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https://www.kommangroup.com/e-bike-motor-hanger-solution/

The ebike motor mount is part of the E-bike frame. In the past, the commonly used process for producing parts such as ebike 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 china 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.

Main Technical Parameters of Motor Hanger
Item NoMaterialProcessingSize(mm)Tensile StrengthYield StrengthElongationWeight(kgs)
D11A356.2Aluminum squeeze casting271*82*93290Mpa230Mpa6%0.836
D13A356.2Aluminum squeeze casting275*122*105290Mpa230Mpa6%0.809
D16A356.2Aluminum squeeze casting270*238*128290Mpa230Mpa6%1.18
8268A356.2Aluminum squeeze casting229*194*95290Mpa230Mpa6%0.8
8274-0A356.2Aluminum squeeze casting270*238*128290Mpa230Mpa6%0.95
Jan-74A356.2Aluminum squeeze casting268*166*96290Mpa230Mpa6%0.95
EP800CA356.2Aluminum squeeze casting250*128*89290Mpa230Mpa6%0.83
8266A356.2Aluminum squeeze casting272*82*166290Mpa230Mpa6%1.09

E-bike motor hanger made by aluminum squeeze casting compare with e-bike motor hanger made by traditional aluminum forging.
E-bike Motor Hanger Made by Traditional Aluminum Forging
E-bike Motor Hanger Made by Aluminum Squeeze Casting

Aluminum Squeeze Casting E-bike Motor Mount Advantages
High production efficiency
The traditional forging process to produce e bike motor mounting bracket 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.

Better product appearance
Obviously, the E-bike motor mount hanger produced by aluminum squeeze casting process has a better appearance because there is no weld seam.

Good mechanical properties
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.

Lower cost
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.

INTRODUCTION OF ALUMINUM SQUEEZE CASTING
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.

Aluminum Squeeze Casting VS Traditional Aluminum Forging E-bike Motor Mount
ItemLiquid forging（squeeze casting）ForgingCounter-pressure castingLow pressure castingGravity castingHigh pressure casting
Surface qualitygoodgoodmediummediumbadgood
Internal qualityformed under the pressure of about 100MPa, with fine grain and fine structureFine grain and fine structure under forgingformed under the pressure of about 0.6 MPa, with coarse grain and loose structureformed under the pressure of about 0.01-0.05 MPa, with coarse grains and loose structurefilled and formed by its own weight, with very coarse grains and loose organizationHigh speed water spraying, no feeding, many internal pores and loose structure
Surface roughnessRa3.2-1.6Ra3.2-1.6Ra6.3-3.2Ra6.3-3.2Ra6.3-3.2Ra3.2-1.6
Heat treatmentSolid solution（T6）Solid solution（T6）Solid solution（T6）Solid solution（T6）Solid solution（T6）no
Production efficiencyHighLowMediumMediumLowHigh
Forming accuracyHigh lever of one-time forming and less machining allowanceLow lever of one-time forming , the process is complex, and a lot of subsequent processing is requiredA lot of subsequent processing is requiredA lot of subsequent processing is requiredA lot of subsequent processing is requiredHigh lever of one-time forming and less machining allowance
Mechanical propertiesClose to forging level without forging streamlineHighest (but there is forging streamline, which makes the metal properties anisotropic)MediumMediumMediumLow

E-bike Motor Mount Equipment Introduction and Capacity
Equipment modelEquipment tonnage(clamping force)QuantityDaily capacity(Mold times)Product weight(kg)Maximum projected area of product(cm2)Die size(mm)Molding pressure(Mpa)
HVSC400T11130000.5-2350650*650*75080-160
1250T(800T)212205-109601260*1150* 1500100-160
2500T(At present,it is the largest squeeze casting model in China)146020-4019601660*1760*1700115-160

Komman has the capabilities of material research and development, structural design and manufacturing verification.
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.

Continuous research and innovation to provide customers with better solutions
Komman has established joint laboratories and lightweight research centers with well-known domestic universities to develop and select the best lightweight materials that meet product performance requirements together with experts in the field of materials. Technological innovation and product development are regarded as the company's sustainable development strategy to provide customers with better solution.
Komman now has the materials as below:
Materialtensile strength/MpaYield Strength/MpaElongation /%Remark
A356.23102508
A3543302404
KM-HS0134030010
KM-HS0232026012High elongation Al-Si
KM-C3803208
KM-HS0244038010High strength Al-Si-Cu-Mg

Komman has an experienced management team, technical development team and production operation team
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%.