterways cold sand core assembly with dry sand enrichment, finally cast forming. We use the plan, successfully casting the motor shell castings with complex shape and hollow inner cavity.(2)Using AnyCastiing for casting process simulation, we simulate the change of the casting process of pouring and solidification process With different process parameters, and then forecast the possible defects, makeing the technology personnel to adopt a more reasonable pouring scheme according to the requirements.(3)Using parameterized CAD software for the motor shell mold design, it's easy to adjust various parameters. When we constantly adjust various molding parameters, the whole design process have a high degree of visualization, which improved the design accuracy and convenience.(4)The use of CAM software programming to the mold processing, using the tool features, in the CAM stage can complete some CAD stage tedious work, such as mold coating layer, the draft Angle, rounded corners, etc.(5) LFC in compaction stage, sand are big impact on foam model and cores, and core must be taken to increase bone or other ways to increase the strength of model; And, to some of the foam model before vibrated semi-closed position the special inspection, these parts will not full fill sand adhering sand castings.(6)For multiple directions, the flexible structure of live piece side smoke can release, but if it is manual work, we need to design a steering mechanism for the live pieces, such as a slot or guide rail, to guarantee consistency of tooling mold. For deep cavity cast iron mould processing, adopt insert or composite structure can save a lot of tooling costand the processing time.