压铸过程管理

1、HTo familiarize operators with the process使操作者熟悉过程HTo have the ability to trouble shoot the parts and machine具有解决零件及机器问题的能力HTo reduce Scrap and Downtime减少废料及停机时间HTo improve productivity提高生产率DefinitionA定义定义A A series of steps, actions, or operations used in making something or bringing about a desire

2、d result.一系列的步骤、行动或者操作，带来预期的结果。DefinitionB定义定义BA series of actions, changes, etc., by which something passes from one condition to another.一系列的举措、变更等，导致某事物从一状态转为另一状态。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%的产品缺陷归咎于各种非机器设置原因。但所有压铸公司的人员都宁愿调整设置，而不是分析及补救问题。原因之一

4、是在我们压铸过程中使用到很多的变量。有时操作者甚至不知道该从哪里开始寻找原因。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.在操作机器时必须记得很重要的一点就是，如果过程运行顺利而你突然遭遇到废件，这就不可能是因为有人调整过你机器上的设置。因此在你检查及修理过其他问题之前不要调整任何设置。IF ITS NOT BROKEN, DONT FIX IT.如果机器没有坏，那么如果机器没有坏，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当我们谈及“过程”时，通常的理解是我们用来铸造一个好零件所用到的参数。However the process can also be the sequence of events that the machine / cell or other equipment moves through during a cycle .但是过程也可以是机器/机床或其他设备在一个周期内移动时发生的一系列事情。HFirst of all lets look at the cycle of the machine / cell and see how a proces

7、s can be effected.首先让我们看一下机器/机床的运作周期，了解如何控制过程Tubes comes down and pours, Shot delay begins管子伸下来且倒料，压射延时开始Shot takes place 压射发生Intensifier fires ( if used ) and Dwell Time starts增压开始（如果是用增压的话），保压时间开始Die Opens ( cores Pull ), Robot moves to part模具打开（ 抽芯 ）机械手开始取出零件Part Ejects From Die零件从模具中顶出来Die lube

8、is Applied , Robot leaves machine with the part喷涂模具，机械手带零件离开机器Part is Quenched while DCM begins to cycle again当压铸机开始新的压射周期时零件放置冷却Part is placed on Trim Tool and Trimmed零件被放在切边机上切边Part is delivered to the operator and inspected零件被交给操作工进行检查Part is packed or sent to next operation.零件被包装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 ?假设现在料勺是满的且模具已经合起而你收到一个准备压铸的信号，接下来会怎么样？HWhat will happen if one of these steps does not occur ?如果其中一个步骤并未进行会发生什么事？_ HWhat effect if any will this have ?如果有后果产生的话，会是什么后果？_HThe cycle will s

10、top. 停止压铸。 HTherefore knowing the process of the machine will help you trouble shoot the problem much better.因此了解机器工作的过程会帮你更好地预见到机器会发生的问题。What will happen if one of these steps does not happen ?如果其中一个步骤没有进行会发生什么事？What effect if any will this have ?如果有后果产生的话，会是什么后果？_HMachine cycle will stop.机器停止运行。HC

11、ycle time will be longer, Possible loss of part over the length of shift.运行周期会变长，或者在长时间的运行中丢失零件。HPossible scrap, Dies may have chance to cool off. Part may be left on the tool too long and stick. etc,可能产生废料；模具可能会冷却下来；零件可能会由于在模具中存留时间过长而难以与模具分离等等。What will happen if one of these steps does not happen

12、?如果其中一个步骤并未进行会发生什么事？The cycle will stop.压铸停止。 What effect if any will this have ?如果有后果产生的话，会是什么后果？As with the machine it is important for you to know the elements that effect you part process.只要跟机器在一起，了解影响到过程的各个因素就是很重要的。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.为了能够做出好的铸件，我们应尽最大可能地遵循一个既定的详细的过程。由此而产生了过程指引手册。 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.在每台机器上都应该有一份过程指导书。

14、这也是一份QS9000文档，应该与机器的零件一样永远在你的机器上。 If there is not a process sheet for the job currently running in youre machine one can be obtain one from your Function Leader.如果你的机器上没有过程指导书你可以向你的直接领导领取一份.“ 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.过程指导书是非常重要的文件。它将是一份最新的可以指导你如何操作机器的各个部件的文件。The process sheet also gives you a reference point to check from when things go wrong and you start making scrap. 过过程指导书在问题及废件开始出现时可以作为指导性文件，告诉你可以参考哪些要点来寻找问题根源。 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.很多时候过程指导书

17、都没能被严肃对待。让我们花点时间来看一下指引手册。如果你觉得你手头的过程指导书并不符合你现在用的机器的实际情况，你可以确认一下你拿到的是否最新版本。如果的确是最新版本，那么你就应该做变更汇报并填报变更表格。“ it does say that ha, ha, ha哈哈哈它的确是这么说的！”Process sheet过程指引手册 Shot Speed压射速度 Firing Points压射点 Metal Temp金属温度 Biscuit Size料柄尺寸 Pressures压力 Shot Delay压射延时 Die Temp模具温度 Cycle Time周期 Die Lube模具喷涂In the

18、 process to make a good casting there is a multitude of different variables.在做出好铸件的过程中有许多的参数变化需要参考。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.如果你的机器本来是好的但由于某些原因部件更换了，现在你开始出现废品。其中一定有某个参数变化了。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.很多时候我们都不是去寻找问题的根源，而是很快地判断一下局势然后就调整其中一个或多个设置。Generally speaking going from a good to a bad situation only one variable has changed, we need to determine which one and why ?通常来说从一个好的局势转变为坏的局势是因为

20、其中某个参数变化了。我们需要决定的是，是哪个参数变化了以及为什么？When most variables change they effect many others, it is important to understand the changes and what they will effect.绝大多数的参数变化会引致很多其他的一些变化。因此了解这些变化及其可能导致的影响是非常重要的。The number one cause of process problems is biscuit size ironically this is also often the hardest to

21、 control.过程问题中的最首要的因素就是料柄尺寸。具讽刺意味的是，这也通常是最难控制的一个因素。Lets review some of the effects that a change in some of the variables will have.让我们来看一下参数变化可能引起的一些变化。Biscuit Size料柄尺寸料柄尺寸Biscuit Too Small料柄太小Out of Process不受过程控制Poor Fill填充不足Increased ShotSpeed压射速度增加Note EnoughPressure压力不足Scrap废料Partial ShotPossib

22、le StuckPart部分压射可能粘模Down Time停机Die Spitting逃料Scrap废料Overtime超时Scrap废料Overtime超时Biscuit Size料柄尺寸料柄尺寸Overtime超时Scrap废料Cold Shot Porosity Lack of Fill Cracks冷压射气缩孔,压铸不足、裂缝Slow Shot Speed慢压射速度Overtime超时Scrap废料No Intensification无增压Shot Ends Too Early压射完成太早Overtime超时Scrap废料Porosityin Casting压铸气缩孔House Kee

23、pingSafety环境、安全Mag Coming Back out ofPour Hole镁自浇注孔退回不受过程控制Biscuit Too Big料柄太大Out Of ProcessIncreased Turbu-lance in Shot Sleeve料缸问题Shot Speeds压射速度压射速度Overtime超时Scrap废料over time超时Down Time停机Possible Stuck Part零件可能受阻Metal Frozen Before it Reaches theGate金属在到达进料口前凝固Too Slow太慢over time超时Fires Down Time

24、点火问题引起停机Die Spits逃料over time超时Die unable to Lockup next cycle模具无法正常进行下一次压射Heavy Flash-ing强烈闪光over time超时Scrap and or stuck Part废料及/或零件受阻Solder build up焊料堵塞Metal enters Die At HighSpeed金属以极快速度进入模具Too Fast太快Shot压射Firing Points着火点着火点over time超时Die Spits Fires Housekeeping逃料,点火,存留Increased Fast Shot Spe

25、ed快压射速度增加Overtime超时Scrap废料Accumulator Runs Out of Oil Before End of Shot增压器在压射结束前油已耗尽TooSoon太快Overtime超时Scrap废料Metal Too Cold To Properly Fill Part金属太冷无法充填零件Not Enough Time To Reach Desired Speed没有足够时间来达到理想速度TooLate太慢Different Firing Points不同的着火点Metal Temp金属温度金属温度Overtime超时Down Time停机时间Multiple Scra

26、p Problems多种废料问题Metal too Cold To Fill Casting金属太冷无法铸造over time超时Cycle Time Machine down to allow metal to heat up周期停机以加热镁液TooCold太冷Cycle Time周期Metal Too Hot Requires more Dwell Time金属太热,需要更多的保压时间Over Time超时De Solder Die Scrap去除粘模Solder Build UP粘模Overtime超时Down time Due to Fires因燃烧停机Die Spits & Mult

27、iple Scrap Problems逃料及多种废料问题TooHot太热Different Metal Temps金属温度不同Pressures压力压力Overtime超时Scrap Related to Fill Problems因充填问题而引致废料Casting Doesnt Fill Properly未能正确充填Shot Speed Slow压射速度太慢TooLow太低Overtime超时Scrap Usually Cracked Castings断裂废料Die Spits Causes Fires逃料导致起火Shot Speed High压射速度太快TooHigh太高Different

28、Pressures不同压力Shot Delay压射延时压射延时Metal Too Hot See Flow chart for Metal Temp金属太热,参见金属温度流程图Overtime超时Scrap废料Metal NotGiven ChanceTo Settle Too Turbulent金属没有机会充填TooLow太慢Overtime超时Scrap废料Metal Too Cold See Flow Chart For Metal Temp金属太冷,参见金属温度流程图TooHigh太快DifferentTimes时间不同 Die Temps模具温度模具温度Scrap废料Scrap废料D

29、ie Life Reduced模具寿命减短Shock Dies模具不稳定/振动Overtime超时Broken Core型心断裂Stuck Casting铸造受阻Too Low太低Cycle Time周期周期Overtime超时Scrap废料Die Gets Too Hot Furnace Cant Keep up模具变得太热,熔炉无法与之适应TooLow太慢Overtime超时Scrap废料Die Gets Too Cold模具变得太冷TooHigh太快Different Times不同时间Die Lube模具润滑模具润滑Down time停机Scrap废料Borken Core型心断裂Do

30、wn Time停机Scrap废料Need To Desolder Die需要粘料Solder Build Up粘料堵塞Overtime超时Scrap废料Stuck Castings铸件受阻Too Lean润滑油太少Overtime超时Scrap废料Porosity气缩孔Black Parts部分发黑Too Rich润滑油太多Different Set-tings不同设置On the die cast machine you have the ability to monitor many of the variables associated with the process.在压铸机上你可以

31、监控与过程有关的各个参数。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.在不同的压射过程中可能会有多个参数的变化,你应该能够分辨出哪些变化是导致了其他哪些变化的。For example例如: int shot speed二次压射速度hi快 fast shot speed快压射速度hi快 intensification hold增压low慢 int. to fast tra

32、nsition二次压射转快压射hi快 biscuit size料柄尺寸low低What is the probable problem ?可能有什么问题发生？lPot level液面高度lTube Temp充液管温度lMetal Temp金属温度lIs the end of the tube clean导管末端是否洁净lDid the metal flow from the tube miss the sleeve.充料时没有对准料缸lCondition of the pot is there a lot of dross.坩埚的状态，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.我们现在可以发现料柄的尺寸就是问题可能产生的直接因素。现在我们需要找到问题的根源。we should look at the following before making adjustments在做出判断前我们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.只有当我们判断出了以上列出的因素中哪些是问题的可能性根源我们才能知道是哪个因素导致了什么问题，直到问题全部解决。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.运用一些基本的逻辑可以大概地预见到绝大多数与过程相关的问

35、题可能发生的范围。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. 有流动问题的零件通常指冷隔，它是金属在一开始就太冷或者

36、在模具中很快冷却的直接结果。现在我们需要分辨的就是金属是在压射之前就已经冷却下来还是在模具中冷却下来的。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.有热缩 的零件通常是因为铸件较厚而模

37、具温度有差异。这也可以归因于料柄太大，尤其是当料柄太大而使增压过程无法发生的时候。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.有气缩孔的零件有可能是因为模具润滑油太多，在零件上表现有发黑现象，也有可能是因

38、为料柄太小，或者压射时的不稳定因素使得压射过程中没有有效地排干净料缸中的空气。A part with a crack is often the result of one of the following,有裂缝的零件通常是由以下某原因造成的：ltoo much pressure during intensification增压过程中太多压力lthe part sticking to the die零件难以与模具脱离lpoor intensification hold持压时间不足lthe metal cooling off at different rates due to die temp

39、and wall stock.由于模具温度及壁厚因素使金属冷却的程度不一。WThese are not all of the scrap related problems that you will encounter however these are the most common.以上所列并不是铸件缺陷的所有可能但却是铸件缺陷最常见的情况。bit is also important for you to realize that the possible reasons given here are not always the reasons for the problems.我们这里

40、列出的各种因素并不一定总是问题的原因，这一点也很重要。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.我们可以对过程进行一些调整，但有些问题可能是跟零件的设计或者模具是有关系的。你在SMMP学习的这些可能不一定是最适合你现有工作的方法，但对你来说很重要的是你的过程是在适当的许可下进行且经过了适当的文件手续。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