壓鑄過程管理

1、HTo familiarize operators with the process使操作者熟悉過程HTo have the ability to trouble shoot the parts and machine具有解決零件及機(jī)器問題的能力HTo reduce Scrap and Downtime減少?gòu)U料及停機(jī)時(shí)間HTo improve productivity提高生產(chǎn)率DefinitionA定義定義A A series of steps, actions, or operations used in making something or bringing about a desire

2、d result.一系列的步驟、行動(dòng)或者操作，帶來預(yù)期的結(jié)果。DefinitionB定義定義BA series of actions, changes, etc., by which something passes from one condition to another.一系列的舉措、變更等，導(dǎo)致某事物從一狀態(tài)轉(zhuǎn)為另一狀態(tài)。HNinety percent of all defects are made because of reasons other than machine settings, however in all die cast companies personnel te

3、nd to adjust (compensate for ) settings rather than identifying and fixing the problem. One reason for this is that there are so many variables associated with our die casting process. Sometimes the operator does not know where to start looking. 90%的產(chǎn)品缺陷歸咎于各種非機(jī)器設(shè)置原因。但所有壓鑄公司的人員都寧愿調(diào)整設(shè)置，而不是分析及補(bǔ)救問題。原因之一

4、是在我們壓鑄過程中使用到很多的變量。有時(shí)操作者甚至不知道該從哪里開始尋找原因。HOne important thing to remember as you run your machine , If the process has been running OK and then suddenly you experience defects, it is unlikely that someone has adjusted settings on your machine. Therefore do not adjust any settings to correct the proble

5、m until you have checked and fixed any other problems.在操作機(jī)器時(shí)必須記得很重要的一點(diǎn)就是，如果過程運(yùn)行順利而你突然遭遇到廢件，這就不可能是因?yàn)橛腥苏{(diào)整過你機(jī)器上的設(shè)置。因此在你檢查及修理過其他問題之前不要調(diào)整任何設(shè)置。IF ITS NOT BROKEN, DONT FIX IT.如果機(jī)器沒有壞，那么如果機(jī)器沒有壞，那么不要去修理它。不要去修理它。Here at SMMP when we talk about the process it is usually understood to be the parameters used to

6、cast a good part.在SMMP當(dāng)我們談及“過程”時(shí)，通常的理解是我們用來鑄造一個(gè)好零件所用到的參數(shù)。However the process can also be the sequence of events that the machine / cell or other equipment moves through during a cycle .但是過程也可以是機(jī)器/機(jī)床或其他設(shè)備在一個(gè)周期內(nèi)移動(dòng)時(shí)發(fā)生的一系列事情。HFirst of all lets look at the cycle of the machine / cell and see how a proces

7、s can be effected.首先讓我們看一下機(jī)器/機(jī)床的運(yùn)作周期，了解如何控制過程Tubes comes down and pours, Shot delay begins管子伸下來且倒料，壓射延時(shí)開始Shot takes place 壓射發(fā)生Intensifier fires ( if used ) and Dwell Time starts增壓開始（如果是用增壓的話），保壓時(shí)間開始Die Opens ( cores Pull ), Robot moves to part模具打開（ 抽芯 ）機(jī)械手開始取出零件Part Ejects From Die零件從模具中頂出來Die lube

8、is Applied , Robot leaves machine with the part噴涂模具，機(jī)械手帶零件離開機(jī)器Part is Quenched while DCM begins to cycle again當(dāng)壓鑄機(jī)開始新的壓射周期時(shí)零件放置冷卻Part is placed on Trim Tool and Trimmed零件被放在切邊機(jī)上切邊Part is delivered to the operator and inspected零件被交給操作工進(jìn)行檢查Part is packed or sent to next operation.零件被包裝或被送至下一道工序。Assume

9、 for the moment that the pot is full, the dies have locked up and you have a shot ready light. What happens Next ?假設(shè)現(xiàn)在料勺是滿的且模具已經(jīng)合起而你收到一個(gè)準(zhǔn)備壓鑄的信號(hào)，接下來會(huì)怎么樣？HWhat will happen if one of these steps does not occur ?如果其中一個(gè)步驟并未進(jìn)行會(huì)發(fā)生什么事？_ HWhat effect if any will this have ?如果有后果產(chǎn)生的話，會(huì)是什么后果？_HThe cycle will s

10、top. 停止壓鑄。 HTherefore knowing the process of the machine will help you trouble shoot the problem much better.因此了解機(jī)器工作的過程會(huì)幫你更好地預(yù)見到機(jī)器會(huì)發(fā)生的問題。What will happen if one of these steps does not happen ?如果其中一個(gè)步驟沒有進(jìn)行會(huì)發(fā)生什么事？What effect if any will this have ?如果有后果產(chǎn)生的話，會(huì)是什么后果？_HMachine cycle will stop.機(jī)器停止運(yùn)行。HC

11、ycle time will be longer, Possible loss of part over the length of shift.運(yùn)行周期會(huì)變長(zhǎng)，或者在長(zhǎng)時(shí)間的運(yùn)行中丟失零件。HPossible scrap, Dies may have chance to cool off. Part may be left on the tool too long and stick. etc,可能產(chǎn)生廢料；模具可能會(huì)冷卻下來；零件可能會(huì)由于在模具中存留時(shí)間過長(zhǎng)而難以與模具分離等等。What will happen if one of these steps does not happen

12、?如果其中一個(gè)步驟并未進(jìn)行會(huì)發(fā)生什么事？The cycle will stop.壓鑄停止。 What effect if any will this have ?如果有后果產(chǎn)生的話，會(huì)是什么后果？As with the machine it is important for you to know the elements that effect you part process.只要跟機(jī)器在一起，了解影響到過程的各個(gè)因素就是很重要的。In order to make a good casting it is important that we operate to a defined pro

13、cess as much as possible. To that end a process sheet has been developed.為了能夠做出好的鑄件，我們應(yīng)盡最大可能地遵循一個(gè)既定的詳細(xì)的過程。由此而產(chǎn)生了過程指引手冊(cè)。 There should be a process sheet at each of the machines. This is a QS 9000 document that should be the same as the part that is currently running in your machine.在每臺(tái)機(jī)器上都應(yīng)該有一份過程指導(dǎo)書。

14、這也是一份QS9000文檔，應(yīng)該與機(jī)器的零件一樣永遠(yuǎn)在你的機(jī)器上。 If there is not a process sheet for the job currently running in youre machine one can be obtain one from your Function Leader.如果你的機(jī)器上沒有過程指導(dǎo)書你可以向你的直接領(lǐng)導(dǎo)領(lǐng)取一份.“ I MAKE PART我制造零件”The process sheet is an important document. This is the latest information available to you

15、 on how to run the part in your machine.過程指導(dǎo)書是非常重要的文件。它將是一份最新的可以指導(dǎo)你如何操作機(jī)器的各個(gè)部件的文件。The process sheet also gives you a reference point to check from when things go wrong and you start making scrap. 過過程指導(dǎo)書在問題及廢件開始出現(xiàn)時(shí)可以作為指導(dǎo)性文件，告訴你可以參考哪些要點(diǎn)來尋找問題根源。 HTo often the process sheet is taken as a joke. Lets take

16、 some time and review a sheet. If you feel that the sheet on your machine does not reflect the part that you are running then you should make sure that you have the latest revision. If you do have the latest revision then you may need to complete a process deviation and process change form.很多時(shí)候過程指導(dǎo)書

17、都沒能被嚴(yán)肅對(duì)待。讓我們花點(diǎn)時(shí)間來看一下指引手冊(cè)。如果你覺得你手頭的過程指導(dǎo)書并不符合你現(xiàn)在用的機(jī)器的實(shí)際情況，你可以確認(rèn)一下你拿到的是否最新版本。如果的確是最新版本，那么你就應(yīng)該做變更匯報(bào)并填報(bào)變更表格。“ it does say that ha, ha, ha哈哈哈它的確是這么說的！”Process sheet過程指引手冊(cè) Shot Speed壓射速度 Firing Points壓射點(diǎn) Metal Temp金屬溫度 Biscuit Size料柄尺寸 Pressures壓力 Shot Delay壓射延時(shí) Die Temp模具溫度 Cycle Time周期 Die Lube模具噴涂In the

18、 process to make a good casting there is a multitude of different variables.在做出好鑄件的過程中有許多的參數(shù)變化需要參考。If your machine is making good parts then for some reason the parts change and now youre making scrap one of the variables have changed.如果你的機(jī)器本來是好的但由于某些原因部件更換了，現(xiàn)在你開始出現(xiàn)廢品。其中一定有某個(gè)參數(shù)變化了。Too often we tend

19、to make a quick evaluation of the situation, adjust one or more set points with out finding the route cause.很多時(shí)候我們都不是去尋找問題的根源，而是很快地判斷一下局勢(shì)然后就調(diào)整其中一個(gè)或多個(gè)設(shè)置。Generally speaking going from a good to a bad situation only one variable has changed, we need to determine which one and why ?通常來說從一個(gè)好的局勢(shì)轉(zhuǎn)變?yōu)閴牡木謩?shì)是因?yàn)?/p>

20、其中某個(gè)參數(shù)變化了。我們需要決定的是，是哪個(gè)參數(shù)變化了以及為什么？When most variables change they effect many others, it is important to understand the changes and what they will effect.絕大多數(shù)的參數(shù)變化會(huì)引致很多其他的一些變化。因此了解這些變化及其可能導(dǎo)致的影響是非常重要的。The number one cause of process problems is biscuit size ironically this is also often the hardest to

21、 control.過程問題中的最首要的因素就是料柄尺寸。具諷刺意味的是，這也通常是最難控制的一個(gè)因素。Lets review some of the effects that a change in some of the variables will have.讓我們來看一下參數(shù)變化可能引起的一些變化。Biscuit Size料柄尺寸料柄尺寸Biscuit Too Small料柄太小Out of Process不受過程控制Poor Fill填充不足Increased ShotSpeed壓射速度增加Note EnoughPressure壓力不足Scrap廢料Partial ShotPossib

22、le StuckPart部分壓射可能粘模Down Time停機(jī)Die Spitting逃料Scrap廢料Overtime超時(shí)Scrap廢料Overtime超時(shí)Biscuit Size料柄尺寸料柄尺寸Overtime超時(shí)Scrap廢料Cold Shot Porosity Lack of Fill Cracks冷壓射氣縮孔,壓鑄不足、裂縫Slow Shot Speed慢壓射速度Overtime超時(shí)Scrap廢料No Intensification無增壓Shot Ends Too Early壓射完成太早Overtime超時(shí)Scrap廢料Porosityin Casting壓鑄氣縮孔House Kee

23、pingSafety環(huán)境、安全Mag Coming Back out ofPour Hole鎂自澆注孔退回不受過程控制Biscuit Too Big料柄太大Out Of ProcessIncreased Turbu-lance in Shot Sleeve料缸問題Shot Speeds壓射速度壓射速度Overtime超時(shí)Scrap廢料over time超時(shí)Down Time停機(jī)Possible Stuck Part零件可能受阻Metal Frozen Before it Reaches theGate金屬在到達(dá)進(jìn)料口前凝固Too Slow太慢over time超時(shí)Fires Down Time

24、點(diǎn)火問題引起停機(jī)Die Spits逃料over time超時(shí)Die unable to Lockup next cycle模具無法正常進(jìn)行下一次壓射Heavy Flash-ing強(qiáng)烈閃光over time超時(shí)Scrap and or stuck Part廢料及/或零件受阻Solder build up焊料堵塞Metal enters Die At HighSpeed金屬以極快速度進(jìn)入模具Too Fast太快Shot壓射Firing Points著火點(diǎn)著火點(diǎn)over time超時(shí)Die Spits Fires Housekeeping逃料,點(diǎn)火,存留Increased Fast Shot Spe

25、ed快壓射速度增加Overtime超時(shí)Scrap廢料Accumulator Runs Out of Oil Before End of Shot增壓器在壓射結(jié)束前油已耗盡TooSoon太快Overtime超時(shí)Scrap廢料Metal Too Cold To Properly Fill Part金屬太冷無法充填零件Not Enough Time To Reach Desired Speed沒有足夠時(shí)間來達(dá)到理想速度TooLate太慢Different Firing Points不同的著火點(diǎn)Metal Temp金屬溫度金屬溫度Overtime超時(shí)Down Time停機(jī)時(shí)間Multiple Scra

26、p Problems多種廢料問題Metal too Cold To Fill Casting金屬太冷無法鑄造over time超時(shí)Cycle Time Machine down to allow metal to heat up周期停機(jī)以加熱鎂液TooCold太冷Cycle Time周期Metal Too Hot Requires more Dwell Time金屬太熱,需要更多的保壓時(shí)間Over Time超時(shí)De Solder Die Scrap去除粘模Solder Build UP粘模Overtime超時(shí)Down time Due to Fires因燃燒停機(jī)Die Spits & Mult

27、iple Scrap Problems逃料及多種廢料問題TooHot太熱Different Metal Temps金屬溫度不同Pressures壓力壓力Overtime超時(shí)Scrap Related to Fill Problems因充填問題而引致廢料Casting Doesnt Fill Properly未能正確充填Shot Speed Slow壓射速度太慢TooLow太低Overtime超時(shí)Scrap Usually Cracked Castings斷裂廢料Die Spits Causes Fires逃料導(dǎo)致起火Shot Speed High壓射速度太快TooHigh太高Different

28、Pressures不同壓力Shot Delay壓射延時(shí)壓射延時(shí)Metal Too Hot See Flow chart for Metal Temp金屬太熱,參見金屬溫度流程圖Overtime超時(shí)Scrap廢料Metal NotGiven ChanceTo Settle Too Turbulent金屬?zèng)]有機(jī)會(huì)充填TooLow太慢Overtime超時(shí)Scrap廢料Metal Too Cold See Flow Chart For Metal Temp金屬太冷,參見金屬溫度流程圖TooHigh太快DifferentTimes時(shí)間不同 Die Temps模具溫度模具溫度Scrap廢料Scrap廢料D

29、ie Life Reduced模具壽命減短Shock Dies模具不穩(wěn)定/振動(dòng)Overtime超時(shí)Broken Core型心斷裂Stuck Casting鑄造受阻Too Low太低Cycle Time周期周期Overtime超時(shí)Scrap廢料Die Gets Too Hot Furnace Cant Keep up模具變得太熱,熔爐無法與之適應(yīng)TooLow太慢Overtime超時(shí)Scrap廢料Die Gets Too Cold模具變得太冷TooHigh太快Different Times不同時(shí)間Die Lube模具潤(rùn)滑模具潤(rùn)滑Down time停機(jī)Scrap廢料Borken Core型心斷裂Do

30、wn Time停機(jī)Scrap廢料Need To Desolder Die需要粘料Solder Build Up粘料堵塞Overtime超時(shí)Scrap廢料Stuck Castings鑄件受阻Too Lean潤(rùn)滑油太少Overtime超時(shí)Scrap廢料Porosity氣縮孔Black Parts部分發(fā)黑Too Rich潤(rùn)滑油太多Different Set-tings不同設(shè)置On the die cast machine you have the ability to monitor many of the variables associated with the process.在壓鑄機(jī)上你可以

31、監(jiān)控與過程有關(guān)的各個(gè)參數(shù)。Several variables may change from shot to shot what you have to be able to do is figure out which change(s) caused the others to change.在不同的壓射過程中可能會(huì)有多個(gè)參數(shù)的變化,你應(yīng)該能夠分辨出哪些變化是導(dǎo)致了其他哪些變化的。For example例如: int shot speed二次壓射速度hi快 fast shot speed快壓射速度hi快 intensification hold增壓low慢 int. to fast tra

32、nsition二次壓射轉(zhuǎn)快壓射hi快 biscuit size料柄尺寸low低What is the probable problem ?可能有什么問題發(fā)生？lPot level液面高度lTube Temp充液管溫度lMetal Temp金屬溫度lIs the end of the tube clean導(dǎo)管末端是否潔凈lDid the metal flow from the tube miss the sleeve.充料時(shí)沒有對(duì)準(zhǔn)料缸lCondition of the pot is there a lot of dross.坩堝的狀態(tài)，是否有很多渣滓。Now that we can see t

33、hat the Biscuit size is the probable cause now we need to look and find the root cause.我們現(xiàn)在可以發(fā)現(xiàn)料柄的尺寸就是問題可能產(chǎn)生的直接因素?，F(xiàn)在我們需要找到問題的根源。we should look at the following before making adjustments在做出判斷前我們需要看一下以下因素.Even once we have determined what the cause is from the possible above then we need to find out w

34、hat caused that to happen until the question can no longer be asked.只有當(dāng)我們判斷出了以上列出的因素中哪些是問題的可能性根源我們才能知道是哪個(gè)因素導(dǎo)致了什么問題，直到問題全部解決。WMost process related problems can at least be trouble shot to within a fairly close proximity of the problem area with the use of some basic logic.運(yùn)用一些基本的邏輯可以大概地預(yù)見到絕大多數(shù)與過程相關(guān)的問

35、題可能發(fā)生的范圍。A part with flow problems usually referred to as cold shut is a direct result of the metal either being too cold at the start or cooling off quickly in the die. Now we have to find out was the metal cold before the shot took place, or did it cool down in the die. 有流動(dòng)問題的零件通常指冷隔，它是金屬在一開始就太冷或者

36、在模具中很快冷卻的直接結(jié)果。現(xiàn)在我們需要分辨的就是金屬是在壓射之前就已經(jīng)冷卻下來還是在模具中冷卻下來的。A part with a heat sink in it is usually attributed to large wall thickness and temperature variation in the die. it can also be attributed to a large biscuit especially if the biscuit is so big that intensification did not occur.有熱縮 的零件通常是因?yàn)殍T件較厚而模

37、具溫度有差異。這也可以歸因于料柄太大，尤其是當(dāng)料柄太大而使增壓過程無法發(fā)生的時(shí)候。Apart that has porosity can be the result of too much die lube shown as a black area on the part, it can also be associated with a small biscuit. or an erratic shot that traps the air in the metal during the shot itself.有氣縮孔的零件有可能是因?yàn)槟＞邼?rùn)滑油太多，在零件上表現(xiàn)有發(fā)黑現(xiàn)象，也有可能是因

38、為料柄太小，或者壓射時(shí)的不穩(wěn)定因素使得壓射過程中沒有有效地排干凈料缸中的空氣。A part with a crack is often the result of one of the following,有裂縫的零件通常是由以下某原因造成的：ltoo much pressure during intensification增壓過程中太多壓力lthe part sticking to the die零件難以與模具脫離lpoor intensification hold持壓時(shí)間不足lthe metal cooling off at different rates due to die temp

39、and wall stock.由于模具溫度及壁厚因素使金屬冷卻的程度不一。WThese are not all of the scrap related problems that you will encounter however these are the most common.以上所列并不是鑄件缺陷的所有可能但卻是鑄件缺陷最常見的情況。bit is also important for you to realize that the possible reasons given here are not always the reasons for the problems.我們這里

40、列出的各種因素并不一定總是問題的原因，這一點(diǎn)也很重要。lwe are able to compensate for many problems with adjustments to the process however some problems are inherent to the design of the part or even the die. The process that you follow at SMMP may not be the best possible for the job, it is important though if you do run the

41、 machine out of process that the proper permission is obtained and that the proper paper work is completed.我們可以對(duì)過程進(jìn)行一些調(diào)整，但有些問題可能是跟零件的設(shè)計(jì)或者模具是有關(guān)系的。你在SMMP學(xué)習(xí)的這些可能不一定是最適合你現(xiàn)有工作的方法，但對(duì)你來說很重要的是你的過程是在適當(dāng)?shù)脑S可下進(jìn)行且經(jīng)過了適當(dāng)?shù)奈募掷m(xù)。lif you are unable to correct a problem with the part do not be afraid to ask, anyone that has worked on similar problems either got help from another person, made lots of scrap