不锈钢手机外框精密锻造质量控制的研究
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摘要
精密锻造成形工艺具有省材、低成本和高效率在特点,同时精密锻造成形的产品具有致密在组织和均一的机械性能。特别是冷锻技术在精密成形领域有着其独特的优势。随着基于知识设计方法在冷锻成形工艺及模具的设计中的广泛应用,冷锻变得更易于操作。但是精密锻造是一个复杂的过程,如何制定锻造工艺将直接关系到最终产品在质量和生产效率。
本文以客户需求为向导,结合实际开发的不锈钢手机外框产品的案例,从材料、热处理、内应力、设备和模具设计方案等方面对锻造工艺进行了分析,结合质量管控的理论,运用田口式质量工程的思维规划了精密锻造成形工艺的实验开发方向。对不锈钢锻造成形工艺的制程进行了实验设计、研究和分析。以快速解决锻造产品的硬度和内应力影响的问题。
论文确定了材料、热处理方案和模具方案作为影响锻造成品硬度和内应力的主要因素。并运用有限元模流分析对产品的局部特征进行仿真成型,运用金属变形理论来研究金属变量和硬度变化之间的关系,得到了硬度与变形量之间的数学关系。对锻造模具的开发提供了理论支持。采用了L9(34)正交表进行实验配置,以硬度和内应力所影响的产品平面度变化量作为质量管控检验目标,通过方差分析来选择最优实验方案。在最后在确认实验中,对抽样样本结果,运用Minitab软件进行了质量控制能力的分析,验证了所选方案的正确性。
Precision forging process has the features of the province of materials, low cost and high efficiency, meanwhile, products made by precision process are with a sophisticated structure and uniform mechanical properties. In the area of precision forming, hard wrought technical has its special advantage. With the situation that knowledge-based design method is applied a wide range in hard wrought forming process and die design, forging become much easier to operate. But the precision forging is a complex process, how to make forging process will directly affect the final product quality and production efficiency.
This paper makes some analysis to forging molding process according to the orientation of customer requirement and actual cases in the development of stainless steel mobile frame from the material, internal stress, heat treating, equipment, mold design, etc. Combined with the theory of quality control and Taguchi quality engineering, the experimental development direction of precision forging process has been planned. And the purpose of this paper is to solve the products’hardness and internal stress issues fast by the way of experimental design, research and analysis to the stainless steel forging process.
The paper defines material, heat treating and mould design as the main factors to affect products’hardness and internal stress. Furthermore, the paper concludes the mathematical relationship between hardness and deformation through five methods: 1. use definite element model analysis to simulated form the products’part characters. 2. use metal deformation theory to study the relationship between metal variables and the changes of metal hardness which supply theory support to the development of die. 3. use L9(34)orthogonal table to do the experiment, 4.set the affection of hardness and internal stress to the changes of products’flatness as the quality control testing target. 5. chose the best program by variance analysis. And in the last confirmation experiment, using Minitab software to analyze the capability of quality control verifies the correctness of the selected program.
本文以客户需求为向导,结合实际开发的不锈钢手机外框产品的案例,从材料、热处理、内应力、设备和模具设计方案等方面对锻造工艺进行了分析,结合质量管控的理论,运用田口式质量工程的思维规划了精密锻造成形工艺的实验开发方向。对不锈钢锻造成形工艺的制程进行了实验设计、研究和分析。以快速解决锻造产品的硬度和内应力影响的问题。
论文确定了材料、热处理方案和模具方案作为影响锻造成品硬度和内应力的主要因素。并运用有限元模流分析对产品的局部特征进行仿真成型,运用金属变形理论来研究金属变量和硬度变化之间的关系,得到了硬度与变形量之间的数学关系。对锻造模具的开发提供了理论支持。采用了L9(34)正交表进行实验配置,以硬度和内应力所影响的产品平面度变化量作为质量管控检验目标,通过方差分析来选择最优实验方案。在最后在确认实验中,对抽样样本结果,运用Minitab软件进行了质量控制能力的分析,验证了所选方案的正确性。
Precision forging process has the features of the province of materials, low cost and high efficiency, meanwhile, products made by precision process are with a sophisticated structure and uniform mechanical properties. In the area of precision forming, hard wrought technical has its special advantage. With the situation that knowledge-based design method is applied a wide range in hard wrought forming process and die design, forging become much easier to operate. But the precision forging is a complex process, how to make forging process will directly affect the final product quality and production efficiency.
This paper makes some analysis to forging molding process according to the orientation of customer requirement and actual cases in the development of stainless steel mobile frame from the material, internal stress, heat treating, equipment, mold design, etc. Combined with the theory of quality control and Taguchi quality engineering, the experimental development direction of precision forging process has been planned. And the purpose of this paper is to solve the products’hardness and internal stress issues fast by the way of experimental design, research and analysis to the stainless steel forging process.
The paper defines material, heat treating and mould design as the main factors to affect products’hardness and internal stress. Furthermore, the paper concludes the mathematical relationship between hardness and deformation through five methods: 1. use definite element model analysis to simulated form the products’part characters. 2. use metal deformation theory to study the relationship between metal variables and the changes of metal hardness which supply theory support to the development of die. 3. use L9(34)orthogonal table to do the experiment, 4.set the affection of hardness and internal stress to the changes of products’flatness as the quality control testing target. 5. chose the best program by variance analysis. And in the last confirmation experiment, using Minitab software to analyze the capability of quality control verifies the correctness of the selected program.
引文
[1] 2006年手机结构件与外壳行业研究报告.中国市场报告网2007.
[2] (美)查尔斯A.哈珀.产中设计材料手册.张玉龙,等译.北京:机械工业出版社,2004.
[3]肖纪美著.不锈钢的金属学问题.北京:治金工业出版社,2006.
[4] (日)田口玄一著.实验设计法.魏锡禄,王世芳,译.北京:机械工业出版社,1987.
[5]陈学文等.冷锻技术的发展现状与趋势.金属成形工艺,2003(3):9-12
[6]姜凌,冷锻模具的有限元分析及优化设计.中国科技信息.2006.1
[7]曾正明主编.机械工程材料手册—金属材料.北京:机械工业出版社,2005.
[8]朱舋元,刘忆著.金属学与热处理.北京:中国林业出版社,2006.
[9] Grange,R.A.沃斯田铁之结晶微细化对钢强化之探讨.金属热处理,1998(59):85-94
[10] P. Marshall. Austenitic Stainless Steels:Microstructure and Mechanical Properites. Elsevier Applied Science Publishers, 1984, p. 424.
[11]罗武庭,姜明资.金属棒晶粒度微机检测系统.小型微型计算机系统,1985(06)
[12]蒋鹏.热锻-冷锻复合塑性成形技术.金属成形工艺,2000(1):27-29.
[13]张公绪,孙静著.新编质量管理学.北京:高等教育出版社,2003.
[14]李卫红,杨练根著.质量统计技术.北京:中国计量出版社,2006,8.
[15]肖诗唐,王毓芳著.新产品开发设计与统计技术.北京:中国计量出版社,2001.
[16]周峙江.手机铝合金外壳关键性能参数质量控制的应用研究.[M].上海交通大学工业工程系,2008,5
[17]安炳淑著.质量专业理论与实务.北京:中国人事出版社,2004.
[18]王毓芳,肖诗唐著.质量改进的策划与实施.北京:中国经济出版社,2005.
[19] Motorola University,SSG102,Utilizing The Six Steps to Six Sigma, Participant Guide, Version 6.0,1997.
[20]陈世明.田口式品质工程技术与技术开发.材料与社会.1992
[21]戴国政,林晖斌.质量工程在SUS304不锈钢伸线制程之改善.[M].逢甲大学.2003.6
[22]金建东,周治平,寇文兵.用正交实验法优化多晶硅制备工艺参数.传感器技术.2003(11):9-11
[23]陈魁编.应用概率统计.北京:清华大学出版社,2000.
[24]王亚辉,王艳芬.方差分析在物理实验中的应用.宜宾学院学报.2009(6):30-31
[25]郭涛.基于预成形设计的锻造过程微观组织优化与实验研究.[M].山东大学2008,4
[26]应富强,张更超,潘孝勇.三维有限元模拟技术在金属塑性成形中的应用.锻压装备与制造技术2003(5):10-13
[27]严翔.微量元素对铸造奥氏体不锈钢组织和性能的影响.[M].华中科技大学2004,4
[28]张更超.楔横轧阶梯轴成形过程的有限元仿真与分析.[M].浙江工业大学,2004,5
[29]夏世升,王广春,赵国群等.直齿圆柱齿轮冷精锻新工艺数值模拟研究.热加工工艺,2003(2):22-23.
[30]管婧.锻造成形过程微观组织优化设计方法研究.[D].山东大学,2008,11.
[31]董占山.第五讲----Minitab在方差分析中的应用.计算机与农业.1997(4):28-34
[32]刘敏.应用Minitab处理质量统计分析问题.橡塑技术与装备.2009(2):18-21
[2] (美)查尔斯A.哈珀.产中设计材料手册.张玉龙,等译.北京:机械工业出版社,2004.
[3]肖纪美著.不锈钢的金属学问题.北京:治金工业出版社,2006.
[4] (日)田口玄一著.实验设计法.魏锡禄,王世芳,译.北京:机械工业出版社,1987.
[5]陈学文等.冷锻技术的发展现状与趋势.金属成形工艺,2003(3):9-12
[6]姜凌,冷锻模具的有限元分析及优化设计.中国科技信息.2006.1
[7]曾正明主编.机械工程材料手册—金属材料.北京:机械工业出版社,2005.
[8]朱舋元,刘忆著.金属学与热处理.北京:中国林业出版社,2006.
[9] Grange,R.A.沃斯田铁之结晶微细化对钢强化之探讨.金属热处理,1998(59):85-94
[10] P. Marshall. Austenitic Stainless Steels:Microstructure and Mechanical Properites. Elsevier Applied Science Publishers, 1984, p. 424.
[11]罗武庭,姜明资.金属棒晶粒度微机检测系统.小型微型计算机系统,1985(06)
[12]蒋鹏.热锻-冷锻复合塑性成形技术.金属成形工艺,2000(1):27-29.
[13]张公绪,孙静著.新编质量管理学.北京:高等教育出版社,2003.
[14]李卫红,杨练根著.质量统计技术.北京:中国计量出版社,2006,8.
[15]肖诗唐,王毓芳著.新产品开发设计与统计技术.北京:中国计量出版社,2001.
[16]周峙江.手机铝合金外壳关键性能参数质量控制的应用研究.[M].上海交通大学工业工程系,2008,5
[17]安炳淑著.质量专业理论与实务.北京:中国人事出版社,2004.
[18]王毓芳,肖诗唐著.质量改进的策划与实施.北京:中国经济出版社,2005.
[19] Motorola University,SSG102,Utilizing The Six Steps to Six Sigma, Participant Guide, Version 6.0,1997.
[20]陈世明.田口式品质工程技术与技术开发.材料与社会.1992
[21]戴国政,林晖斌.质量工程在SUS304不锈钢伸线制程之改善.[M].逢甲大学.2003.6
[22]金建东,周治平,寇文兵.用正交实验法优化多晶硅制备工艺参数.传感器技术.2003(11):9-11
[23]陈魁编.应用概率统计.北京:清华大学出版社,2000.
[24]王亚辉,王艳芬.方差分析在物理实验中的应用.宜宾学院学报.2009(6):30-31
[25]郭涛.基于预成形设计的锻造过程微观组织优化与实验研究.[M].山东大学2008,4
[26]应富强,张更超,潘孝勇.三维有限元模拟技术在金属塑性成形中的应用.锻压装备与制造技术2003(5):10-13
[27]严翔.微量元素对铸造奥氏体不锈钢组织和性能的影响.[M].华中科技大学2004,4
[28]张更超.楔横轧阶梯轴成形过程的有限元仿真与分析.[M].浙江工业大学,2004,5
[29]夏世升,王广春,赵国群等.直齿圆柱齿轮冷精锻新工艺数值模拟研究.热加工工艺,2003(2):22-23.
[30]管婧.锻造成形过程微观组织优化设计方法研究.[D].山东大学,2008,11.
[31]董占山.第五讲----Minitab在方差分析中的应用.计算机与农业.1997(4):28-34
[32]刘敏.应用Minitab处理质量统计分析问题.橡塑技术与装备.2009(2):18-21