1、FORD MANUFACTURING STANDARDCONTROL OF CASTING MANUFACTURING PROCESSESW-CMS2nd EditionStandard: W-CMS Issue Date: 14-July-08 Global Manufacturing Standards Revision Date 14-July-09 W-CMSGIS1 Item Number: N/AGIS2 Classification: ProprietaryPage 1 of 58Ford Motor Company Date Issued: 7/14/2008 Date Rev
2、ised: 7/14/2009W-CMS DEVELOPMENT TEAM:Executive Sponsor:Terry AldeaAuthor:Tim CovertChris GambinoJim LoefflerGlobal Contributors:Glenn AustinPaul BallasDennis BarbierDr Alexandre BarrosDr Julian BassettJoe CarusoDavid CroomRodrigo CunhaBill CurtissRoger DavisJoe FilipovichBrad GuthrieRon HasenbuschS
3、tefan HeinzMartin JonesMike JuddJani KalidindiChris MoranoVenkat NaraEd OswaldDr Ozgur OzdemirBrian NellenbachEben PrabhuPatrick PryceTom RecchiaTom ScislowiczVijay ShendeRandall ThomasFrank TibaudoReiner TillenburgUemit UrsavasZhi Jian (Eddie) Wang Mike WarrenGlen WeberStandard: W-CMS Issue Date: 1
4、4-July-08 Global Manufacturing Standards Revision Date 14-July-09 W-CMSGIS1 Item Number: N/AGIS2 Classification: ProprietaryPage 2 of 58Ford Motor Company Date Issued: 7/14/2008 Date Revised: 7/14/2009ITEM SUBJECT PAGE1. DESCRIPTION AND REQUIREMENTS 41.1 SCOPE 41.2 SPECIFICATION OF REQUIREMENTS 51.3
5、 PROCESS SPECIFICATION 51.4 PROCESS AND QUALITY CONTROLS 51.5 CONTROL PLAN 51.6 STATISTICAL METHODS AND PRE_CONTROL CHARTING 62. COMPUTER AIDED ENGINEERING GUIDELINE 7CASTING SIMULATION MODELING GUIDELINE2.1 FLUID FILL variation is in the measuring system). In some cases the process variable natural
6、ly demonstrates a small variation between samples or drift, as long as it doesnt go too close to the pre-established control limit. Some examples of key process input variables where pre-controls work well:Time dependant process factors (i.e. Mg fade in ductile iron) naturally drift, which is accept
7、able if controlled to a safe margin within the process limits. Alloy chemistry demands allow nominal offset biased targeting from the specification mid point.Pre-control provides key metal casting processes with pre-established control limits, process specification limits and reaction points to assu
8、re process control for those process characteristics indentified as HICs in W-CMS. The application of Pre-control charting is broken down into the following 2 steps:A. Collection of Data. The process characteristic being monitored shall have its data displayed in a fixed-frequency, time-dependent pl
9、ot. By charting the process data, trends are displayed for the attending operator and site management to quickly assess the variable being monitored.Must be in place for those process-specific HICs.Charting system must provide trending assessment.B. Control of Process. By specifying control limits t
10、hat are safely within the specification limits, the process shall be controlled against shifting or drifting outside of the process limits. Using the universal Green-Yellow-Red traffic light color codes, the attending operator and site managers shall implement reaction steps, contain suspect product
11、,and prevent casting parts with a process factor out of specification. Must demonstrate process control with data.Must indicate 2 possible reaction points/plans:*Yellow = Adjust Process*Red = Stop Process, Contain Aluminium HPDC: o X-Ray Acceptance Criteria ASTM E-505 Level X maximum for all types o
12、r Porosity specified to level X or better Ductile Iron castings: o X-Ray Acceptance Criteria ASTM E-446 Level X maximum for all types*(Where X is defined in the ASTM standards as a number in the range 1 to 4)The scope of the X-ray Quality Operating System Guideline is primarily for the non-destructi
13、ve testing and inspection of metal cast components from supplier production operations of ferrous and non-ferrous materials. It is applicable to all X-ray inspection systems including 100% production inspection, production sample audit and diagnostic inspection type systems. Non-destructive testing
14、using x-ray inspection applies as a detection method for casting failure modes such as: shrinkage porosity, sponge porosity, gas porosity, inclusions (foreign material of dissimilar metal density differences), cold shot (cold flow) - porosity trails, and large voids/large cracks. Capability of detec
15、tion for x-ray systems may be limited by the geometry/size of the defect and may therefore be inadequate for detecting: cracks (tightly closed), inter-metallic inclusions (oxides, sulphides, etc), cold shuts, non-knits, folds, or core contamination. The purpose is to provide a guideline for safe ope
16、ration of x-ray inspection in accordance with applicable regulations and to communicate the x-ray inspection quality operating system expectations for global standardization by promoting best practices. An x-ray checklist (see X-ray Checklist Tab) is available for x-ray system evaluations to these e
17、xpectations. The checklist covers the key aspects of x-ray inspection systems including:Safety (including linkage to local regulations)Manipulation (Part and/or X-ray Equipment)X-ray SourceImage QualityOperating SystemsPreventative MaintenanceThis guideline does not specify the type of x-ray system
18、or image quality to detect a given casting anomaly. The guideline is intended to be a tool to enhance operation of x-ray inspection systems but does not make any guarantees of the x-ray inspection process because quality assurance is the responsibility of the supplier according to the processes defi
19、ned in the control plan The x-ray specific standardization team included: Glenn Austin, Tim Covert, Bill Curtiss, Roger Davis, Brad Guthrie, Ron Hasenbusch, Martin Jones, Mike Judd, Jim Loeffler, and Glen Weber. Standard: W-CMS Issue Date: 14-July-08 Global Manufacturing Standards Revision Date 14-J
20、uly-09 W-CMSGIS1 Item Number: N/AGIS2 Classification: ProprietaryPage 9 of 58Ford Motor Company Date Issued: 7/14/2008 Date Revised: 7/14/2009Area Casting Simulation Characteristics G/Y/REvidence or Gap identifiedGeneral ItemsConfirm there is evidence of multiple simulation trials before optimizatio
21、n is complete.Simulation study uses the tooling CAD model of the production dies or patterns. Simulation study uses the present release level for part model.Confirm that supplier can provide evidence of correlation between simulation and actual results.Simulation Setup - Pre-processorConfirm that mo
22、del has actual geometries for inlet gate thickness, overflows, risers, gate runners. Confirm that model is identified consistently (inlets, casting, overflows, vents, etc.)Confirm that simulation setup is reviewed by customer design teams (i.e. CPMT)Confirm that simulation uses initial temp data tha
23、t is consistent with actual data in plant.Simulation Setup - Mesh:The mesh adequately captures the part, overflow geometry.Confirm in-gate thickness is adequately meshed (normal to direction of metal flow) Simulation Setup - Material/HTC:Confirm that the material being used in simulation is the same
24、 as the design spec.Confirm that the Heat Transfer Coefficients (HTC) are appropriate (ref prior examples monthly Checksheet weigh scalePouring time each run Checksheet timerPouring Temperature HIC continuous Pre-control Thermocouple AlamsDisa Pouring - Overspill Prevention into empty molds Each Shi
25、ft Error Proofing MethodVerification of effectivness of the error proof -checksheetCarbon Roller or sand damRemoval of gates and risers each mold Work instruction Visual inspection Automated systemCasting profile tolerance (gate /flash/riser connector) every shift per print Visual / gagingMismatch /
26、 mold shift every shift per print Visual / gagingIf applicable, Shot blasting every shift Work instruction Time / shot sizeIf applicable, cubing each shift Cubing drawing Dimensional gage or CMMCasting condition (surface flaws/handling damage/ short pours) HIC 100% Visual aide Visual inspectionPart
27、Internal Integrity per ES or Print Acceptance Criteria NDT ( Real-time Xray) Auto-defect recognitionSurface Integrity per ES or Print Acceptance Criteria NDT (FPI)Resonance Inspection or Ultrasonic TestingSurface hardness each shift or HT basket Pre-control BrinellLab Boss - indention measurementDim
28、ensionalSC/PTC/HIC1st Piece and Last PieceEach cavity /shiftPer Part Print: Special Characteristics/Pass Through Characteristics. Consider pattern/core die features prone to damage or wear. Dimensional gage or CMMAt PPAP: Full layout with point cloud scanning (Laser or light)Microstructure Analysis
29、HICsEach shift - Blocks/HeatdsProduct Validation - othersTraceable to cast machineDendrite arm space each shift Minimum fixed limit Visual comparator Image analyzerGrain size Each shift Minimum fixed limit Visual comparator Image analyzerEutectic Modification Each shift Minimum fixed limit Visual co
30、mparatorEutectic SegregationCasting inspection (surface flaws / handling damage / short pours) 100% Visual aide Visual inspectionLeak testing (if specified) per Print/ES or PV plan Acceptance CriteriaAir decay or air-under-water or mass airflowLeak Test Robustness Standard GTS-1.4.1Mechanical Proper
31、ty (from part if possible)per Material Spec, ES, or Print Tensile tesing UTS-YS-Elongation Laser extensometer?Pattern Cavity # 100% Work instruction Checksheet On parts and riserCast Date per Design Record Work instruction Year, Month and DayPinstamping of casting timePart number/Supplier Code/Ford
32、Logo Branding E108 Work instruction ChecksheetCore Box Cavity # (if feasible) 100% Work instruction Checksheet Easily viewedRecycling Code CAD E5Heat Treatment covered by W-HTX / For potential other product specific requirements reference the Print/ES/eSOWGreen 0Yellow 0Red 0N/A 0Effective Score#DIV
33、/0!Part ID / Traceability requirements (ALL MUST BE LEGIBLE ON THE CASTING)9Cleaning / Finishing Operation7Product Testing and Inspections8Molding / Pouring Operation6Rating Table SummaryW-CMSGIS1 Item Number: N/AGIS2 Classification: ProprietaryPage 17 of 58Ford Motor CompanyDate Issued: 7/14/2008Da
34、te Revised: 7/14/2009Area CharacteristicChar. Class. (min level)Test / Inspection Frequencies (Minimum) Recommended Control Method Measuring SystemBest Practices and Additional Information G/Y/R Evidence or Gap identifiedCertification each lotLot/Document controlRestricted substance compliance (WSS-
35、M99P9999-A1) CertVerify supplied sampleRadioactivity testing Metal Chemistry each lot Pre-control Spectrometer Verify supplied sampleVisual Cleanliness each lot Store appropriately Visual VisualApproved Source List each lot Approval list Approval processMetal Chemistry: Major elements HICevery 2 hou
36、rs or each heatPre-Control:Cu Fe Mg Si SpectrometerRegular Round Robin w/ other test LabsMetal Chemistry: Other elementsevery 2 hours or each heatFixed Limits:Mn Zn Ti Sr P Na Ca Pb Ni Cr Sn Bi SbSpectrometerInvestigate the necessity for Be Li Ce Mo V Zr Ag Tl WMetal Temperature Continuous Pre-contr
37、ol Thermocouple AlarmsSpecific Gravityevery 2 hours or each heat Pre-control Reduced pressure testAl-scan or Hydrogen AnalyzersInclusion checkProduct qualification dependent Pre-control K-moldProcess verification using Prefil/PoDFA with quantified Metallographic Analysis resultsMetal and furnace cle
38、aning PM weekly Checksheet PM SystemDegas & Flux Injection cleaningMetal Chemistry: Major elements Each shiftPre-Control:Cu Fe Mg Si Ti Sr SpectrometerRegular Round Robin w/ other test LabsMetal Chemistry: Other elements Each shiftFixed Limits:Mn Zn Ti Sr P Na Ca Pb Ni Cr Sn Bi SbSpectrometerInvesti
39、gate the necessity for Be Li Ce Mo V Zr Ag Tl WMetal Temperature HIC continuous Pre-control Thermocouple AlamsMetal and furnace cleaning PM weekly Checksheet PM System FiltrationSpecific Gravity HICevery 2 hours or each heatPre-controlRotary Degassing Reduced pressure testAl-scan or Hydrogen Analyze
40、rsFiltration continuous Checksheet PM SystemGrain Refinement HIC every 4 hours Pre-control Spectrometer cooling curveEutectic Modification HIC every 4 hours Pre-control Spectrometer cooling curveDie Qualification Each die Layout CMMFord Die Materials StandardsDie PM programEach production run Define
41、d frequencyPM System based on shot countFord Tooling Mangement SystemDie Verification HICs Pre Die Set Checksheet VariousFord Tooling Mangement SystemDe-calcification of water flow pathsWater / Hot oil plumbing flow checkT/C function checkEjector pin functionCore condition (Replacement)Any misc item
42、s (vacuum, cylinders)Die Cleaning frequency defined Checksheet PM SystemDie Verification 1st / Last Shot Checksheet VisualGlobalManufacturing W-CMS: Aluminum Squeeze Casting Process Controls Checklist Standards 1234Raw materialsMelting OperationMetal Holding (Die Cast Machine Molten Metal)Tooling W-
43、CMSGIS1 Item Number: N/AGIS2 Classification: ProprietaryPage 18 of 58Ford Motor Company Date Issued: 7/14/2008Date Revised: 7/14/2009Startup Process HICs Each startup ChecksheetDie preheat to temperatureWater line verification Flow meter Auto die waterHot oil verification Hot Oil Unit gageShot param
44、eter verification Start up Shot Process Start up Shot ProcessDie spray system verification Set up sheet/visualDie pre-heat to temp T/CScrap standard number of piecesStartup & Cycle interruption Shot Process Autoscrap processShot Monitoring Parameters HICs Each shot Shot control systemShot monitoring
45、 softwareShot Control w/auto scrapCycle TimeSlow Shot VelocityFast Shot VelocityIntensification PressureCavity pressure transducer measurementBiscuit LengthSlow shot distanceIntensification Rise TimePouring method each shot Auto pouring ladle Biscuit LengthDie Temperature HIC Every 4 hours Pre-contr
46、ol Infrared or T/C reading Continuous monitoring with auto scrapDie Temperature Controls (Cooling/Heating) Each shot Flow control Flow meterWater cooling / Hot Oil / Vacuum AssistDie Spray System Verification (Pattern + Nozzles + Amount) HIC Each shift Checksheet Visual spray and castingAir Blowoff
47、System Verification Each shift Checksheet Visual spray and castingPlunger tip lubrication (shot end) Each shot Auto lubrication Setup verificationShot Curve auto alarm for high frictionLube concentration Daily Pre-controlRefractometer or specific gravityAuto die lube system with flow control Part co
48、oling Each shot Air or water Finishing cellDe-sprue Each shot saw cut gate heightAutomated finishing cellTrim pressTrim Each shotAutomated finishing cellTrim pressPart Internal Integrity per ES or Print Acceptance Criteria NDT (Real-time X-ray) Auto-defect recognitionSurface Integrity per ES or Prin
49、t Acceptance Criteria NDT (FPI) Resonance InspectionSurface hardness each HT basket Pre-control Brinell Lab BossMechanical Property (from part if possible)per Material Spec, ES, or Print Tensile tesing UTS-YS-Elongation Laser extensometerVisual inspection HIC 100% Acceptance Criteria VisualDimensionalSC/PTC/HIC1st Piece and Last PieceEach cavity /shiftPer Part Print: Special Characteristics/Pass Through Characteristics. Consider key die features prone to damage or
