Talk about the relationship between the quality and output of die casting products
Mon Jun 19 11:35:09 CST 2023
From product to development to mass production, realize the two-stage process from 3D drawings to real objects. During the research and development stage, every problem in product manufacturing is thoroughly investigated and solved. Among them, in the early stage of the mold development process, it is necessary to solve the encountered problems in the production process and solve the production problems, and collect the problems in the development process for derivation and promotion, and fully compile them into the operation documents to prevent similar problems from happening again.
1. Matters needing attention in the R&D process
(1) When analyzing the product structure, fully consider the manufacturability of die-casting, reasonably optimize and improve the product, meet the requirements of the principle of uniform wall thickness of the die-casting process, communicate effectively with customers, rationally optimize the thickness position, and simplify the shape, Jointly develop and strive to make better product structures and solutions;
(2) Multi-faceted joint review in the early stage of the mold, the position and structure that are prone to problems, and the backup plan is considered. During the analysis process, we often consider the next backup plan with the idea of not being able to solve the problem, which can promote more excellent solutions. To prevent the failure of the scheme, there is no room for improvement, and the optimization space should be considered repeatedly when making the scheme;
(3) In the initial trial production process, product problems and mold making problems need to be collected and fed back to the product engineer in charge and the mold factory. Keep up-to-date problem information and pass it on to the decision-making party for resolution to avoid recurrence of similar problems. Only by doing a good job in mold quality can we increase production and ensure quality during mass production;
(4) It is very important to rationalize the choice of smelting aluminum water: to improve product quality, such as automotive products, in order to improve the mechanical properties of the product, it is necessary to add an appropriate amount of magnesium to the raw material to improve the tensile strength and yield strength of the product; or communication products need In order to improve the directing rate of products, it is necessary to put forward higher requirements for the proportion adjustment of aluminum-phase silicon in smelting aluminum water, etc;
(5) It is very important to ensure the normal operation of equipment automation. During the initial production process of the mold, due to the switching of production tooling, more or less production unit failures will be caused. It is necessary for equipment automation personnel to quickly troubleshoot and solve problems. At the same time, equipment automation personnel There are also higher levels and requirements to ensure the normal realization of advanced production unit functions;
(6) Rationalization of tooling design, especially the detection of key characteristics of multiple products, such as product thickness, weight loss, interference position, leakage, air bubble test, etc., which seriously affect product quality characteristics; among them, the biggest problem of enterprises is often in the inspection method It is easy to have problems with inspection tooling, such as measuring and checking tools that cannot identify product characteristics;
(7) Fully consider the characteristics of the die-casting mold. Fully consider the scour of the mold gate and the cracking of the product in the later stage; whether to cut the insert and make a spare mold.
2. Matters needing attention in the mass production stage
(1) Mass production quality problems emerge in endlessly, which are closely related to the manufacturing process. Batch quality accidents may occur in each production link, such as lax inspection of smelting returned materials, which may easily lead to the scrapping of the entire furnace of molten aluminum in large smelting furnaces, resulting in excessive production. All machine products are scrapped;
(2) Process control is also crucial during die casting production, including appearance size control and internal quality control. Real-time monitoring of product changes in the production process, and timely measures, otherwise unnecessary waste will be caused, which means that the current monitoring must be subdivided into each production unit for responsibility, and abnormalities should be dealt with quickly and the results will be fed back , to ensure the product; to resume production efficiently and quickly;
(3) Defects found during the post-processing of the product, such as: lack of meat, excess meat, air holes, size deviation, etc., need to be quickly fed back, the mold should be processed, and the verification mark records should be made to prevent the same type of defects from happening again;
(4) The maintenance of mold tooling is extremely critical in the mass production stage. In particular, it is necessary to strictly manage and control the production life of the mold, carry out regular maintenance and regular replacement of spare parts, and regularly determine the shape and size of the product, and conduct a regular comprehensive assessment of the current status of the mold. It is convenient to provide Give the production unit an accurate information;
(5) Die-casting, especially on-site management is also extremely important: such as switching time control of tools and equipment; management of punches, connectors, spraying T equipment, cooling waterways, etc. Work after the tooling is completed, so as to avoid the termination of production due to tooling problems during continuous production; for example, during the production process of the mold, the screw of the push plate is loose, the screw of the slider falls, the push rod is broken, the core is broken, etc., and the impact continues Production factors are eliminated to enable continuous production. Only continuous production can stabilize and improve quality. In short, in the development process of our die-casting products, the two stages of R&D and mass production are interdependent. Only when problems are found in the R&D process, they can be improved and controlled and passed to the mass production stage, and the problems that occur in the R&D process will be resolved in the mass production stage. Summarize and provide an empirical data during research and development, form a closed-loop system, improve product risk identification capabilities, process development capabilities, thereby improving product quality and product output. Product quality and output are actually relatively independent, and they are also two indicators of mutual guarantee. Only when the quality is done well can there be good output, and only when the output is well done can there be a stable quality.