高效节能电动机用铸铜转子压铸过程的数值模拟研究
发布时间：2018-08-28 10:16
【摘要】：电动机广泛应用于现代社会的各个领域,是国民经济发展和日常生活中最重要的动力设备之一。目前我国电动机的耗电量约占社会总用电量的60%左右,所以提高电动机的能效对于促进能源的节约利用、保护环境以及可持续发展都具有非常重要的意义。而传统的铸铝转子是电动机功率损失的重要部件,严重制约着电动机效率的提升。因此,降低转子的损耗是提高电动机效率的一种重要途径。由于铜本身优良的导电性、散热性和耐磨性等,以铸铜转子代替铸铝转子所制成的电动机具有温升低、损耗低、效率高、易于结构设计、震动小和噪音低等优点,采用铸铜转子技术已成为研发超高效率电动机的有效措施之一。虽然铸铜转子具有许多优点,但由于铜的压铸温度高达1100℃以上,这样高的浇注温度对于模具材料以及压铸机的压室都是很大的考验。此外,铜在熔炼过程中易氧化、铜液流动性差,也使铸铜转子的压铸生产过程比较困难,这些因素成为了目前影响铸铜转子广泛应用的主要障碍。针对上述问题,本文基于流体模拟软件FLOW-3D,实行了对铜转子压铸过程的数值模拟,并采用正交试验设计方法,对压铸工艺的关键参数进行了优化,为铸铜转子压铸生产的工艺设计提供了理论依据。论文的主要研究工作和成果如下:(1)以电动机用铸铜转子为研究对象,建立了铸铜转子压铸工艺过程的数值模拟模型。并利用FLOW-3D软件,对其压铸充型过程进行了数值模拟,获得了铜熔体流动过程中的流场、温度场、速度场以及卷气、表面氧化膜等的分布情况。(2)基于数值模拟研究方法,讨论了压铸工艺关键参数:浇注温度、充填速度和模具温度等对铸铜转子质量的影响规律,为压铸工艺参数的确定提供了有效的基础数据及理论依据。(3)采用正交试验设计方法,建立了浇注温度为1100～1250℃、充填速度为30～45 m·s-1、模具温度为250～400℃的三因素四水平正交试验方案,分析参数改变对缺陷生成率的影响。通过优化分析确定了最优的工艺参数方案。(4)采用优化的工艺参数,进行了铸铜转子的压铸工艺实验,并对压铸件进行了微观组织分析,实验结果与模拟结果相吻合,获得了铸件表面质量好,内部缩孔和缩松缺陷率较小的压铸件。
[Abstract]:Motor is widely used in all fields of modern society and is one of the most important power equipment in the development of national economy and daily life. At present, the electric power consumption of electric motor in our country accounts for about 60% of the total power consumption in our country, so it is very important to improve the energy efficiency of motor for promoting energy conservation and utilization, protecting the environment and sustainable development. The traditional cast aluminum rotor is an important part of motor power loss, which seriously restricts the efficiency of motor. Therefore, reducing rotor loss is an important way to improve motor efficiency. Because of the excellent electrical conductivity, heat dissipation and wear resistance of copper, the motor made of cast copper rotor instead of cast aluminum rotor has the advantages of low temperature rise, low loss, high efficiency, easy structure design, low vibration and low noise, etc. The application of cast copper rotor technology has become one of the effective measures to develop ultra-high efficiency motor. Although the cast copper rotor has many advantages, since the copper die-casting temperature is as high as 1100 鈩，
本文编号：2209095
[Abstract]:Motor is widely used in all fields of modern society and is one of the most important power equipment in the development of national economy and daily life. At present, the electric power consumption of electric motor in our country accounts for about 60% of the total power consumption in our country, so it is very important to improve the energy efficiency of motor for promoting energy conservation and utilization, protecting the environment and sustainable development. The traditional cast aluminum rotor is an important part of motor power loss, which seriously restricts the efficiency of motor. Therefore, reducing rotor loss is an important way to improve motor efficiency. Because of the excellent electrical conductivity, heat dissipation and wear resistance of copper, the motor made of cast copper rotor instead of cast aluminum rotor has the advantages of low temperature rise, low loss, high efficiency, easy structure design, low vibration and low noise, etc. The application of cast copper rotor technology has become one of the effective measures to develop ultra-high efficiency motor. Although the cast copper rotor has many advantages, since the copper die-casting temperature is as high as 1100 鈩，
本文编号：2209095
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