Research On Fiber Reinforced Composite Material Automobile Vacuum Booster Bracket Forming Qualitiy

Automobile parts lightweight is an important part of automobile lightweight.The traditional vacuum booster bracket is made of steel or aluminum,and other materials.And is manufactured by casting,so thebracket is heavy.Use the light quality,high strength of the fiber-reinforced composite material instead of traditional metal materials can significantly reduce the weight of the bracket.Among the fiber-reinforced composite materials,long glass fiber reinforced nylon composite material has light weight,high strength,creep resistance,corrosion resistance,chemical resistance,and low cost qualities.And it can significantly reduce the vacuum booster bracket weight The injection forming process can form various shapes of complex products,and can work with computer to optimize the product structure and forming process.In addition,the forming process can achieve the advantage of automation control,so it plays an important role in many lightweighting forming process,and becomes one of the main way of lightweight of automobile components forming process.The research on the structure design and optimization of automobile vacuum booster bracket,using lightweight fiber reinforced composite,the corresponding forming technology to produce lightweight automobile parts with good mechanical properties has significance meaing for the realization of the automobile lightweight,reduction of manufacturing cost,and meeting of service performance.According to the vacuum booster bracket working environment and service requirmgnt,long glass-fiber reinforced nylon composite material vacuum booster bracket was designed.and structure was optimized.By means of static analysis,modal analysis and simulation analysis,the vacuum booster bracket’s structure was optimized Using CAE software.to study the influence of process parameters on the vacuum booster bracket forming qualities The influence sequence of of process parameters on forming quality by partial factors test methods,and to seek the process parameter that has the greatest impact on the vacuum booster bracket warpage defect.The influence of the interaction between different process parameters on the forming quality was studied by using response surface methodology.And the prediction model of the warpage defect is established.The genetic algorithm is used to optimize the warpage defect and to find the best value of the warpage defect.According to the vacuum booster bracket structure optimization and forming process scheme optimization,the forming experiment performance test were done.It is concluded that pressure maintaining time and melt temperature have the greatest influences on the warpage,the mold temperature,and packing pressure have least effects.and when the pressure maintaining time is 12 s,melt temperature is 303℃,packing pressure is 80%,mold temperature is 100℃,V/P conversion point is 97.24%,coolant temperature is 21.5 ℃,cooling Reynolds number 11000,injection time is2.58 s,then the final weighted warpage defect is 0.61789 mm.According to the process optimization scheme,the tests of vibration performance,thermal endurance performance,braking force deformation resistance,the drawing performance of performance were carried out.The test results show that after optimimization,the vacuum booster bracket’s performances meet the requirements of product value.and the forming quality is good.