限位器包塑开裂失效分析与工艺优化  

Failure Analysis and Process Optimization of Plastic Cladding Cracking of Door Arrester

作　　者：郑波 郭文浩 朱晓怡 Zheng Bo;Guo Wenhao;Zhu Xiaoyi(SAIC Volkswagen Automotive Co.,Ltd.,Shanghai 201805)

机构地区：[1]上汽大众汽车有限公司,上海201805

出　　处：《汽车工艺与材料》2025年第3期69-72,共4页Automobile Technology & Material

摘　　要：为解决某车型车门限位器在开关门耐久试验中的开裂问题,借助偏振光显微镜和模流分析对零件进行缺陷分析并制定工艺优化措施。结果表明:延长钢芯抛丸时间可有效去除表面毛刺,减少锐边周围注塑后的微缺陷与应力集中;延长限位臂水煮时间可提升包塑吸水率,从而提高缺口冲击强度与破坏应力;在模具中增设排气镶块可增加分模线减少包塑内部气穴;调整限位臂注胶孔可使包塑材料流动不均匀位置转移至低应力区,降低失效风险。最终通过开关门耐久试验验证了工艺优化后零件的可靠性,解决了限位器包塑开裂失效问题。In order to address cracking failure of door arrester of a vehicle in door slamming durability test,polarized microscope and mold flow analysis are used to analyze defects in parts and develop process optimization measures.The results show that extending the shot blasting time of steel core can effectively remove surface burrs and reduce microdefect and stress concentration around sharp boundary after injection molding.Extending boiling time can improve water absorption of plastic cladding,thereby enhancing the notch impact strength and failure stress.Adding exhaust insert in the tooling can improve parting line and reduce air pockets inside the plastic cladding.Adjust injection hole of check link arm to transfer the uneven flow of material to low stress zone,reducing failure risk.Finally,the reliability of optimized parts is verified via door slamming durability test,which solves plastic cladding cracking failure.

关 键 词：限位器 开关门耐久试验 偏振光显微镜 模流分析 包塑开裂 

分 类 号：U467.1[机械工程—车辆工程]