Research On Optimization Of Production Process Of Automobile Bumper

With the development of economy and science and technology,the automobile has become the main means of transportation for people to travel.With the gradual improvement of environmental protection requirements,lightweight,energy conservation and emission reduction have become the main goals of the development of the automobile industry today.Plastic products are widely used in automobile industry because of their excellent mechanical properties and low mass density,which makes them more suitable for light weight.The application of plastic products in automobile parts mainly focuses on automobile interior and exterior decoration products,such as dashboard,rearview mirror and automobile bumper.In the automotive plastic parts,the bumper as the most prominent parts of the car shape,its product quality requirements are very high,the process is complex.Compared with the production process of other automobile plastic parts,the production process of automobile bumper not only includes injection molding,but also goes through painting,welding and other processes,so as to produce assembly pieces that meet the quality requirements.In addition,compared with interior decoration products,the replacement cycle of bumper products is short,usually 2-3 years the whole car factory needs to change the appearance of the bumper model,in order to stimulate consumers' buying enthusiasm,so the process development work of bumper products is very heavy.Combining with the actual production requirement,the bumper production process:injection molding,painting,welding process simulation analysis,the combination of theoretical calculation and experimental design,study the effect of process parameters on product quality,optimize process parameters,improve production quality and production efficiency of bumper products,for the bumper has a guiding significance for product development and industrial production.To enhance the quality and production efficiency of bumper injection molded parts,this article through the Moldflow software for bumper plastic products and mould structure are analyzed in the early stage of the design,to simulate the runner layout,clamping force,the system pressure,the product uniformity of the thickness,the position of weld line,sink mark,product surface temperature,and optimize the gate location,product structure and mold structure;The automatic loading and unloading of the product in the injection mold was studied,the influence of fixed mold and moving mold on the product quality was studied,and the mechanical grip was designed and optimized.Analysis of the influence of process parameters on the quality of the products,based on the orthogonal LATIN software,got L25 orthogonal data,each group of factors as initial parameters Moldflow simulation,obtained the corresponding index of shrink mark and warping,through analysis,the influence product buckling deformation and the main technical parameters of the shrink mark,in order to improve the production efficiency,little impact on the quality of product of the process parameters for the parameter optimization,reduces the takt time in injection molding,and meet the quality requirements of injection parts is obtained,which improve the efficiency of injection molding.In order to improve the quality of the pipeline robot automatic spray type bumper and the production efficiency,this paper studies the hanging fixture layout and chain speed affect the production efficiency,using the simulation software to get the optimal hanging fixture layout,design,and completed the hanging fixture hanging fixture positioning in the production of research on the quality of the product,and the hanging fixture positioning is optimized;The parameters such as spray flow rate,rotating cup flow rate,high voltage static electricity and robot speed were calculated theoretically.Based on the method of controlling single variable and the parameter value calculated by theory,the influence of different spraying parameters on product quality was studied through designing spraying test,and the spraying distance,rotating cup flow rate,rotating cup speed and spraying speed range satisfying the requirements of product quality were obtained.In order to improve the quality and production efficiency of the bumper after ultrasonic welding,this paper carries on the design research from the welding equipment structure and the mold structure,optimizes the mold positioning structure design,ensures the stability of the product on the mold;The influence of ultrasonic welding head design on welding efficiency is studied.Combined with the product structure,the design innovatively adopts sub parent welding head to reduce welding action and improve welding efficiency.Through design test,the welding stress and welding time on the welding strength and the influence of product appearance quality test to determine the quality meet the requirement of welding stress and welding time value,and using the structure obtained from the experiment,studies the equipment in depth mode,impact on the quality of welding,welding depth got the reasonable range of values,the welding depth achieved in welding production,fast with process parameter setting and debugging purposes.