Study on Optimization of High-Pressure Casting Process and Improvement of Mechanical Properties for Damping Spacer Based on ABAQUS

A damping spacer rod is a key protective device in ultrahigh voltage transmission lines, which not only keeps the distance of split wires and limits the whipping and collision caused by the relative motion between sub-wires, but also inhibits the vibration of wires. This study aims to solve the problem of typical faults, such as loose wire clamps, that are prone to occur in damping isolation rods during long-term operation in ultra-high voltage transmission lines. Taking the spacer rod FGZ-450/34B as the object, a new high-pressure casting process for spacer rod frames is explored. The spacer rods were simulated by using the ABAQUS finite element software to predict the stress distribution and identify the dangerous sections. Based on this, the mold process was optimized to avoid die-casting defects. Meanwhile, mechanical property tests were carried out on the products produced by the two types of molds. The research finds that by optimizing the mold process, the die-casting quality of the dangerous section of the spacer rod can be effectively improved, and the best high-pressure die-casting scheme has been obtained through comparison. This research achievement provides technical support for enhancing the anti-vibration performance, anti-loosening reliability, short-circuit current thermal shock resistance, and anti-ultraviolet aging performance of damping isolation rods. It is of great significance for ensuring the stable operation of ultra-high voltage transmission lines and improving the production process level of damping isolation rods.