EV structural part mold design focuses on thin-wall forming, high strength and low deformation, adopting targeted optimization for new energy aluminum casting characteristics.
EV structural part mold thin-wall area is defined as 2–4mm, requiring cooling channel spacing controlled within 18mm to avoid uneven solidification deformation.
LPDC casting mold is the mainstream for lightweight EV parts, with filling speed optimized to 0.8–1.2m/s to prevent thin-wall incomplete filling defects.
CPC counter-pressure casting mold is preferred for high-load structural parts, improving casting tensile strength by 10% compared with ordinary LPDC molds.
Gravity casting mold applies to thick-wall EV structural parts above 5mm, with open exhaust design to adapt to large-volume molten aluminum filling.
Procast CAE simulation for EV molds needs to analyze thin-wall temperature gradient, controlling local temperature difference below 45℃ to reduce thermal stress deformation.
H13 hot-work steel for EV molds requires ultra-fine grain treatment, improving thermal fatigue resistance by 22% for frequent thin-wall cycle production.
Casting mold porosity shrinkage of EV parts must be controlled below 0.6%, stricter than ordinary aluminum wheel mold industrial standards.
EV mold gating system adopts multi-point sequential feeding, reducing thin-wall shrinkage cavity probability by 40% compared with single-point feeding.
Casting mold trial-test for EV structural parts requires 5 consecutive qualified samples, one more time than wheel molds to verify structural stability.
EV mold cavity tolerance is controlled at ±0.02mm, higher than conventional casting molds to match precision new energy assembly requirements.
With the rapid development of new energy vehicles, EV structural part mold has become a core customized product in the aluminum casting mold industry. Different from conventional aluminum wheel mold, new energy structural parts feature thin wall, complex structure and high mechanical performance requirements, putting forward higher standards for mold design and manufacturing. LPDC casting mold is widely used for lightweight chassis and body parts, relying on precise pressure control to complete thin-wall rapid forming. For suspension and load-bearing structural parts with higher strength requirements, CPC counter-pressure casting mold is the optimal choice, which improves casting compactness and mechanical properties through high-pressure feeding. Thick and simple structural parts can adopt cost-effective gravity casting mold solutions. In the design process, Procast CAE simulation is used to accurately predict thin-wall filling, solidification and temperature field changes, targeting the problem of easy deformation of thin-wall castings. The optimized H13 hot-work steel process enhances mold durability under high-frequency alternating temperature working conditions. Strict casting mold porosity shrinkage control and high-standard casting mold trial-test ensure that each batch of EV castings meets automotive industry precision and strength thresholds. The overall design logic of EV molds takes lightweight, high strength and high dimensional consistency as the core, realizing mass stable production of new energy aluminum alloy structural parts.
FAQs
Q1: What wall thickness is defined as thin-wall for EV casting molds? A1: 2–4mm thin-wall structure, requiring targeted cooling optimization.
Q2: Which mold is best for high-load EV structural parts? A2: CPC counter-pressure casting mold, improving tensile strength by 10%.
Q3: What is the maximum temperature difference allowed for EV mold simulation? A3: Local temperature difference strictly controlled below 45℃.
Q4: What is the porosity standard for EV aluminum castings? A4: Controlled below 0.6%, stricter than ordinary wheel castings.
Q5: How many trial tests are required for EV structural molds? A5: 5 consecutive qualified samples required for mass production approval.
Q6: What is the cavity tolerance of precision EV molds? A6: High-precision standard ±0.02mm for new energy assembly.
Q7: How to reduce thin-wall shrinkage of EV castings? A7: Adopt multi-point sequential feeding, reducing shrinkage rate by 40%.
