铸钢件WC9控制计划

1、CONTROL PLAN控制计划Page 1 of 4Machine,Part/Process Name/Device,ProcessOperationJig, Tools forNumberDescription 操作Mfg.过程号描述机器、设备、工具Characteristics特性SpecialChar.NoProductProcessClass产品过程特殊特性Product/Process Specification/ Technique生产 (过程 )规范、技术要求SiO2 96%Methods 方法EvaluationMeasurement Technique评估测量技术Sampl

2、e 样品Control MethodSizeFreq.控制方法容量频次Reaction Plan反应计划Internal Lab内部实验室IncomingSuppliers010InspectionFacility进料检验供应商的设Raw1Sand原砂Resin2树脂Grain size: 40-70 Mesh 或 50-100Mesh 砂子颗粒度 :40/70内部实验室检目或 50-100 目测 inspectionDust 0.5%, 粉尘含量 : 小于 0.5%in internalMoisture: 0.3%, 含水量 :小于 0.3%labAcid reduction: 5ml/50

3、g酸耗值 : 小于 5ml/50gNitrogen content: 0.3%,含氮量 : 0.3%Water content 2%, 含水量 : 小于或等于 2%Viscosity (20oC) 100mPa.s,粘度 : 100mPa.s （ 20 ） 内部实验室检Free Formaldehyde content0.4%. 自由甲醛含量 :小于等 测 inspection于 0.4%.in internal1BatchQI-09-41每批供应商合格证 / 记录1Batchsupplier每批certificate/recordSegregate ， Disposal / returnto

4、 supplier 隔离，返回供应商 .备 ,工具Harden3er固化剂固化剂采用 FC01、 FC02、FC03 、FC04、 FC05，粘度、密度、总酸度要求参考： 铸造原辅材料标准 5.13.1labYQR-07-95Internal Lab内部实验室Scraps4& alloys废钢及合金 .内部实验室检清 洁 , 化 学 成 分 可 接 收 .clearness,acceptablechemical测 inspectioncompositionin internallab1BatchQI-09-41每批Page 2of 4Patterndimensionsshallconformt

5、o patternprintandGages,Pattern20 Inspection模型检验Sand30 mixing混砂Layout ,ruler 划线,尺子Mixture machine(cont inued)Mixer连续式混砂机Mixture11Patterndimensions模型尺寸Sand properties型砂性能Riser ，runner ，chill ，moldappearance ，process specifications. Check locating pins; visual surfacequality of pattern.模型尺寸符合图纸,工艺图 ,检查

6、定位销位置度,模型表面质量 .Tensile test results of sand specimens hardened for 24hours: 0.45-0.95Mpa. Loss on ignition2.5%24 小时终强度为0.45-0.95Mpa, 灼烧减量小于2.5%.calipers and首件Rework orCMM etc.1/ 每QI-09-48modifying计量仪器 ,卡批返工或修理钳等 .TensileAdjust &testingWeek6segregatemachineYQI-07-53ly 周调整/ 隔离强度测试机Molding40 Core make造

7、型及制芯machine(continued)Mixer连续式混砂机Coating1dimesions ，degree ofcompaction冒口，浇道，冷铁，铸型外观，尺寸，紧实度No ram-off, No free sand in mold cavities, Gas venting isVisualEachFixing or rejectopen, Cavities are well formed .Parting line is flat.目视1YQI-07-19-06每型修理或拒收型腔内无浮砂，扎出气孔，型腔表面好，分型面平整.Coating50 涂料Mold60 assembly

8、合箱Melting70 熔炼bucket, brush, baume scale涂料桶 ,毛刷 , 波美比重计Crane行车Inductionfurnace中频炉111Coating涂料波美比重coating baume涂料scaleAssembly quality合箱Chemicalcomposition.化学成分.Coating shall be uniformly coating and driedcompletely.波美度 65-75,涂料应涂刷均匀,涂刷点燃并充分干燥.Free from loosen sand in the cavities.型腔内无浮砂 .Thecompress

9、ed air :4-6atm.压缩空气压力4-6 大气压。 Copeand drag shall be accurately locating, tightly contacted.上下箱合箱应紧密.Ensure good jointing on parting face toavoid shift and core shift.确保分型面结合良好,防止错箱 ,抬芯 .WC9 内控要求：C:0.11-0.14,Si:0.35-0.55, Mn:0.45-0.65,P:0.020,S: 0.020,Cr:2.10-2.40,Ni: 0.40,Mo:0.92-1.00,Cu: 0.10,W: 0.

10、05,Al:0.030-0.050,(Ni+Cu+W): 1.00,波美比重计检每一Rework or测 baume1QI-09-65adject料桶scale返工或调整Visual1EachYQI-07-18-1Rework目视每型返工spectrum1Each记录 Record/Adjust or reject光谱每炉QI-09-10调整或拒收Page 3of4PouringLadle080浇注浇包Knock-outManual090Riser cuttinwork 人工清落砂砂Riser cutting割枪 Cutting100切割浇冒口torchShot blastShot blast

11、110machine抛丸抛丸机1231Castin1 gs铸件Castingappeara1nce quality铸件Pouringtemp.浇注温度Pouringtime浇注时间Coolingtime冷却时间timeSurfacequality表面质量Appearance外观质量1530-1550Pouring time:8-12s24 小时不得用大锤捶击铸件本体No hammering on casting bodyNo heavy damage, no over-cut, no big cracks, misrun or run-off etc.无重损伤 ,无砸伤 ,无大的裂纹 , 无浇

12、不满 ,无跑箱等 .Without adhered sand. Suggested time is 20 minutes min.shot size is correct.(1.0-2.0MM)无粘砂 ,抛丸时间为20 分钟 ,钢丸尺寸为1.0-2.0MM.Thermocoupl e热电隅Stopwatch秒表Timer记时器Visual目视Record记录Time &visual时间和目视111111Ladle每包Mold每型Mold每型Each每型EachHeat每炉Each每批PC-173-04-CS Record/ 记录YQI-07-54QI-09-10YQI-07-23QI-09-0

13、1LQI-08-02QI-09-03工艺卡号：PC-173-05-CSQI-09-13QI-09-14Record/ 记录Visual目视QI-09-03Segregate隔离Segregate隔离Segregate隔离Rework返工Rework/reject 返工/ 拒收Rework返工ElectricTemperaturHeat/Coal gase holding120treatmentfurnace1time热处理电阻炉或煤保温温度气炉保温时间CastingCastingRepairWeldinginternal130weldingmachine1squality焊补焊机铸件铸件内部质

14、量GrindingCastinAppearanceGrinders140打磨打磨工1gs外观铸件Heat treatment processing card热处理工艺卡Remove all defects , then welding per WPS-M-184and testing by MT/PT.去除全部超标缺陷， 按 WPS-M-184进行焊补，并用 MT/PT检测合格。用砂轮机去除缺陷。Visual目视VT, RTVisual目视111Each每件Each每件Each每件Visual目视QI-09-02Weldingsupervise焊接监督QI-09-44 、 GP-QA-040R

15、eject拒收Rework/adjust 返工/ 调整Rework/adjust 返工/ 调整spectrum光谱1Chemicalcomposition化学成分WC9 规格要求：C:0.05-0.15,Si: 0.60,Mn:0.40-0.70,spectrumEachP: 0.040,S: 0.045,1meltCr:2.00-2.75,Ni: 0.50,Mo:0.90-1.20,光谱每炉Cu: 0.50,W: 0.10,(Cu+Ni+W):1.00,Page 4of4RecordReject记录拒收Finalinspec150tion & test终检和试验Universaltensil

16、e test machine 强度试验机2Mechanicalproperties机械性能屈服强度 : 275 MPa ,抗拉强度 :485-655 MPa,Tensile test延伸率 : 20%,强度试验机 .收缩率 : 35%,Each1 melt每炉RecordReject记录拒收Measure量具DPI34Dimensions尺寸Surfacedefects表面缺陷Drawing: 图纸 093836-16order form订单order formGP-QA-040订单11Each每件Each每件RecordRework/reject记录返工/ 拒收RecordRework/re

17、ject记录返工/ 拒收Re-heat160 treatment再次热处理Electric /Coal gas furnace 电阻炉或煤气炉1CastingTemperature holdingstime铸件保温 温度保温时间Heat treatment processing cardRecord热处理工艺卡记录Visual ,Free from adhered scales, shot size is correctGP-QA-040Each1Heat每炉QI-09-13Rework/rejectQI-09-14返工/ 拒收Final shot170 blast终抛丸Shot blastmachine抛丸机1Castings铸件铸件无粘砂 ,钢丸尺寸正确 ;standard.The quality of casting conform the standard ofGP-QA-040目视 ,铸件表面质量符合 GP-QA-040标准 .GP-QA-040标准 .(1)Casting dimensions 铸件尺寸 ;(2)MechanicalpropertiesEach1每件V