CQI-27铸造系统评估CSAspecialProcessCastingSystemAssessment,Version1,Issue10_2015表格推荐下载.xlsx
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CQI-27铸造系统评估CSAspecialProcessCastingSystemAssessment,Version1,Issue10_2015表格推荐下载.xlsx
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Address:
PhoneNumber:
Website:
Type(s)ofCastingProcessesatthisFoundry:
ProcessTableANumberofEmployeesatthisFoundry:
DuctileIronProcessTableBGreyIronDateofAssessment:
ProcessTableCCentrifugalLinersDateofPreviousAssessment:
ProcessTableDAluminumSemi-PermanentMoldProcessTableEAluminumSPMCylinderHeadsProcessTableFAluminumGreenSandProcessTableGInvestmentCasting(Iron/Steel)ProcessTableHAluminumHighPressureDieCastProcessTableIMagnesiumHighPressureDieCastProcessTableJAluminumPermanentMoldProcessTableKAluminumPistonsProcessTableLZincHighPressureDieCastProcessTableMCompactedGraphiteIronCurrentQualityCertification(s):
DateofRe-assessment(ifnecessary):
PersonnelContacted:
Name:
Title:
Phone:
Email:
Auditors/Assessors:
Company:
NumberofFailFindings(specifybyProcessTable):
2015AutomotiveIndustryActionGroupISBN#:
9781605343310CQI-27SpecialProcess:
CastingSystemAssessmentVersion1,10/2015PROCESSTABLEA-DuctileIronAllrequirementsgivenbelowaresubordinatetocustomerspecificrequirements.WhenperformingtheCQI-27CastingAssessmenttheauditorshallverifyfoundryisconformingtocustomerrequirements;
includingacustomerapprovedControlPlandefiningtheagreeduponinspectiontestingandfrequencies.*Ifminimumrequirementsarenotmet,providesupportingrecordstojustifyactualconditions.Whatisthescopecoveredbythisaudit?
Theentirefoundry?
Aspecificproductline?
Aspecificpartnumber?
Other?
Describethescopeoftheaudit:
ItemCategory/ProcessStepMinimumRequirementObservations/CommentsaboutActualConditionPass/Fail/NotApplicable1.0CastingDesignandToolingA1.1DesignSoftware1.Castingplantmustbecomplianttocustomerspecificsoftwarerequirements.2.CastingplantmusthaveandmaintaincustomerspecificrequirementsformathdatatransferforthetoolingandforpartDrawings/Models.A1.2CastingSimulation1.ThecastingplantmustusesolidificationmodelingsoftwaresuchasMagmaSoft,AnyCasting,ProCast,EKK,FLOW-3DorsimilarsoftwareapprovedbythecustomerProductEngineeringonthecastingaspartofthedesignprocessforthegatingandfeedingsystempriortotoolingconstructionandprototypepartsubmission.Simulationmustincludebothfillandsolidificationanalysis.2.ResultsmustbereviewedwiththeCustomerProductEngineering.3.AtanyhighstressfeaturesintheFEA,thesimulationshouldavoidhotspots,airentrapment,multiplemetalfrontsconverging.A1.3FEAAnalysis1.ThedesignresponsiblepartymustcompleteanFEA(FiniteElementAnalysis)forthecasting.Theultimatetensilestrength,yieldstrength,andpercentelongationusedintheFEAmustbeoverthelowerlimitofengineeringrequirementforthespecifiedalloyforsimilarapplications.2.Thefoundryshouldknowthespecificfeaturesofthecastingwheremaximumstressesexceed50%oftheYieldStrength.Forpurposesofthisassessment,theexpressionhighstressreferstoanyfeatureexceeding50%oftheYieldStrength.3.AnyhighstressfeaturesidentifiedintheFEAmustbeevaluatedwhencastingsimulationsarereviewed,andwhenestablishingproductauditssuchaswallthickness,microstructure,hardness,x-ray,crackinspections.A1.4CastingDatum1.Ifthecastingplantcreatestherawcastingdrawing,thatdrawingmustbeapprovedbythecustomerProductEngineering.2.Ifthecastingplantcreatesthetolerancelimitsbetweentherawcastingdrawingandanyotherdrawing,thosetolerancelimitsmustbeapprovedbythecustomerProductEngineering.3.Wheneverpossible,theX-Y-ZdatumsurfacesusedonthemachinedcomponentsshouldbethesameX-Y-Zdatumsurfacesastherawcastings.Thisisfordimensionalcontrolpurposesandminimizingdatumshiftsbetweenthecastingandmachinedsurfaces(oneofthecausalfactorsrelatedtothin-wallconditions).4.TheX-Y-Zrawcastingdatumsurfacesshouldbeononepieceofthetooling.A1.5CastingToolMaterialAllproductioncoreboxesandmoldingpatternsshouldbemadefromsteelalloysunlesscustomerProductEngineeringapprovesalternatematerial.A1.6CoreBoxDesignCoreboxesmustbedesignedsuchthatfilingonthelocatingsurfacesofcoreprintsisnotallowed.Avoidblowtubes,vents,partinglinesonthelocatingsurfaces.A1.7CoreBoxVentsSlottedcontouredventsarerecommendedtobeusedoncastingcavitysurfacesofcoretoolingcavities.A1.8ToolingMaintenance1.Thelifeofthetoolingistrackedbasedonnumberofcycles.2.Thereisanitemizedlistofregularmaintenanceitemscompletedatpre-definedfrequencies.3.Checksheettotrackcompletionofregularmaintenance.4.Abrasivesystems(suchasshotblastandhandgrinding)notpermittedforcleaningtooling.Non-abrasivesystems(suchasdryice,highpressurewaterblast,solventwashingandultrasonic)arerequired.A1.9ToolChanges1.Replacementinserts(newsteel),wherethereisacustomerspecificrequirement,aPPAPapprovalmayberequired.Customerspecificrequirementsmayrequireaprocesschangerequestsubmissionwithpossibleproductiontrialrunrequirements.2.Alltoolingrepair(welding,grinding,machining,insertreplacement)requiresdimensionalverification(internalapproval)priortore-institutingthetoolforproductionvolumes.3.ThesuppliercomplieswithallcustomerrequirementsrelatedtowhichPPAPrequirementsareneededwhentoolingiscorrected.A1.10CastingTraceability1.Allcastingsproducedmustbeidentifiedwithcustomerbrandingrequirements,castingplantlogo(asapplicable),castingpartnumber,cavitynumber,andcastdateindesignatedlocationspercustomerrequirements.2.Insomeapplications,traceabilitytobothcastingmachineand/ormeasuredprocessparametersspecifictothecastingmayberequired.Identificationmustbeaccurateandreadilyvisibleonnon-machinedsurfaces,andmustnotinterferewithpartinglines,appearance,function,processingorassembly.2015AutomotiveIndustryActionGroupISBN#:
97816053433102CQI-27SpecialProcess:
CastingSystemAssessmentVersion1,10/2015A1.11FixturesandGages1.Gageandfixtureplanmustbereviewedandapprovedbycustomer.(Mayincludein-linegageequipmentfor100%checkofcriticaldimensionsasidentifiedonpartspecificationand/orpartdrawing.).2.ThedimensionalaccuracyofallfixturesandgagesmustbeperCustomerrequirements.Typically,allfixturesandgagesshallbebuilttoatolerancethatis10%orlessofpartworkingtolerance.Somecustomersmayrequireallfixturesandgagestobebuiltto+/-5micronmaximumaccuracy(thisreferstotheactualgage,notthepart).3.Allsurfacesoffixturesandgageswhichtouchthepartshouldbemadefromhardtoolsteel.4.Thetipsofallclampsonfixturesandgagesmayrequiretobebuiltwithreplaceabletips.5.VariablegagesmustpassGageR&
RperAIAGorsimilarstandard.6.Allfixturesandgagesmustbecertifiedperiodicallyeitherbyin-houseifcapableorbythirdparty.2.0MetalControlA2.1Incoming/ReturnedMaterialStorageRaw/Returnedmaterialsmustbestoredwithoutmixingtheminmarkedstorageareasbytype.A2.2ChargingMaterialsandAlloyAdditionsChargematerialsandalloysgoingintomeltingfurnacesmustbeweighedfirst.A2.3MetalChemistry1.Chemistrymustbecontrolledateachkeypointintheprocess(melting,holding,andpouring).2.Theremustbeaspectrometeronsiteforchemistrycontrol.IndustryStandards,suchasASTME1999,mustbefollowedforsampling,verification,standardizationandcalibration.3.ElementalC/Sanalyzer(LECOorsimilar)ispreferredforfinalcarbonandsulfurcontrol.Ifaspectrometerisusedforfinalcarbonandsulfurcontrol,thetestsamplemustbecooledfastenoughtoavoidfreegraphite.AdailyverificationofthespectrometerbacktoaC/Sanalyzermayberequired;
resultsofthecross-checkmustbedocumented.Thelimitsonthecross-checkmustbereviewedandapprovedbythecustomer.4.ThespectrometermusthavecertifiedMastercalibrationStandardswhichcovertherangeofeachchemistryelementbeingcontrolled.TheseCalibrationMastersshouldbeonsite.5.AproceduremustbepostednearthespectrometerwhichclearlydefinesthepermissibletolerancerangeoftheMastercalibrationStandards.6.Theremustbecontrollimitsforallkeyelementsofthematerialgradeincludingcarbonequivalent(C+1/3Si)andcustomerdefinedelements.7.Theremustbeaminimumlimitforsulfur.Preferablyover0.006%.A2.4ChemistryForanyelementswithcustomerspecifiedmandatorylimits,theselimitsmustbereducedbythetolerancepermittedontheMastercalibrationStandards.A2.5ChemistryAThermalArrestunit,alsoknownasaCEMeter,shouldbeusedonthemeltdeckforin-processchecks.A2.6MetalTemperature1.Immersionisthepreferredmethodfortemperaturechecksateachmetalholdinglocationwithupperandlowercontrollimits.2.Holdingfurnacesmustbecapableofcontrollingmetaltemperatureatthemetalextractionpointto+/-10C.A2.7Inoculation1.Allmetalmustbepost-inoculated.Thiscouldbeintheladle,in-stream,orinthemold.2.Post-inoculationbasedonweightispreferred.Ifthepost-inoculationadditionisbasedonvolumeortimers,theremustbearegularaudittoverifytheweight.A2.8CarbonRaiserItispreferredthatthecarbonraiserusedasanadditiontoelectricmeltingfurnacesbelessthan0.3%volatilescontent.VolatilescontentcanbeprovidedonMaterialCertificationfromsupplierofthecarbonraiser.PetroleumCokeby-productsandindustrialgraphitescrapswithhighvolatilescontentcancauseporosityincastings.Thisvolatilesrequirementdoesnotapplytoorganiccharcoalcarbonraiserssuchascharredcoconuthulls.3.0MagnesiumTreatmentA3.1TreatmentLadle1.Formsormoldsmustbeusedtobuildorrepairthetreatmentladle.Thedimensionofthereactionchambermustbeverifiedafterthebuildorrepair.2.Forope
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