【摘要】：電動機廣泛應(yīng)用于現(xiàn)代社會的各個領(lǐng)域,是國民經(jīng)濟發(fā)展和日常生活中最重要的動力設(shè)備之一。目前我國電動機的耗電量約占社會總用電量的60%左右,所以提高電動機的能效對于促進能源的節(jié)約利用、保護環(huán)境以及可持續(xù)發(fā)展都具有非常重要的意義。而傳統(tǒng)的鑄鋁轉(zhuǎn)子是電動機功率損失的重要部件,嚴重制約著電動機效率的提升。因此,降低轉(zhuǎn)子的損耗是提高電動機效率的一種重要途徑。由于銅本身優(yōu)良的導(dǎo)電性、散熱性和耐磨性等,以鑄銅轉(zhuǎn)子代替鑄鋁轉(zhuǎn)子所制成的電動機具有溫升低、損耗低、效率高、易于結(jié)構(gòu)設(shè)計、震動小和噪音低等優(yōu)點,采用鑄銅轉(zhuǎn)子技術(shù)已成為研發(fā)超高效率電動機的有效措施之一。雖然鑄銅轉(zhuǎn)子具有許多優(yōu)點,但由于銅的壓鑄溫度高達1100℃以上,這樣高的澆注溫度對于模具材料以及壓鑄機的壓室都是很大的考驗。此外,銅在熔煉過程中易氧化、銅液流動性差,也使鑄銅轉(zhuǎn)子的壓鑄生產(chǎn)過程比較困難,這些因素成為了目前影響鑄銅轉(zhuǎn)子廣泛應(yīng)用的主要障礙。針對上述問題,本文基于流體模擬軟件FLOW-3D,實行了對銅轉(zhuǎn)子壓鑄過程的數(shù)值模擬,并采用正交試驗設(shè)計方法,對壓鑄工藝的關(guān)鍵參數(shù)進行了優(yōu)化,為鑄銅轉(zhuǎn)子壓鑄生產(chǎn)的工藝設(shè)計提供了理論依據(jù)。論文的主要研究工作和成果如下:(1)以電動機用鑄銅轉(zhuǎn)子為研究對象,建立了鑄銅轉(zhuǎn)子壓鑄工藝過程的數(shù)值模擬模型。并利用FLOW-3D軟件,對其壓鑄充型過程進行了數(shù)值模擬,獲得了銅熔體流動過程中的流場、溫度場、速度場以及卷氣、表面氧化膜等的分布情況。(2)基于數(shù)值模擬研究方法,討論了壓鑄工藝關(guān)鍵參數(shù):澆注溫度、充填速度和模具溫度等對鑄銅轉(zhuǎn)子質(zhì)量的影響規(guī)律,為壓鑄工藝參數(shù)的確定提供了有效的基礎(chǔ)數(shù)據(jù)及理論依據(jù)。(3)采用正交試驗設(shè)計方法,建立了澆注溫度為1100～1250℃、充填速度為30～45 m·s-1、模具溫度為250～400℃的三因素四水平正交試驗方案,分析參數(shù)改變對缺陷生成率的影響。通過優(yōu)化分析確定了最優(yōu)的工藝參數(shù)方案。(4)采用優(yōu)化的工藝參數(shù),進行了鑄銅轉(zhuǎn)子的壓鑄工藝實驗,并對壓鑄件進行了微觀組織分析,實驗結(jié)果與模擬結(jié)果相吻合,獲得了鑄件表面質(zhì)量好,內(nèi)部縮孔和縮松缺陷率較小的壓鑄件。
[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，

本文編號：2209095