EV Battery Pack Housing Die Project
Challenge
The client needed a stamping die set for an aluminum alloy battery pack lower housing. Challenges included: poor formability of aluminum alloy prone to cracking; large part dimensions (1800mm×1200mm) with flatness requirement ≤0.5mm; tight project timeline of only 12 weeks.
Solution
Optimized aluminum sheet forming parameters through CAE simulation, used isothermal forming technology to control material flow. Adopted modular die design with special coating treatment on critical areas to prevent aluminum adhesion. Parallel design and manufacturing with multi-shift rotation.
Result
Dies delivered on time with 98.5% part forming qualification rate, flatness controlled within 0.3mm, exceeding expectations. Client placed additional orders for battery pack upper housing and cooling plate dies, becoming their core battery pack die supplier.