Lossless one-time forming process for vehicle-mounted camera shell for new energy vehicle

Abstract

A vehicle-mounted camera serves as a core sensing part of an automobile intelligent driving system, and the manufacturing quality of a shell of the vehicle-mounted camera directly affects the imaging precision and the service life of the camera. A traditional manufacturing process commonly adopted in the current industry has many technical bottlenecks that firstly, mechanical damage is inevitably caused to the surface of a workpiece by a multi-procedure machining process, the appearance of a product is influenced by the surface defects, and the corrosion resistance and the welding reliability of the product can be remarkably reduced; secondly, the problem of accumulative errors caused by a step-by-step forming process seriously restricts the size precision of a product, and the requirement of high-precision optical assembly is difficult to meet; moreover, a traditional process is low in production efficiency, serious in mold loss and incapable of meeting the production requirements of the new energy automobile industry for large-batch and low-cost parts, and the lossless one-time forming process and device for the vehicle-mounted camera shell for the new energy automobile are provided. By optimizing blank pretreatment, DEFORM simulation parameters, a gradient pressure forming process and a non-destructive surface treatment technology, the precise size requirement can be met through one-time forming, and the problems of surface damage, size errors and low production efficiency caused by a traditional process are effectively solved; the method has the remarkable advantages of improving the product yield, reducing the mold loss and guaranteeing the long-term use stability.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of new energy vehicle parts manufacturing technology, in particular to a new energy vehicle camera shell non-destructive one-step forming process. BACKGROUND

[0002] As the core perception component of the intelligent driving system of the vehicle, the shell manufacturing quality of the vehicle-mounted camera directly affects the imaging accuracy and service life of the camera. The traditional manufacturing process widely used in the current industry has many technical bottlenecks: first, the multi-process machining process inevitably causes mechanical damage to the surface of the workpiece, which not only affects the appearance of the product, but also significantly reduces the corrosion resistance and welding reliability of the product; second, the cumulative error problem caused by the step-by-step forming process seriously restricts the dimensional accuracy of the product, making it difficult to meet the requirements of high-precision optical assembly; third, the production efficiency of the traditional process is low, and the mold is severely damaged, which cannot meet the production demand of large quantities and low cost of parts in the new energy vehicle industry; finally, the existing technology pays insufficient attention to the surface treatment of the product, which causes hidden dangers in the sealing and long-term stability of the finished product. These technical defects jointly restrict the further improvement of the product quality of the vehicle-mounted camera shell. SUMMARY

[0003] The purpose of the present application is to provide a new energy vehicle camera shell non-destructive one-step forming process to solve the existing problems.

[0004] The technical solution of the present application is as follows: A new energy vehicle camera shell non-destructive one-step forming process, characterized by the following steps: S1, blank pretreatment: Select Al1070 or Al1050 aluminum alloy blank, wherein the yield strength of Al1070 is 30MPa; Cut according to the theoretical size of the shell, the perpendicularity of the cut surface is ≤0.05mm, and the cutting surface is free of burrs; After cutting, perform stress relief annealing treatment: temperature 280-320℃, holding time 1-2 hours, and cooling to room temperature with the furnace; S2, DEFORM simulation optimization: Establish a three-dimensional model of the shell, input the material mechanics parameters, the elastic modulus of Al1070 is 69GPa, and the Poisson's ratio is 0.33; Simulate the metal flow trajectory, optimize the blank size, increase the length by 5%-8% compared with the theoretical value, and ensure that the minimum width of the metal flow channel is ≥3.36mm; Simulate the maximum strain value at the corner, and set the corner process angle of the mold to ≥R0.25mm according to the simulation output; S3, one cold extrusion forming: The mold is designed without demolding slope, and the inner wall of the cavity is provided with staggered diamond laser micro-texture, with a unit size of 50 μm x 50 μm, a depth of 5-10 μm, and a reduced metal flow friction coefficient; Gradient pressurization is implemented by a servo press: First stage (0-1.2s): load 5±1T, strain rate 0.05-0.1s⁻¹, realizing pre-deformation of the blank; Second stage (1.2-3.2s): load 15±2T, pressure maintaining 3-5s, making the metal uniformly fill the mold cavity; Third stage (3.2-5.0s): the maximum load is calculated according to the formula Fmax=k・A・σs, wherein k=1.2-1.5, A is the projected area of the blank, and σs is the material yield strength. After forming, the metal grid inside the shell has no flow-through and folding, and the clamping surface flatness is ≤0.05mm; S4, non-destructive surface finishing: Magnetic lapping: Φ0.5-1mm ceramic abrasive with hardness ≤HV300 is used, the rotating speed is 300-500r / min, lapping for 5-8 minutes, and the surface roughness is reduced from Ra3.2μm to Ra≤1.6μm; Non-contact leveling: for the area with out-of-tolerance flatness, electromagnetic force is used for micro-deformation leveling, and the single deformation amount is ≤0.03mm; S5, precise cleaning and full inspection: Ultrasonic cleaning: neutral cleaning agent (pH6.5-7.5) is used, the water temperature is 50-60℃, and cleaning is performed for 10-15 minutes to remove surface grease and abrasive residue. After cleaning, the surface grease residue is ≤0.1mg / cm²; Full inspection: Three-coordinate measurement size tolerance ±0.05mm, and the flatness of the laser welding surface is ≤0.03mm; Neutral salt spray test for 96 hours, no oxidation corrosion on the surface; the laser welding area is subjected to penetration detection, and no cracks or pores are found.

[0005] Further, the application also proposes that after stress relief annealing in step S1, the surface of the blank is subjected to electrolytic polishing treatment to remove the oxide layer, and the surface roughness is reduced to Ra≤3.2μm.

[0006] Further, the application also proposes that the DEFORM simulation in step S2 also outputs a mold wear prediction value. When it is predicted that the wear amount of a certain area is >0.02mm, the mold of the area is made of SKD11 material with a hardness of HRC58-62, and is plated with chromium with a plating layer thickness of 5-8μm.

[0007] Further, the application also proposes that in the third stage of gradient pressurization in step S3, the measured value of the maximum load Fmax deviates from the calculated value by ≤5%, and the equipment automatically stops when the deviation exceeds.

[0008] Further, the application also proposes that in step S3, the mold is provided with a conformal cooling water channel: the inlet water temperature is 20-25℃, the flow rate is 1-2L / min, and the real-time heat generated during extrusion is removed.

[0009] Further, the application also proposes that in step S4, the magnetic grinding adopts a bidirectional rotating magnetic field, so that the abrasive uniformly wraps the surface of the shell, and the surface after grinding has no directional scratches.

[0010] Further, the application also proposes that in step S5, after ultrasonic cleaning, hot air drying is used: the temperature is 60-80℃, the air speed is 2-3m / s, the drying time is 5-8 minutes, and the surface water residue is ≤1mg / cm².

[0011] Further, the application also proposes that in step S2, the DEFORM simulation outputs a fillet compensation amount ΔR=0.05・e⁻ᵋ, wherein ε is a strain distribution deviation coefficient, and when ε>0.3, the mold corner process angle is increased by ΔR compensation amount based on R0.25mm.

[0012] Further, the application also proposes that in step S3, after cold extrusion forming, the shell thread connection part is pre-set with a self-tapping thread hole, and the diameter of the self-tapping thread hole is smaller than that of the self-tapping screw by 0.1-0.2mm, so as to avoid material tearing caused by direct tapping.

[0013] Further, the application also proposes that in step S5, the full inspection also includes air tightness detection: 0.2MPa compressed air is filled into the inner cavity of the shell, and the pressure is maintained for 30 seconds, and the leakage amount is ≤1×10⁻ 5 Pa・m³ / s.

[0014] The beneficial effects of the application are: The new energy vehicle-mounted camera shell lossless one-time forming process and device provided by the application realizes precise size requirements through optimization of blank pretreatment, DEFORM simulation parameters, gradient pressurization forming process and lossless surface treatment technology, effectively solves the problems of surface damage, size error and low production efficiency caused by traditional processes, and has the significant advantages of improving product yield, reducing mold loss and ensuring long-term use stability. DETAILED DESCRIPTION

[0015] With reference to the embodiments of the present application, the technical solutions in the embodiments of the present application will be described clearly and completely. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments of the present application, all the other embodiments obtained by a person of ordinary skill in the art without creative work, fall within the protection scope of the present application.

[0016] In the prior art, the manufacturing process of the vehicle-mounted camera shell faces problems such as surface damage caused by multi-process processing, precision cumulative error caused by multiple molding, low molding efficiency, and lack of non-destructive processing. The traditional process adopts multi-stage molding and post-processing procedures, which causes scratches and indentations on the surface of the workpiece, affecting corrosion resistance and welding strength. Multiple clamping and positioning causes size tolerance accumulation, and the superposition of internal metal stress causes late deformation risk. In addition, hard abrasive grinding and residual moisture cause insufficient surface quality, making it difficult to meet high precision and high reliability requirements.

[0017] To solve the above problems, the inventors found that surface damage and multiple molding are the core factors restricting the quality of the shell. By analyzing the metal flow rule, it is realized that optimizing the blank size and mold structure can reduce the molding times. For friction coefficient control, a micro-textured mold design idea is proposed. To solve the surface treatment damage, soft abrasive and electromagnetic leveling technology are explored. Combined with simulation prediction and gradient pressure strategy, an integrated molding scheme is formed to avoid the process fragmentation problem of traditional process.

[0018] Therefore, the present application proposes a new energy vehicle-mounted camera shell non-destructive one-time forming process, including the following steps: blank pretreatment: selecting a specific aluminum alloy and performing stress relief annealing; DEFORM simulation optimization: establishing a three-dimensional model to analyze the metal flow trajectory, optimizing the blank size and mold process angle; one-time cold extrusion molding: using a non-demolding slope mold and a gradient pressure strategy to control the load in stages; non-destructive surface finishing: using soft ceramic abrasive for magnetic grinding, combined with electromagnetic force micro-deformation leveling; precision cleaning and full inspection: ultrasonic cleaning with neutral cleaning agent, and implementing size tolerance and sealing performance detection.

[0019] Among them, the stress relief annealing refers to eliminating the internal residual stress of the blank by heat treatment in a specific temperature range, which can be realized by using a box-type resistance furnace to ensure the stability of the initial state of the material. The DEFORM simulation optimization refers to predicting the metal flow behavior based on finite element analysis, establishing a model through computer-aided engineering software, and correcting the blank size and mold geometric parameters. The gradient pressure strategy refers to adjusting the load of the press in stages, which can be realized by using a servo control system to avoid overloading deformation of the material. The staggered diamond laser micro-texture refers to processing micro-geometric texture on the inner wall of the mold cavity, which is formed by laser engraving equipment to reduce the friction resistance of metal flow. The non-contact flattening refers to using electromagnetic field to generate controllable deformation force, which is implemented by an electromagnetic generator to eliminate surface damage caused by mechanical contact.

[0020] Compared with the prior art, the traditional process relies on multiple forming and machining, which makes it difficult to control the surface quality and dimensional accuracy. The present scheme eliminates the multi-process connection error through integrated forming process, and reduces the trial molding times by combining simulation optimization. The mold micro-texture design and gradient pressure strategy work together to achieve high-precision profile forming in single forming. The non-contact flattening and soft abrasive grinding technology breaks through the traditional surface treatment method, avoiding secondary damage. The precise cleaning process effectively controls the residues, which significantly improves the product consistency compared with the traditional process.

[0021] The present application further proposes that the surface of the blank is subjected to electrolytic polishing treatment after stress relief annealing to remove the oxide layer and reduce the surface roughness to Ra≤3.2 μm.

[0022] Among them, the electrolytic polishing treatment refers to a process of removing micro-protrusions on the surface of the metal through electrochemical dissolution, which can be realized by using an acidic electrolyte under the action of a direct current electric field. The surface micro-high points are preferentially dissolved by anodic dissolution to form a smooth surface. This treatment can eliminate the oxide layer formed during the annealing process and avoid interference of the oxidation residues in the subsequent forming process.

[0023] Among them, the surface roughness Ra≤3.2 μm refers to controlling the electrolytic polishing parameters to make the surface profile arithmetic mean deviation not exceed the threshold value, which can be realized by adjusting the electrolyte temperature, current density and polishing time. This roughness range not only ensures the lubrication requirement of metal flow during subsequent cold extrusion, but also avoids material loss caused by excessive polishing.

[0024] The present application further proposes that the DEFORM simulation in step S2 also outputs a mold wear prediction value. When it is predicted that the wear amount of a certain area exceeds a threshold value, the mold in that area is made of a specific material and plated with chromium.

[0025] The DEFORM simulation refers to a numerical simulation process established by a metal forming finite element analysis software, which can be specifically implemented by DEFORM-3D software, and the die surface wear distribution in the forming process is predicted by inputting material parameters and process conditions. The die wear prediction value refers to the die surface material loss calculated by the software, which can be specifically implemented by the Archard wear model based on contact pressure and sliding distance to calculate the wear depth. The SKD11 material refers to high-carbon high-chromium alloy tool steel, which can be specifically implemented by JIS G4404 standard steel, and its high hardness characteristics can resist abrasive wear caused by metal flow. Chromium plating refers to forming a metal chromium layer on the die surface by electrochemical deposition, which can be specifically implemented by hexavalent chromium plating process, and the thickness of the plating layer is adjusted by controlling the current density and plating time to form a protective layer with wear resistance and surface integrity.

[0026] The application further proposes a technical scheme for real-time monitoring and automatic control of the maximum load in the third stage of gradient pressurization. When the deviation between the measured load and the theoretically calculated value exceeds the set threshold, the equipment protection mechanism is triggered.

[0027] The maximum load measured value and the formula calculation value deviation ≤5% refers to the allowable error range between the actual applied load and the theoretically calculated value in the forming process, which can be specifically implemented by the linkage of the pressure sensor and the control system. This feature ensures that the forming process meets the material flow requirements and avoids overload risks. The automatic shutdown of the equipment refers to immediately terminating the processing flow when the load deviation exceeds the allowable range, which can be specifically implemented by the linkage of the emergency stop module of the servo drive system and the central controller. This feature prevents defective products from being produced under abnormal working conditions and protects the integrity of the die structure.

[0028] The application further proposes that the die is provided with a conformal cooling water channel, the water inlet temperature is controlled at 20-25°C, and the flow rate is controlled at 1-2 L / min to remove the heat generated by extrusion in real time.

[0029] The conformal cooling water channel refers to the spatial consistency between the flow path of the cooling medium and the geometry of the die cavity, which can be specifically implemented by additive manufacturing technology or precision casting technology. The flow distribution matching the high heat generation area of the die is generated by a three-dimensional topology optimization algorithm. This structure enables the cooling medium to cover all heat source areas of the die contact surface. The water inlet temperature of 20-25°C refers to the initial temperature range of the cooling medium, which can be specifically implemented by a constant-temperature water cooling unit combined with a PID temperature control system. This temperature range can avoid work hardening of aluminum alloy materials due to sudden cooling and ensure sufficient heat exchange temperature difference. The flow rate of 1-2 L / min refers to the volume of the medium flowing through the cooling water channel per unit time, which can be specifically implemented by a variable frequency water pump combined with a flowmeter closed-loop control. This flow rate range ensures heat exchange efficiency while avoiding high flow rate induced turbulent impact.

[0030] The application further proposes that the magnetic force grinding adopts a bidirectional rotating magnetic field, so that the abrasive is uniformly wrapped on the surface of the shell, and the surface after grinding has no directional scratches.

[0031] The bidirectional rotating magnetic field refers to a control mode of forming a composite magnetic field force by alternately changing the rotating direction of the magnetic field. Specifically, it can be realized by alternately energizing two groups of electromagnetic coils arranged orthogonally, and the periodic change of the magnetic field direction is realized by changing the current direction and intensity of the coils. The uniform wrapping refers to the distribution state of the abrasive covering the surface of the shell at multiple angles under the action of the magnetic field force. Specifically, the abrasive can form a dynamic balance in bidirectional rotation by adjusting the frequency and intensity of the magnetic field, so as to ensure that each region of the surface of the shell is uniformly ground.

[0032] The application further proposes that after ultrasonic cleaning, hot air drying is used, the temperature is controlled in the range of 60-80℃, the wind speed is controlled in the range of 2-3m / s, and the drying time is controlled in the range of 5-8 minutes, so that the surface water residue is reduced to below 1mg / cm².

[0033] The temperature range of the hot air drying refers to the balance interval of the evaporation efficiency and the material thermal stability determined by thermodynamic calculation. Specifically, a segmented temperature control system can be used to realize it, which can accelerate water evaporation and avoid deformation of the aluminum alloy shell due to heating. The wind speed control refers to the air flow intensity parameter established according to the fluid mechanics model. Specifically, a frequency conversion fan can be used to realize it in combination with a guide cover structure, which can break the surface water film while preventing the shell from being displaced due to air flow impact. The drying time refers to the process time based on the matching of the internal cavity structure characteristics of the shell. Specifically, an infrared humidity sensor can be used for real-time monitoring to realize dynamic regulation and control, so as to ensure complete drying of the internal cavity of the shell with complex geometry. The surface water residue refers to the quantitative control index calibrated by the weighing method. Specifically, a high-precision moisture detector can be used for online monitoring to form a process parameter closed-loop feedback mechanism.

[0034] The application further proposes that in step S2, the DEFORM simulation outputs a fillet compensation amount ΔR=0.05・e⁻ᵋ, where ε is a strain distribution deviation coefficient. When ε>0.3, the die corner process angle is increased by the compensation amount ΔR based on R0.25mm.

[0035] The strain distribution deviation coefficient ε refers to the deviation degree of the actual strain and the theoretical strain distribution in the metal flow process. Specifically, it can be calculated by the strain field data output by the DEFORM simulation software, and is used to quantify the uniformity of metal flow in different regions. The fillet compensation amount ΔR is a nonlinear correction parameter based on the strain deviation. Specifically, it is calculated by using the exponential function relation ΔR=0.05・e⁻ᵋ. This function form can reflect the nonlinear influence of the strain deviation on the material accumulation degree.

[0036] The application further provides a self-tapping thread bottom hole at the threaded connection part of the shell after cold extrusion forming, and the diameter of the bottom hole is smaller than the diameter of the self-tapping screw by a certain range, so as to avoid material tearing caused by direct tapping.

[0037] The self-tapping thread bottom hole refers to a hole formed in advance by a mold structure during shell forming, and the hole can be directly formed by a punch structure of a cold extrusion mold. The bottom hole provides a plastic deformation space for the subsequent self-tapping screw. The size relationship that the diameter of the bottom hole is 0.1-0.2 mm smaller than the diameter of the self-tapping screw is a matching parameter determined by finite element simulation, and the size range can be realized by adjusting the diameter of the mold punch, so as to ensure the formation of a complete thread profile during tapping and avoid excessive deformation of the material.

[0038] The application further provides airtightness detection in the full inspection link of step S5, specifically including filling compressed air into the inner cavity of the shell and maintaining pressure, and judging the sealing performance by detecting the leakage amount.

[0039] The airtightness detection refers to simulating the actual working pressure of the shell by filling compressed air, detecting whether the shell has a leakage defect, and specifically can be realized by using a differential pressure sensor or a flowmeter to quantitatively evaluate the integrity of the sealing structure of the shell. The 0.2 MPa compressed air refers to the set detection pressure value, which can be realized by a proportional pressure regulating valve, and the pressure can effectively expose small leakage defects and avoid plastic deformation of the shell. The pressure maintaining time of 30 seconds refers to the duration of maintaining the detection pressure, which can be controlled by an electromagnetic valve to ensure the stability of the leakage amount measurement. The leakage amount ≤1×10⁻ 5 Pa·m³ / s refers to the maximum allowable leakage threshold, which can be realized by using a high-precision micro-leakage detector, and the threshold is set based on the dustproof and waterproof level requirements of the vehicle-mounted camera.

[0040] Through the above technical solutions, the application solves the problem of insufficient surface sealing caused by the absence of non-destructive treatment in the traditional process, effectively identifies the internal micro-leakage defects of the shell, and ensures the long-term stable operation of the camera in a humid and dusty environment. The detection result is directly related to the product reliability index, providing a quantifiable quality control standard for mass production, and avoiding the risk of contamination of the optical components or short circuit of the circuit of the camera caused by sealing failure.

[0041] The above only describes the embodiments of the application and does not limit the protection scope of the application. For those skilled in the art, the application can have various changes and modifications. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the application shall be included in the protection scope of the application.

Claims

1. A non-destructive one-step molding process for a vehicle-mounted camera housing for a new energy vehicle, characterized in that: The following steps are involved: S1. Pretreatment of blanks: Al1070 or Al1050 aluminum alloy billets are selected, wherein the yield strength of Al1070 is 30MPa; Cutting should be done according to the theoretical size of the shell, with a verticality of ≤0.05mm and no burrs on the cutting surface; After unloading, stress relief annealing treatment is carried out: temperature 280-320℃, keep warm for 1-2 hours, and cool to room temperature with the furnace; S2, DEFORM simulation optimization: Establish a three-dimensional shell model and input material mechanical parameters: Al1070 elastic modulus 69 GPa, Poisson's ratio 0.33; Simulate and analyze the metal flow trajectory to optimize the billet size, increasing the length by 5%-8% compared to the theoretical value, ensuring the minimum width of the metal flow channel is ≥3.36mm; The simulation outputs the maximum strain value at the corner, and based on this, the mold corner process angle is set to ≥ R0.25mm; S3, one-step cold extrusion molding: The mold adopts a design without demoulding slope, and the inner wall of the cavity is provided with staggered diamond laser micro-texturing with a unit size of 50μm×50μm and a depth of 5-10μm to reduce the metal flow friction coefficient; Using servo press to implement gradient pressurization: The first stage (0-1.2s): load 5±1T, strain rate 0.05-0.1s⁻¹, to achieve pre-deformation of the blank; The second stage (1.2-3.2s): load 15±2T, hold pressure for 3-5s, so that the metal evenly fills the mold cavity; Stage 3 (3.2-5.0s): The maximum load is calculated according to the formula Fmax=k・A・σs, where k=1.2-1.5, A is the projected area of ​​the blank, σs is the yield strength of the material, and after forming, the metal mesh inside the shell has no flow through or folding, and the flatness of the clamping surface is ≤0.05mm; S4. Non-destructive surface finishing: Magnetic grinding: Using ceramic abrasive with a hardness of ≤HV300 and a rotation speed of 300-500r / min, grinding for 5-8 minutes, the surface roughness is reduced from Ra3.2μm to Ra≤1.6μm; Non-contact leveling: for areas with excessive flatness, leveling is performed through electromagnetic force with micro-deformation, and the single deformation is ≤0.03mm; S5. Precision cleaning and full inspection: Ultrasonic cleaning: Use a neutral detergent (pH 6.5-7.5), water temperature 50-60°C, cleaning for 10-15 minutes to remove surface grease and abrasive residues. After cleaning, the surface grease residue should be ≤ 0.1mg / cm². Full inspection: The three-coordinate measurement dimensional tolerance is ±0.05mm, and the laser welding surface flatness is ≤0.03mm; Neutral salt spray test for 96 hours showed no surface oxidation corrosion; penetration test of laser welding area showed no cracks or pores.

2. A non-destructive one-step molding process for a vehicle-mounted camera housing for a new energy vehicle according to claim 1, characterized in that: After the stress relief annealing in step S1, the surface of the blank is electrolytically polished to remove the oxide layer and reduce the surface roughness to Ra≤3.2μm.

3. A non-destructive one-step molding process for a vehicle-mounted camera housing for a new energy vehicle according to claim 1, characterized in that: In step S2, the DEFORM simulation also outputs a predicted value for mold wear. When the predicted wear amount in a certain area is greater than 0.02 mm, the mold in that area is made of SKD11 material with a hardness of HRC58-62 and is chrome-plated with a coating thickness of 5-8 μm.

4. A non-destructive one-step molding process for a vehicle-mounted camera housing for a new energy vehicle according to claim 1, characterized in that: In the third stage of the gradient pressurization in step S3, the deviation between the measured value of the maximum load Fmax and the value calculated by the formula is ≤5%. If the deviation is exceeded, the equipment automatically shuts down.

5. A non-destructive one-step molding process for a vehicle-mounted camera housing for a new energy vehicle according to claim 1, characterized in that: In step S3, the mold is provided with a conformal cooling water channel: the water inlet temperature is 20-25°C, the flow rate is 1-2 L / min, and the heat generated by extrusion is taken away in real time.

6. A non-destructive one-step molding process for a vehicle-mounted camera housing for a new energy vehicle according to claim 1, characterized in that: In step S4, the magnetic grinding adopts a bidirectional rotating magnetic field so that the abrasive evenly wraps the shell surface, and there are no directional scratches on the surface after grinding.

7. A non-destructive one-step molding process for a vehicle-mounted camera housing for a new energy vehicle according to claim 1, characterized in that: After ultrasonic cleaning in step S5, hot air drying is performed: temperature 60-80°C, wind speed 2-3m / s, drying time 5-8 minutes, and surface moisture residual ≤1mg / cm².

8. A non-destructive one-step molding process for a vehicle-mounted camera housing for a new energy vehicle according to claim 1, characterized in that: In step S2, the DEFORM simulation outputs the fillet compensation amount ΔR=0.05·e⁻ᵋ, where ε is the strain distribution deviation coefficient. When ε>0.3, the mold corner process angle increases the ΔR compensation amount based on R0.25mm.

9. A non-destructive one-step molding process for a vehicle-mounted camera housing for a new energy vehicle according to claim 1, characterized in that: After cold extrusion in step S3, a self-tapping thread bottom hole is preset at the threaded connection part of the shell, and the diameter is 0.1-0.2mm smaller than the minor diameter of the self-tapping screw to avoid material tearing caused by direct tapping.

10. The non-destructive one-step molding process for a vehicle-mounted camera housing for a new energy vehicle according to claim 1, characterized in that: The full inspection in step S5 also includes an airtightness test: fill the inner cavity of the shell with 0.2MPa compressed air and maintain the pressure for 30 seconds. The leakage is ≤1×10⁻ 5 Pa・m³ / s.