铸钢件WC9控制计划

1、 CONTROL PLAN 控制计划Page 1 of 4Part/Process Number 过程号Process Name/Operation Description 操作描述Machine, Device,Jig, Tools for Mfg.机器、设备、工具Characteristics 特性Special Char. Class 特殊特性Methods方法Reaction Plan反应计划NoProduct产品Process过程Product/Process Specification/ Technique生产(过程)规范、技术要求Evaluation Measurement Te

2、chnique 评估测量技术Sample 样品Control Method 控制方法Size容量Freq. 频次010Incoming Inspection进料检验Internal Lab内部实验室1Raw Sand原砂SiO2 96% Grain size: 40-70 Mesh或50-100Mesh 砂子颗粒度:40/70 目或50-100目Dust < 0.5%,粉尘含量:小于0.5% Moisture: <0.3%, 含水量:小于0.3%Acid reduction: < 5ml/50g 酸耗值: 小于5ml/50g内部实验室检测 inspection in inte

3、rnal lab1Batch 每批QI-09-41 Segregate ，Disposal / return to supplier 隔离，返回供应商.Suppliers Facility供应商的设备,工具2Resin树脂Nitrogen 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） Free Formaldehyde content 0.4%.自由甲醛含量:小于等于0.4%.内部实验室检测 inspection in internal

4、 lab1Batch 每批供应商合格证/记录 supplier certificate/recordYQR-07-953Hardener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Internal Lab内部实验室4Scraps & alloys废钢及合金.清洁,化学成分可接收.clearness,acceptable chemical composition内部实验室检测 inspection in internal lab1Batch 每批QI-09-41 Page 2of 4 020Pattern Inspecti

5、on模型检验Layout ,ruler划线, 尺子1Patterndimensions模型尺寸Pattern dimensions shall conform to pattern print and process specifications. Check locating pins; visual surface quality of pattern. 模型尺寸符合图纸,工艺图,检查定位销位置度,模型表面质量. Gages, calipers and CMM etc.计量仪器,卡钳等.1首件/每批QI-09-48 Rework or modifying返工或修理030Sand mixin

6、g混砂Mixture machine(continued)Mixer连续式混砂机1Sand properties型砂性能Tensile test results of sand specimens hardened for 24 hours: Mpa. Loss on ignition 2.5%24小时终强度为Mpa,灼烧减量小于2.5%.Tensile testing machine强度测试机6Weekly周 YQI-07-53Adjust & segregate调整/隔离040MoldingCore make造型及制芯Mixture machine(continued)Mixer连

7、续式混砂机1Riser，runner，chill，mold appearance，dimesions，degree of compaction 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 is open, Cavities are well formed .Parting line is flat.型腔内无浮砂，扎出气孔，型腔表面好，分型面平整.Visual目视1Each 每型YQI-07-19-06Fixing or reject修理或拒收050Coating涂料Coating buck

8、et, brush, baume scale涂料桶,毛刷, 波美比重计1Coating涂料涂料波美比重coating baume scale.Coating shall be uniformly coating and dried completely.波美度65-75,涂料应涂刷均匀,涂刷点燃并充分干燥.波美比重计检测baume scale1每一料桶QI-09-65 Rework or adject 返工或调整060Mold assembly合箱Crane行车1Assembly quality合箱Free from loosen sand in the cavities. 型腔内无浮砂.Th

9、e compressed air :4-6atm.压缩空气压力4-6大气压。Cope and drag shall be accurately locating, tightly contacted. 上下箱合箱应紧密.Ensure good jointing on parting face to avoid shift and core shift. 确保分型面结合良好,防止错箱,抬芯.Visual目视1Each 每型YQI-07-18-1Rework 返工070Melting熔炼Induction furnace中频炉1Chemical composition.化学成分WC9内控要求：C:

10、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:0.05, Al:0.030-0.050, (Ni+Cu+W):1.00,spectrum光谱1Each 每炉记录Record/ QI-09-10Adjust or reject 调整或拒收Page 3of4080Pouring浇注Ladle浇包1Pouring temp.浇注温度1530-1550Thermocouple热电隅1Ladle 每包PC-173-04-CS Record/记

11、录YQI-07-54QI-09-10YQI-07-23Segregate 隔离2Pouring time浇注时间Pouring time:8-12sStopwatch 秒表1Mold 每型Segregate隔离3Cooling time冷却时间24小时Timer记时器1Mold 每型Segregate隔离090Knock-outRiser cuttin落砂Manual work人工清砂1time不得用大锤捶击铸件本体 No hammering on casting bodyVisual目视1Each 每型QI-09-01LQI-08-02QI-09-03工艺卡号：PC-173-05-CSRew

12、ork 返工100Riser cutting 切割浇冒口割枪Cutting torch1Castings铸件Surface quality表面质量No 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,无浇不满,无跑箱等.Record 记录1EachHeat每炉QI-09-13QI-09-14 Record/记录 Rework/reject返工/拒收110Shot blast抛丸Shot blast machine抛丸机1Casting appearance quality铸件Appea

13、rance外观质量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.Time & visual 时间和目视1Each 每批Visual 目视 QI-09-03Rework 返工120Heat treatment热处理Electric /Coal gas furnace电阻炉或煤气炉1Temperature holding time 保温温度 保温时间Heat treatment processing c

14、ard 热处理工艺卡Visual 目视1Each 每件Visual目视 QI-09-02Reject 拒收130Repair welding焊补Welding machine 焊机1Castings铸件Casting internal quality铸件内部质量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。 VT, RT1Each 每件Welding supervise焊接监督Rework/adjust返工/调整140Grinding

15、打磨Grinders 打磨工1Castings铸件Appearance外观用砂轮机去除缺陷。Visual目视1Each 每件QI-09-44、GP-QA-040Rework/adjust返工/调整Page 4of4150Final inspection & test终检和试验spectrum光谱1Chemical composition化学成分WC9规格要求：C:0.05-0.15, Si:0.60, Mn:0.40-0.70,P:0.040, S:0.045,Cr:2.00-2.75, Ni:0.50, Mo:0.90-1.20,Cu:0.50, W:0.10,(Cu+Ni+W):1

16、.00,spectrum光谱1Each melt 每炉Record 记录Reject 拒收Universal tensile test machine强度试验机2Mechanical properties机械性能屈服强度:275 MPa ,抗拉强度:485-655 MPa,延伸率: 20%,收缩率: 35%,Tensile test强度试验机.1Each melt 每炉Record 记录Reject 拒收Measure量具3Dimensions尺寸Drawing:图纸093836-16order form订单1Each每件Record 记录Rework/reject返工/拒收DPI4Surfa

17、ce defects表面缺陷GP-QA-040order form订单1Each每件Record 记录Rework/reject返工/拒收160Re-heat treatment再次热处理Electric /Coal gas furnace电阻炉或煤气炉1Castings铸件Temperature holding time 保温 温度 保温时间Heat treatment processing card 热处理工艺卡Record 记录1EachHeat每炉QI-09-13QI-09-14Rework/reject返工/拒收170Final shot blast终抛丸Shot blast machine抛丸机1Castings铸件Free from adhered scales, shot size is correct 铸件无粘砂,钢丸尺寸正确;The quality of casting conform the standard of GP-QA-040铸件表面质量符合GP-QA-040标准.Visual , GP-QA-040 standard. 目视, GP-QA-040标准.1Each每件Visual 目视Rework 返工180终检检验员Castings铸件(1)Cas