Parameter Prediction And Optimization Design Simulation Of Vacuum Booster Housing Punching Flange

Vacuum booster is the main component of automobile brake system,as the main body-o uter panel of vacuum booster, front case's shape is complex, and it has stringent requirement s on the dimensional precision, the strength of the parts and wall thickness after molding. Es pecially, because the flanging-hole on the middle of front case connect with brake master cyl inder hermetically, so its' dimensional precision requirements very high, and must be ensure the airtightness after connecting with brake master cylinder.The traditional method to conduct the stamping formation of booster front housing is implement the technical configuration works by using corrected equations, design moulds and test them repeatedly with accumulated hands-on experience, but it usually leads to long development period and high initial cost, so it is hard to develop the optimal product in this way. With the rapid development of computer technology, the digital simulation technology can not only be used to do simulation analysis for the process of stamping formation about booster front housing, but also do pre-analysis targeting the process of panel formation, it can predict any potential technical defects including wrinkle, crack, thinning, spring back and fix them. By utilizing digital simulation technology, the number of mould testing will be less, the mould structure and its process parameter can also be optimized so that the stamping processing of products becomes more efficient because this technology largely reduce the development period and R&D cost of new products and enhance the product quality and its competitiveness.The AutoForm software was used to simulate the punching and flanging process of the front shell of the booster and the punching and flanging process of the master cylinder bore.Firstly, through the process calculation to determine the former shell punching process in the deep drawing coefficient, punching flange height, blank diameter, blanking force, drawing force and blank holder force, which provides the raw data for the numerical simulation process parameter setting. The initial model was established using 3D design software, use the IGS format to import the mathematical model into the AutoForm software, through the rational optimization of the relevant process parameters, and the process optimization of punching and flanging process of the front shell of the booster is finished, to achieve the process to complete the complex, thereby reducing the number of processes. Designed to complete before the shell punching flange composite mold, the system describes the punching in the cold punching process of the punching, scratches and scratches, wrinkling,rupture, rebound, slip line, thinning, flap material accumulation and other booster before the shell production process common of the punching defects, and puts forward the corresponding control measures to the corresponding defects, improve the quality of the before shell, It is very important for the process arrangement and design of the drawing process of other parts.