The intake manifold is a very complex product, because it must have very tight dimensional tolerances in the face of a very high geometric complexity, in terms of shape and thickness variation. In cases like these, the risk of having to resort to a very large number of correction loops is very high.

Objective:

Reduce the number of tests required to fine-tune the product and process
Define the profile of the vibration weld joint
Predict through the simulation the warpage of the part and build the mold accordingly.

Activity:

• Product and process debugging, through the preventive analysis of critical issues
• Mold construction
• Test and validation at Omas, including welding, leak test and burst test.

Synergy between simulation, design and mold construction

The great criticalities of geometry, characterized by complex 3D shapes, by thickness jumps, by the need for flatness in the welding tracks, together with the tendency to deform the glass fiber reinforced material, required a very accurate rheological check, with particular attention to warpage and cooling.
The information deriving from the rheological simulation was used to optimize the geometry of the object, mainly in the welding profile and to apply differentiated shrinkage factors in the different areas of the mold, to obtain a design piece from the first test.

Weld

The setup of the positions and the welding operations were carried out directly at the supplier together with the mold test.

Product verification

The welded samples were subjected to leak and burst tests using specially set up test benches.

Metrology

In the intake manifolds, the respect of dimensional tolerances is fundamental, but also very complicated because there can be over 500 dimensions on the 2D drawing, with very tight tolerances. The close collaboration with the customer allowed for the definition of the part program in PC-DIMIS and the 3D measurement of all the dimensions.

Result

The preventive debugging approach to the product and process made it possible to define precise and accurate choices before the construction of the mold.
This allowed us to obtain very good samples from the first test and to arrive at the SOP after only one optimization loop.