This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Defect Prediction in Copper Motor Rotor Die Casting using Numerical Simulation
Technical Paper
2005-01-1562
ISSN: 0148-7191, e-ISSN: 2688-3627
Annotation ability available
Sector:
Language:
English
Abstract
Copper die-casting is still a relatively new casting process and the numerical formulation of this process is still in its developmental stages. A casting simulation software - ADSTEFAN was used to numerically determine the porosity in edge-gated copper rotor die-casting. The results obtained from simulation were then compared to the real die-cast copper rotors that were produced. Shot profiles are shown to be very instrumental in controlling porosity. Profiles designed to pre-fill a portion of the gate end ring at the slow shot speed prior to accelerating to the fast velocity to fill the conductor bars and ejector end ring are shown to be very effective in minimizing and controlling porosity. Since the electrical conductivity of copper is nearly 60% higher than that of aluminum, substituting copper for aluminum in the rotor would markedly increase the electrical efficiency of the motor.
Authors
Citation
Badarinarayan, H., Takahashi, I., Cowie, J., and Midson, S., "Defect Prediction in Copper Motor Rotor Die Casting using Numerical Simulation," SAE Technical Paper 2005-01-1562, 2005, https://doi.org/10.4271/2005-01-1562.Also In
References
- Takahashi Isamu Anzai Koichi Niyama Eisuke Sannakanishi, Shinji “Mold Filling Simulation of Die Casting by Stefan3D” Proceedings of the Australian Die Casting Congress Melbourne, Victoria 2000
- Brush E.F. Jr. Midson S.P. Walkington W.G. Peters D.T. Cowie J.G. “Porosity Control in Copper Rotor Die Castings” Proceedings of the North American Die Casting Association Die Casting Congress Indianapolis, IN 2003
- Copper Development Association Inc. and the International Copper Association, Ltd. “Technology Transfer Report - The Die-Cast Copper Motor Rotor” April 2004