What are the main functions and structural features of Gearbox Housings Die Casting?

Main Functions and Structural Features of Gearbox Housings Die Casting

1. Transmission Support and Torque Transmission

The gearbox housing supports the assembly of key components such as gears and bearings, ensuring smooth torque transmission during high-speed operation and preventing twisting or displacement. Die casting allows for the one-time molding of complex internal cavities and positioning holes, guaranteeing assembly accuracy and rigidity.

2. Heat Dissipation and Thermal Management

The aluminum alloy housing itself has a high thermal conductivity, allowing heat generated during gear meshing to be quickly dissipated to the environment, reducing localized temperature rise and improving overall reliability. The product manual indicates that the die-cast aluminum housing provides a wide heat dissipation area in stress zones, balancing strength and heat dissipation.

3. Leakage Prevention and Sealing

The internal oil passages and oil holes of the gearbox require tight sealing to prevent oil leakage. The die-casting mold design employs parting surfaces, sliders, and core-pulling mechanisms to achieve uniform wall thickness and smooth surfaces, thus meeting the structural requirements of high airtightness and leak-proofness. 4. Lightweighting and Structural Strength

Through one-time die casting, overall lightweighting can be achieved while maintaining a wall thickness of ≥4mm, reducing the overall vehicle weight. The high strength and high rigidity of aluminum alloy materials ensure that the shell retains sufficient bending and torsional resistance while achieving lightweighting.

Why is aluminum alloy the mainstream material for Gearbox Housings Die Casting?

1. Low Density for Lightweighting

The density of aluminum alloy is approximately 2.7g/cm³, only one-third that of steel, significantly reducing the overall weight of the gearbox and meeting the lightweighting requirements of new energy vehicles.

2. High Strength and Rigidity

Through alloy formulation (such as AlSi9Cu3) and heat treatment, yield strength and tensile strength comparable to steel can be obtained while maintaining good toughness, meeting the structural requirements of the gearbox under high speed and high torque conditions.

3. Excellent Thermal Conductivity

The thermal conductivity of aluminum alloy is approximately 150 W/(m·K), far exceeding that of traditional cast iron. This allows for rapid heat transfer from gear meshing to the outer casing surface, improving heat dissipation efficiency and reducing the risk of localized overheating.

4. Easy Machining and Suitable for Die Casting

Aluminum alloy has a low melting point and good fluidity, making it suitable for high-pressure die casting processes. This allows for the one-time forming of complex cavities and thin-walled structures, significantly shortening mold development cycles and reducing subsequent machining costs.