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Related Components: Stainless steel protection tubes for high-voltage harnesses, bus bar sleeves for motor controllers (mostly 304 stainless steel thin-walled tubes with a thickness of 0.8-1.2mm).
Key Forming Processes:
Necking + Sealing: The sleeve ends are necked down to a diameter matching the harness connectors (tolerance ±0.05mm), and the terminals adopt an "inward curling and sealing" process to prevent sharp pipe mouths from damaging the harness insulation layer;
Stepped Flaring: The connection end of the sleeve and the controller interface is flared into two stages—one stage adapts to the sealing rubber ring, and the second stage is used for flange fixing—achieving dual protection of "mechanical fixation + insulation sealing".
Technical Value: The formed sleeves reach an IP67 protection rating, tolerating a temperature range of -40℃ to 125℃, and meet the insulation and weather resistance requirements of high-voltage systems.
Related Components: High-pressure hydrogen pipes (316L stainless steel, pressure resistance 70MPa), inlet/outlet connection pipes for hydrogen circulation pumps.
Key Forming Processes:
Tapered Necking + Mirror Polishing: The ends of hydrogen pipes are necked into a 15° tapered surface, matching tapered sealing joints to achieve "gasket-free sealing". After necking, the inner wall undergoes electrolytic polishing (roughness Ra ≤ 0.8μm) to avoid hydrogen embrittlement impurity accumulation;
Flange Flanging + Integrated Punching: The pipe ends are flanged to form a 10mm-wide flange surface, with 4 φ6mm mounting holes punched simultaneously. The flatness error of the flange is ≤ 0.1mm, ensuring tight fitting with the hydrogen pump interface.
Equipment Requirements: "Inert gas-protected forming" equipment is required to prevent air from entering the pipes during processing and causing oxidative contamination.
Related Components: Front suspension control arm sleeves (aluminum alloy tubes, diameter φ30-φ50mm), transverse stabilizer bar connection tubes.
Key Forming Processes:
Flattening + Punching: The sleeve ends are cold-formed to a thickness of 8-10mm, with mounting holes matching ball joints punched simultaneously. The perpendicularity error of the flattened surface is ≤ 0.2mm;
Knurling + Necking: The outer surface of the stabilizer bar connection tube ends is knurled (knurl pitch 1.5mm), then necked down for interference fit with the stabilizer bar, increasing torsional strength by 30% after assembly.
Application Value: The formed aluminum alloy tubes are 40% lighter than steel components while meeting the 100,000-cycle fatigue impact test requirements of suspension systems.
Related Components: Subframe connection sleeves (Q345B seamless steel tubes, wall thickness 3-5mm).
Key Forming Processes:
Flaring + Chamfering: Both ends of the sleeve are flared to a diameter 5mm larger than the main body, forming a "socket" structure for easy insertion and welding of longitudinal beams; the flared ends are chamfered (C2mm) to avoid slag accumulation during welding;
Special-Shaped Necking: Some sleeve ends are necked into square or oval shapes to adapt to special-shaped bracket interfaces, with a cross-sectional dimension tolerance of ±0.3mm.
Related Components: Filler sleeves for door anti-collision beams (high-strength steel tubes, tensile strength ≥ 1500MPa), reinforced sleeves for sill beams.
Key Forming Processes:
Gradual Necking: Both ends of the anti-collision beam sleeve are gradually necked from φ40mm to φ30mm, forming a "tapered transition" that absorbs energy through progressive deformation during collisions;
Sealing + Rib Pressing: The sleeve terminals are sealed by stamping, with 3 annular reinforcing ribs pressed on the outer surface to improve buckling resistance. The sealing port achieves airtightness of 0.3MPa without leakage (meeting waterproof and anti-rust requirements for some vehicle models).
Test Data: The formed anti-collision beam reduces door intrusion by 25% in side collision tests.
Related Components: Seat slide rail sleeves (galvanized steel tubes, diameter φ18mm), armrest frame support tubes.
Key Forming Processes:
Grooving + Necking: The slide rail sleeve ends are necked down, then axially grooved (groove width 8mm) to form "elastic jaws" that match the slide rail locking pins; the groove edges are deburred to avoid abnormal noise during sliding;
Bending + End Flattening: The armrest frame support tubes are first bent into shape, then flattened at both ends. Mounting holes are drilled after flattening, with a perpendicularity error of ≤ 0.15mm between the flattened surface and the bent tube axis.
Related Components: Transmission lubricating oil pipes (aluminum alloy tubes, wall thickness 1.5mm), cooling tubes for dual-clutch transmissions.
Key Forming Processes:
Pagoda-Shaped Flaring: The lubricating oil pipe ends are flared into a "pagoda shape" (3 stages) to match the pagoda joints of rubber hoses, with an insertion force ≥ 500N to prevent detachment;
S-Shaped Necking: The cooling tube ends are necked into an S-shaped cross-section to adapt to the special-shaped interface of the transmission housing, with no wrinkles on the inner wall after necking, ensuring coolant flow loss < 3%.
Related Components: Resonator sleeves for engine intake pipes (plastic-reinforced steel tubes), crankcase ventilation pipes (fluororubber-coated steel tubes).
Key Forming Processes:
Bell Mouth + Inner Chamfering: The intake pipe sleeve ends are flared into a 60° bell mouth, with the inner surface chamfered (R1mm) to reduce airflow resistance, improving engine intake efficiency by 2%;
Thread Forming + Seal Grooving: The ventilation pipe ends are processed with external threads (M18×1.5) and turned with seal grooves (3mm wide, 1mm deep), matching fluororubber seals to achieve oil-resistant sealing.
