铸铝电机转子压铸模具设计与工艺参数优化

发布时间：2018-05-03 03:40

  本文选题：铸铝电机转子 + 压铸模具　； 参考：《南京理工大学》2017年硕士论文

【摘要】：铸铝电机转子鼠笼成型过程中,其压铸模具与压铸机床常常出现匹配程度不高,制定的工艺参数易受到噪声因素干扰等问题。为了满足企业实际需求,以铸铝转子铝笼为对象,设计一套能够实现与压铸机床最优匹配的压铸模具,并确定一组能够保证内部质量最优、噪声因素影响不明显的工艺参数组合。首先,确定压铸模具的浇注系统的形式和结构,对压铸机进行了选型与校核。利用p-Q2图技术对内浇口截面积进行优化,当内浇口截面积为307.29mm2时,浇注系统与压铸机床的匹配程度达到最优。其次,采用数值模拟技术,研究直流道水道模型对温度场影响,模型在第12次热循环中,达到热平衡状态。讨论冷却系统关键参数对温度场的影响,结果表明当水温为50℃、管壁与型腔距离为52mm、冷却水道管径为14mm时,具有合理的模具温度梯度,并且型腔表面升温速度高。并验证在该冷却系统下,铸件符合顺序凝固,且缩松缩孔率分布降低。再者,对模具进行整体设计,包括模具型腔零件的尺寸进行计算、根据充型过程数值模拟设计排气槽、顶出机构设计、压紧机构设计与油缸选型、导向机构设计,并完成模具的整体装配。对转子鼠笼的生产工艺进介绍,完成了模具的试模,经过试模发现转子表面质量良好。最后,通过数值模拟正交试验和稳健性分析、极差分析,确定慢压快压转换点为250mm,充型速度为2.5m/s,铝液温度680℃,模具温度为280℃,缩松缩孔体积最小为5.816295cc,且对噪声因素不敏感,影响的主次为铝液温度、模具温度、充型速度、慢压快压转换点。经过x光无损探伤检测表明,建立的数值模拟模型可以有效反应实际生产缩松缩孔的分布状态。经过试模,确定最终工艺参数方案慢压快压转换点为280mm,压射速度为2.73m/s,铝液温度692℃,模具温度为274℃。经过研究,设计的模具与压铸机床匹配程度高,经过调试的工艺参数方案能够使得内部关键区域缺陷减少、缩松缩孔率下降。生产的铸铝转子符合工厂的实际需求,能够满足客户的需求。
[Abstract]:In the process of casting aluminum motor rotor cage, the matching degree between die casting die and die casting machine is not high, and the process parameters are easily disturbed by noise factors. In order to meet the actual needs of the enterprise, a set of die casting mould which can realize the optimum match with the die casting machine tool is designed, and a group of die casting dies which can guarantee the best internal quality is designed. Noise factors have no obvious effect on the combination of process parameters. First, the form and structure of the casting system are determined, and the die casting machine is selected and checked. The cross section area of the inner gate is optimized by using p-Q2 diagram technology. When the cross section area of the inner gate is 307.29mm2, the matching degree between the gating system and the die-casting machine is optimal. Secondly, the numerical simulation technique is used to study the influence of the DC channel model on the temperature field. The model reaches the state of thermal equilibrium in the 12th thermal cycle. The influence of the key parameters of the cooling system on the temperature field is discussed. The results show that when the water temperature is 50 鈩，

本文编号：1836845