Design of Low Pressure Casting Die for Aluminum Alloy Battery Tray of Electric Vehicle

Design of Low Pressure Casting Die for Aluminum Alloy Battery Tray of Electric Vehicle

The battery is the core component of an electric vehicle, and its performance determines the technical indicators such as battery life, energy consumption, and service life of the electric vehicle. The battery tray in the battery module is the main component that performs the functions of carrying, protecting, and cooling. The modular battery pack is Arranged in the battery tray, fixed on the chassis of the car through the battery tray, as shown in Figure 1. Since it is installed on the bottom of the vehicle body and the working environment is harsh, the battery tray needs to have the function of preventing stone impact and puncture to prevent the battery module from being damaged. The battery tray is an important safety structural part of electric vehicles. The following describes the forming process and mold design of the aluminum alloy battery tray for electric vehicles.

The stress-bearing parts and areas with high mechanical performance requirements of castings need to be properly cooled or fed to avoid shrinkage porosity or thermal cracking. The basic wall thickness of the casting is 4mm. The heat dissipation of the mold itself will affect the solidification. A cooling system is set up for its important parts. After the filling is completed, it is cooled by water. The specific cooling time needs to be adjusted at the pouring site to ensure that it is far away from the gate. The sequence of solidification is formed at the gate end, and the gate and riser are solidified at the end to achieve the effect of feeding. The part with thicker wall thickness adopts the method of adding water cooling to the insert. This method has a better effect in the actual casting process and can avoid shrinkage porosity. Since the cavity of low-pressure casting metal is closed, it does not have good air permeability like sand molds, nor does it exhaust through risers in general gravity casting. The exhaust of low-pressure casting cavity will affect the filling process of molten aluminum and Casting molding quality. The low-pressure casting mold can be exhausted through the gaps in the parting surface, push rod, etc., exhaust grooves and exhaust plugs [4].
The exhaust size design in the exhaust system should be conducive to exhaust without overflowing. A reasonable exhaust system can prevent castings from defects such as insufficient filling, loose surface, and low strength. During the pouring process, the final filling area of the aluminum liquid, such as the side rest and the riser of the upper mold, needs to be equipped with exhaust gas.

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