Scholarlink

<p>With the rapid global growth of the electric vehicle (EV) industry, there is a corresponding surge in demand for charging infrastructure. The ‘High Voltage Socket Shells’ (HVSS) used in EV charging stations are subjected to long-term exposure to harsh and complex environments, necessitating increasingly stringent requirements for quality and reliability. Traditionally, HVSS components are produced through die-casting of aluminium alloys, a process that often results in defects such as entrapped air pockets, shrinkage, and porosity. These manufacturing defects, particularly internal shrinkage, have been identified as the primary factors contributing to the reduced service life and fatigue of HVSS components. Therefore, this study utilizes a commercial modelling software to numerically simulate the one-piece die-casting moulding process of HVSS to study the factors which affect the generation of shrinkage defects. Firstly, the effects of liquid aluminium casting temperature, mould preheating temperature, and holding pressure on shrinkage are investigated separately. Secondly, the Box-Behnken Design response surface method is used to establish the regression model, which is analysed to investigate the influence law of multi-factor interaction on casting shrinkage defects. Finally, the optimized HVSS machine process and casting structure for the blank were developed, which in turn reduced internal shrinkage in the casing, enhanced the product’s fatigue resistance, and lowered both production costs and maintenance costs for the supporting moulds.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Numerical Simulation and Process Parameter Optimization of High-Pressure Socket for Automobile Based on Integral Die Casting

  • 期刊论文

  • 发表日期：

    2025年1月3日

查看全文
  • Shuaifeng Zhao,
  • Haotian Ye,
  • Ruijie Gu,
  • Hao Xing,
  • Jianjun Xie,
  • Zhiguang Liu

摘要

With the rapid global growth of the electric vehicle (EV) industry, there is a corresponding surge in demand for charging infrastructure. The ‘High Voltage Socket Shells’ (HVSS) used in EV charging stations are subjected to long-term exposure to harsh and complex environments, necessitating increasingly stringent requirements for quality and reliability. Traditionally, HVSS components are produced through die-casting of aluminium alloys, a process that often results in defects such as entrapped air pockets, shrinkage, and porosity. These manufacturing defects, particularly internal shrinkage, have been identified as the primary factors contributing to the reduced service life and fatigue of HVSS components. Therefore, this study utilizes a commercial modelling software to numerically simulate the one-piece die-casting moulding process of HVSS to study the factors which affect the generation of shrinkage defects. Firstly, the effects of liquid aluminium casting temperature, mould preheating temperature, and holding pressure on shrinkage are investigated separately. Secondly, the Box-Behnken Design response surface method is used to establish the regression model, which is analysed to investigate the influence law of multi-factor interaction on casting shrinkage defects. Finally, the optimized HVSS machine process and casting structure for the blank were developed, which in turn reduced internal shrinkage in the casing, enhanced the product’s fatigue resistance, and lowered both production costs and maintenance costs for the supporting moulds.