The E-bike motor mount is part of the E-bike frame. In the past, the commonly used process for producing parts such as E-bike motor mounting plate and hanger is forging. Compared with aluminum alloy forging process, aluminum liquid forging（aluminum squeeze casting） has the advantages of high production efficiency, reducing processing volume, reducing cost, and producing parts with more complex structure. Using aluminum squeeze casting to produce an E-bike motor hanger will be the trend in the future. At present, Komman air suspension manufacturer has provided E-bike motor mount hangers for many international E-bike manufacturers. If you have interest, please contact us, we can provide a sample for free.
|E-BIKE Motor Hanger|
|Product Appearance||Item No||Material||Processing||Size(mm)||Tensile Strength||Yield Strength||Elongation||Weight(kgs)|
|D11||A356.2||Aluminum squeeze casting||271*82*93||290Mpa||230Mpa||6%||0.836|
|D13||A356.2||Aluminum squeeze casting||275*122*105||290Mpa||230Mpa||6%||0.809|
|D16||A356.2||Aluminum squeeze casting||270*238*128||290Mpa||230Mpa||6%||1.18|
|8268||A356.2||Aluminum squeeze casting||229*194*95||290Mpa||230Mpa||6%||0.8|
|8274-0||A356.2||Aluminum squeeze casting||270*238*128||290Mpa||230Mpa||6%||0.95|
|Jan-74||A356.2||Aluminum squeeze casting||268*166*96||290Mpa||230Mpa||6%||0.95|
|EP800C||A356.2||Aluminum squeeze casting||250*128*89||290Mpa||230Mpa||6%||0.83|
|8266||A356.2||Aluminum squeeze casting||272*82*166||290Mpa||230Mpa||6%||1.09|
The traditional forging process to produce ebike motor mount plates and hangers with complex structures requires complex procedures and requires a lot of post-processing. It may need to be forged for more than 3 times to form, and the production efficiency is low. However, the aluminum alloy liquid die forging process can be formed at one time. The machining allowance is small, and the efficiency is high.
Obviously, the E-bike motor mount hanger produced by aluminum squeeze casting process has a better appearance because there is no weld seam.
Generally speaking, the mechanical properties of parts produced by forging process are the best. However, for parts such as E-bike motor mounting plate produced by forging process, due to the existence of forging streamline, the metal properties show anisotropy. However, the parts produced by aluminum squeeze casting have no forging streamline, and the mechanical properties are close to forging, which can fully meet the needs of customers.
Traditional forging process to produce E-bike motor mount hangers may need to forge for more than 3 times to form, a lot of post-processing is required. However, aluminum squeeze casting process can reduce the cost by 40% - 60% compared with traditional forging because of its simple air ride suspension custom process and less machining allowance.
Liquid forging, namely squeeze casting, also known as melt forging in Japan, is a method to apply large mechanical pressure (about 100MPa) to the liquid or semi-solid metal entering the mold cavity to form and solidify it to obtain castings.Due to the simultaneous existence of high-pressure solidification and plastic deformation, the casting has dense structure, no defects such as porosity and porosity, and fine grain. T6 heat treatment can be carried out. Its mechanical properties are significantly higher than ordinary castings and close to the forging level of the same alloy. It is an excellent process to realize lightweight.
|Item||Liquid forging（squeeze casting）||Forging||Counter-pressure casting||Low pressure casting||Gravity casting||High pressure casting|
|Internal quality||formed under the pressure of about 100MPa, with fine grain and fine structure||Fine grain and fine structure under forging||formed under the pressure of about 0.6 MPa, with coarse grain and loose structure||formed under the pressure of about 0.01-0.05 MPa, with coarse grains and loose structure||filled and formed by its own weight, with very coarse grains and loose organization||High speed water spraying, no feeding, many internal pores and loose structure|
|Heat treatment||Solid solution（T6）||Solid solution（T6）||Solid solution（T6）||Solid solution（T6）||Solid solution（T6）||no|
|Forming accuracy||High lever of one-time forming and less machining allowance||Low lever of one-time forming , the process is complex, and a lot of subsequent processing is required||A lot of subsequent processing is required||A lot of subsequent processing is required||A lot of subsequent processing is required||High lever of one-time forming and less machining allowance|
|Mechanical properties||Close to forging level without forging streamline||Highest (but there is forging streamline, which makes the metal properties anisotropic)||Medium||Medium||Medium||Low|
|Equipment model||Equipment tonnage(clamping force)||Quantity||Daily capacity(Mold times)||Product weight(kg)||Maximum projected area of product(cm2)||Die size(mm)||Molding pressure(Mpa)|
|2500T(At present,it is the largest squeeze casting model in China)||1||460||20-40||1960||1660*1760*1700||115-160|
Leading technology, leading quality and leading service" is Komman's quality policy. In 2008, the company passed the ISO / TS16949 management system certification.
We can use CAE analysis to optimize the structure according to the working conditions and extreme conditions of the product, and then combine the molding process to check the structure to achieve the perfect unity of "lightweight" and "high quality". We also have advanced testing equipment that can verify the composition and mechanical properties of various materials, and quickly verify product composition and performance. At the same time, we can also use scanning electron microscopes, metallographic microscopes, and high-magnification X-ray machines to perform product inspections. Extreme microstructure analysis, extreme verification of products through corrosion resistance and fatigue resistance tests.
Komman now has the materials as below:
|Material||tensile strength/Mpa||Yield Strength/Mpa||Elongation /%||Remark|
|KM-HS02||320||260||12||High elongation Al-Si|
|KM-HS02||440||380||10||High strength Al-Si-Cu-Mg|
The core members of our team have more than 10 years of working experience in casting industry on average, and have research experience in all kinds of casting process, especially in low-speed casting process. At the same time, the proportion of R & D personnel reaches 25%.