The paper presents methods for improving the quality of rotor squirrel cages in the casting phase at Electroprecizia Electrical Motors Săcele. For this purpose, there are analysed the results of theoretical and experimental research on the existing interdependencies between the quality of rotor squirrel cages obtained by casting and the metallurgical quality of aluminium melts, respectively the parameters of the casting process. When balancing rotor squirrel cages, the non-homogeneity of the compactness of the cast aluminium mass raises a number of technological problems. This non-homogeneity of the compactness is determined by the presence of voids (bubbles, pores) in the cast material. However, the compactness of the aluminium mass (the voids in the cast aluminium) has a decisive influence on the electrical efficiency of the electric motor due to the drastic local modification of the electrical resistivity. Based on an analysis of the results obtained, there can be concluded that the development of a new family of electric motors, of super premium energy efficiency class (IE4), also involves the analysis and detection of the causes that lead to the formation of bubbles and pores in the cast aluminium mass, on the current process flow, subsequently reducing them by improving the existing technologies or even by replacing them.
The electrical steel laminations which compose the rotor and stator core for electrical motors have complex 2D shapes. When these parts require small batches of production, they can be efficiently manufactured only by flexible methods. The paper presents the results of using abrasive waterjet machining (AWJ) to obtain such parts within the frame of a research project with EU funding. The main objective of the research was the analysis of geometrical and dimensional accuracy of the parts which will confirm that AWJ is a suitable process in this case. The parts were measured on an optical digital profilometer. The measurement process was not simple because the parts are relatively large and cannot be focused only by one shot by the camera. Also, another important issue were the profile edges inconsistencies due to the burrs. Those problems and the limitations of the measurement technology did not allow the automation of measurement. The results and discussions proved that AWJ can be used successfully for manufacturing such parts and the machining process is traceable.
Designing the profile of cutting tools is a specific problem in manufacturing engineering. The profile of the cutting tool has a direct influence on the dimensional and shape precision of the machined parts. When it comes to cutting tools for internal turning, the problem of profile design becomes even more complex, because of the added restrictions the profile and the cutting tool itself are subjected to. Despite its importance and complexity, this problem has been rather poorly considered in the literature. Some side aspects, such as measuring the profile, its wear, and its influence on the part’s geometrical precision have been studied, but not the design process of the profiled shape of cutting edges. This research fills a gap in the literature. It considers profiled cutting tools, in general; and, in particular, investigates tilted cutting edges. The novelty of the present article lies in a method to determine the profile of cutting tools for turning inner-profiled surfaces. The method is CAD-based and provides accurate results. It considers the part’s inner profile, its inner diameter, and the tilting angle of the cutting edge. In addition, possible undercuts are taken into account. The method was validated using two relevant case studies. Despite profiled cutting tools having a certain drawback, which is emphasized in the article, this is balanced by the advantages that their use offers manufacturing.
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