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The rapid development of new energy vehicles demands significant improvements in connector structures and performance standards. Wire harness connectors, crucial for linking various electrical components, face challenges due to their small size and thin-walled structure, which can lead to dimensional shrinkage and warping during injection molding. To address these issues, this study optimizes the injection molding process by fine-tuning parameters such as melt temperature, mold temperature, injection time, holding pressure/time, and cooling time. By integrating the Taguchi method with grey relational analysis, the study enhances the molding process for thin-walled composite connectors. This combined approach provides a comprehensive framework for optimizing multiple quality objectives and improving the overall performance of injection-molded composite components. [ABSTRACT FROM AUTHOR]

Transmission gear is a key component of vehicles and its surface integrity affects the safety of the transmission system as well as the entire mechanical system. The design and optimization of allowances in form grinding are important for improving dimensional accuracy and machining efficiency during the manufacturing of heavy-duty gears. This work aims to investigate the effects of grinding allowance allocation on surface morphology, grinding temperature, microstructure, surface roughness, and microhardness fluctuation during the form grinding of 20Cr2Ni4A gears. Results indicated that grinding temperature was primarily influenced by rough grinding involving significant grinding depths exceeding 0.02 mm. The ground surface exhibited slight work hardening, while thermal softening led to a reduction in microhardness of around 40 HV. Ground surface roughness Ra varied from 0.930 μm to 1.636 μm, with an allowance allocation of the last two passes exerting the most significant influence. Analysis of surface and subsurface microstructures indicated that a removal thickness of 0.02 mm during fine grinding was insufficient to eliminate the roughness obtained from rough grinding. Evident ridges, gullies, and surface defects such as material extraction, adhesion, and plastic deformation were also observed. The proposed grinding strategy was validated in practical manufacturing with good surface quality and geometrical accuracy. [ABSTRACT FROM AUTHOR]