技术质量管理与辊式冷弯成型产品质量稳定性研究和实践
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摘要
技术质量管理是近年来新兴的一门综合了质量管理理论和工程技术的交缘学科,其在企业研发、制造、销售以及客服等领域发挥了积极作用,赢得了愈来愈多企业经营者和研究人员的青睐。技术质量管理不等同于一般意义的质量管理或者是技术管理,而是指技术层面上的质量管理,利用更丰富的技术手段使企业设计、生产过程与质量管理层有效的衔接起来,以达到解决质量问题,稳定质量以及提高质量的目的。
冷弯成型工艺距今已有百年的历史,但是由于产品品种繁多、生产过程影响因素多,理论解析十分困难,孔型和工具设计任务复杂,长期依靠经验和试验生产。从而对冷弯产品的质量管理不断提出新的挑战。将技术质量管理理论应用于冷弯成型工艺将是一次有益的尝试,不仅可以为冷弯成型的质量管理提供观念启发和技术支持,也将拓宽技术质量管理的工程应用领域。
首先,本文介绍了质量管理及其发展历程,概述了辊式冷弯成型工艺及辊弯产品的质量管理的现状。
其次,系统地阐述了技术质量管理理论,论述了技术质量管理所倡导的质量观及其主要研究内容,介绍了在工程实践中使用到的方法和工具。
再者,以泛亚公司辊弯成型生产性为例,针对孔型设计和生产过程及设备两方面影响辊弯产品质量的因素进行分析。根据分析结果提出了解决辊弯产品质量不稳定问题的方案,并论证其可行性。介绍了方案实施情况,包括试验流程和数据分析方法及结果。提出了对试验方案的改进意见,并论述了其理论依据。
最后,对全文进行总结,指出待改进的方面,并展望了技术质量管理理论的应用前景。
As a new theory emerging in recent years, technology & quality management is integrated with traditional quality management and engineering technology, and earned a reputation of more and more business operators and researchers, because of its positive behavior in the design, manufacture, marketing and customer service areas of corporations. Technology & quality management is not tantamount to traditional quality management or technology management, but the technical level of quality management, More abundant means of technology to make enterprises design, production process and quality management effective convergence, in order to solve the quality problem, stable quality and quality improvement goals.
Cold roll forming (CRF) has 100 years of history, but because of product variety and factors affecting the production process, it is very difficult for theoretical analysis and tools & roll pass design, relying on the experience and long-term production test. So it is a challenge for the quality management of CRF products.
To apply technology & quality management theory to CRF will be a useful attempt, not only can provide with inspiration and technical support to quality management, but also will broaden the project management application of technology & quality management.
First, this paper introduced quality management and its development course, and overviewed CRF technology and its product quality management status.
Second, elaborated technology & quality Management theory, discussed the quality conception advocated by technology & quality Management and its main content, and introduced the practice in the use of methods and tools.
Moreover, analyzed the factors affecting product quality including roll pass design, production process and equipment, considering CRF product line in CIS corporation as an example. Suggested a solution for product quality problems based on analysis results, and demonstrated its feasibility. Introduced the implementation of the program, including laboratory procedures and data analysis methods and results. Improved the program and discussed its theoretical basis.
Finally, summarized all the work, suggested the aspects for improvement, and forecasted the future of technology & quality management.
冷弯成型工艺距今已有百年的历史,但是由于产品品种繁多、生产过程影响因素多,理论解析十分困难,孔型和工具设计任务复杂,长期依靠经验和试验生产。从而对冷弯产品的质量管理不断提出新的挑战。将技术质量管理理论应用于冷弯成型工艺将是一次有益的尝试,不仅可以为冷弯成型的质量管理提供观念启发和技术支持,也将拓宽技术质量管理的工程应用领域。
首先,本文介绍了质量管理及其发展历程,概述了辊式冷弯成型工艺及辊弯产品的质量管理的现状。
其次,系统地阐述了技术质量管理理论,论述了技术质量管理所倡导的质量观及其主要研究内容,介绍了在工程实践中使用到的方法和工具。
再者,以泛亚公司辊弯成型生产性为例,针对孔型设计和生产过程及设备两方面影响辊弯产品质量的因素进行分析。根据分析结果提出了解决辊弯产品质量不稳定问题的方案,并论证其可行性。介绍了方案实施情况,包括试验流程和数据分析方法及结果。提出了对试验方案的改进意见,并论述了其理论依据。
最后,对全文进行总结,指出待改进的方面,并展望了技术质量管理理论的应用前景。
As a new theory emerging in recent years, technology & quality management is integrated with traditional quality management and engineering technology, and earned a reputation of more and more business operators and researchers, because of its positive behavior in the design, manufacture, marketing and customer service areas of corporations. Technology & quality management is not tantamount to traditional quality management or technology management, but the technical level of quality management, More abundant means of technology to make enterprises design, production process and quality management effective convergence, in order to solve the quality problem, stable quality and quality improvement goals.
Cold roll forming (CRF) has 100 years of history, but because of product variety and factors affecting the production process, it is very difficult for theoretical analysis and tools & roll pass design, relying on the experience and long-term production test. So it is a challenge for the quality management of CRF products.
To apply technology & quality management theory to CRF will be a useful attempt, not only can provide with inspiration and technical support to quality management, but also will broaden the project management application of technology & quality management.
First, this paper introduced quality management and its development course, and overviewed CRF technology and its product quality management status.
Second, elaborated technology & quality Management theory, discussed the quality conception advocated by technology & quality Management and its main content, and introduced the practice in the use of methods and tools.
Moreover, analyzed the factors affecting product quality including roll pass design, production process and equipment, considering CRF product line in CIS corporation as an example. Suggested a solution for product quality problems based on analysis results, and demonstrated its feasibility. Introduced the implementation of the program, including laboratory procedures and data analysis methods and results. Improved the program and discussed its theoretical basis.
Finally, summarized all the work, suggested the aspects for improvement, and forecasted the future of technology & quality management.
引文
[1]郎志正.质量管理及其技术和方法.北京:中国标准出版社.2003
[2] F·泰勒著,蔡上国译.科学管理原理.上海:上海科学技术出版社,1982
[3]朱兰,戈弗雷著,焦叔斌等译.朱兰质量手册.第五版,北京:中国人民大学出版社,2003
[4]刘桂珍,顾立志.质量控制.北京:国防工业出版社,2004
[5]约瑟夫·A·德菲欧,威廉·W·巴纳德著,杨坤译.朱兰研究院论六西格玛――突破与超越.北京:中国人民大学出版社,2005
[6]丁爱玲.辊弯成型工艺研究:[硕士学位论文].太原:华北工学院,2002
[7]林时宪编译.国外冷弯型钢.北京:冶金工业出版社,1984
[8]石秀芳.过程质量控制.电子质量,2003(3):76~77
[9]韩志武,刘才,陆卫平等.工艺参数对简单断面型钢辊弯成型过程的影响.技术学报,2002,38(3):331~333
[10] George T.Halmos. Roll Forming Handbook. CRC press Taylor & Francis Group,2006
[11]李春霞.冷弯成型力学理论模拟及实验研究:[硕士学位论文].昆明:昆明理工大学,2005
[12]周宏宇.槽钢辊弯成型的数值模拟及工艺参数研究:[硕士学位论文].秦皇岛:燕山大学,2004
[13]王先进,涂厚道.冷弯型钢生产及应用.北京:冶金工业出版社, 1994
[14]李凯.法国DIRICKX AXIS70冷弯成型工艺的计算机仿真:[硕士学位论文].北京:北京工业大学,2006
[15] M.Lindgren. Cold Roll Forming of a U-channel Made of High Strength Steel. Materials Process Technology, 2005(7)
[16] M.Lindgren. Finite Element Model of Roll Forming of a U-channel. Presented at International Conferences on Technology of Plasticity, Verona, Italy, 2005(10)
[17] M.Lindgren. An Improved Model for the Longitudinal Peak Strain in the Flange of a Roll Formed U-channel Developed by FE-analyses. Finite Elements in Analysis and Design,2005(6)
[18] A.J. Nickel. Roll Forming Collected Articles and Technical Papers. Fabricators & Manufacturers Association, International, 1994
[19]赵家黎,郭伟,牛占文等.基于误差流理论的多工位装配过程质量稳定性.机械工程学报,2006,42(11):88~93
[20]喻漠南.企业经营管理系统工程学.北京:国防工业出版社,1991
[21] Reich.Yoram, Levy.Eyal. Managing product design quality under resource constraints. International Journal of Production Research,2004,42 (13):2555～2572
[22]张公绪,孙静.新编质量管理学.北京:高等教育出版社,2003
[23]刘鸿恩,张列平.质量功能展开(QFD)理论与方法——研究进展综述.系统工程,2000,18(2):1~6
[24]刘广第.质量管理学(第二版).北京:清华大学出版社,2003
[25]谢永珍.公司治理状况评价中的专家质量模型.工业技术经济.2003(5):104~105
[26] Apley D W, DING Yu.A characterization of diagnosability conditions for variance components analysis in assembly operations.IEEE Transactions on Automation Science and Engineering,2005,2(2):101～110
[27]小奈弘.高精度辊弯成型的实验与研究.北方工业大学机电工程研究所,1999
[28] Voort, Vander. Metallography Principles and Practice. McGraw-Hill, Inc, New York. 1984
[29]陈锋.材料力学.武汉:华中理工大学出版社,1999
[30] Farzin M, Tehrani M S, Shameli E. Determination of buckling limit of strain in cold roll forming by the finite element analysis. Journal of Material Processing Technology, 2002, 125-126:626～632
[31] S.M. Panton, J.L.Duncan, S.D. Zhu. Longitudinal and shear strain development in cold roll forming. Journal of Materials Processing Technology,1996(60):219～224
[32]弗罗伊德,苏雷什著,卢磊等译.应力、缺陷的形成和表面演化.北京:科学出版社, 2007
[33]胡松林.板带连续辊式冷弯成型的喂入过程分析.钢管,1998 ,27(4):65～70
[34] R. Deltombe, M. Dubar, A. Dubois, etal. A new methodology to analyse iron fines during steel cold rolling processes. Wear ,2003 (254):211～221
[35]黄丽华,王家平.金相图像分析仪的现状及发展前景探讨.光学仪器,2003,25(6):50～53
[36] D.E.Laughlin, S.Kumar, Peng Yingguo,etal. Engineering the microstructure of thin films for perpendicular recording. Magnetics, 2005 ,41(2):719～723
[37] J.Villain, H.Steinberger. Reliability of microsystems from the material point of view. PROC. 23rd International Conference on Microelectronics, NI?, Yugoslavia,2002 (1):75～79
[38]张小川,陈庄,向勇等.基于PLC的磨加工生产线在线质量控制系统.轴承,2004(12):11～13
[39]刘海英.基于计算机技术的工序质量控制系统研究.中国机械工程, 2003,14(13):1118～1121
[40]黄丽华,王家平.金相图像分析仪的现状及发展前景探讨.光学仪器,2003, 25(6):50～53
[41] Hisaki Watari, Hiroshi Ona. Characteristic features of shape defects occurring in the cold roll forming of pre-notched products. Journal of Materials Processing Technology 1998(80–81):225～231
[42] Zhi-Wu Han, Cai Liu, Wei-Ping Lu etal. The effects of forming parameters in the roll-forming of a channel section with an outer edge. Journal of Materials Processing Technology ,2001 (116) :205～210
[43] Hiroshi Ona. Cold roll forming for high tensile strength steel sheet proposition on forming of thin spring steel sheet pipe. Journal of Materials Processing Technology, 2004 (153–154): 247～252
[44] M. Tajdaria, M. Farzin. Numerical analysis of cold roll forming of symmetrical open sections. Journal of Materials Processing Technology ,2002 (125-126): 633～637
[45]刘晗.应变电测技术在状态测试与评估中的应用研究.宝钢技术,2003(6):51～55
[46]徐晗,陈灼民,武松涛.电阻应变测量方法浅析.测控技术,2002,21(8):24～26
[2] F·泰勒著,蔡上国译.科学管理原理.上海:上海科学技术出版社,1982
[3]朱兰,戈弗雷著,焦叔斌等译.朱兰质量手册.第五版,北京:中国人民大学出版社,2003
[4]刘桂珍,顾立志.质量控制.北京:国防工业出版社,2004
[5]约瑟夫·A·德菲欧,威廉·W·巴纳德著,杨坤译.朱兰研究院论六西格玛――突破与超越.北京:中国人民大学出版社,2005
[6]丁爱玲.辊弯成型工艺研究:[硕士学位论文].太原:华北工学院,2002
[7]林时宪编译.国外冷弯型钢.北京:冶金工业出版社,1984
[8]石秀芳.过程质量控制.电子质量,2003(3):76~77
[9]韩志武,刘才,陆卫平等.工艺参数对简单断面型钢辊弯成型过程的影响.技术学报,2002,38(3):331~333
[10] George T.Halmos. Roll Forming Handbook. CRC press Taylor & Francis Group,2006
[11]李春霞.冷弯成型力学理论模拟及实验研究:[硕士学位论文].昆明:昆明理工大学,2005
[12]周宏宇.槽钢辊弯成型的数值模拟及工艺参数研究:[硕士学位论文].秦皇岛:燕山大学,2004
[13]王先进,涂厚道.冷弯型钢生产及应用.北京:冶金工业出版社, 1994
[14]李凯.法国DIRICKX AXIS70冷弯成型工艺的计算机仿真:[硕士学位论文].北京:北京工业大学,2006
[15] M.Lindgren. Cold Roll Forming of a U-channel Made of High Strength Steel. Materials Process Technology, 2005(7)
[16] M.Lindgren. Finite Element Model of Roll Forming of a U-channel. Presented at International Conferences on Technology of Plasticity, Verona, Italy, 2005(10)
[17] M.Lindgren. An Improved Model for the Longitudinal Peak Strain in the Flange of a Roll Formed U-channel Developed by FE-analyses. Finite Elements in Analysis and Design,2005(6)
[18] A.J. Nickel. Roll Forming Collected Articles and Technical Papers. Fabricators & Manufacturers Association, International, 1994
[19]赵家黎,郭伟,牛占文等.基于误差流理论的多工位装配过程质量稳定性.机械工程学报,2006,42(11):88~93
[20]喻漠南.企业经营管理系统工程学.北京:国防工业出版社,1991
[21] Reich.Yoram, Levy.Eyal. Managing product design quality under resource constraints. International Journal of Production Research,2004,42 (13):2555～2572
[22]张公绪,孙静.新编质量管理学.北京:高等教育出版社,2003
[23]刘鸿恩,张列平.质量功能展开(QFD)理论与方法——研究进展综述.系统工程,2000,18(2):1~6
[24]刘广第.质量管理学(第二版).北京:清华大学出版社,2003
[25]谢永珍.公司治理状况评价中的专家质量模型.工业技术经济.2003(5):104~105
[26] Apley D W, DING Yu.A characterization of diagnosability conditions for variance components analysis in assembly operations.IEEE Transactions on Automation Science and Engineering,2005,2(2):101～110
[27]小奈弘.高精度辊弯成型的实验与研究.北方工业大学机电工程研究所,1999
[28] Voort, Vander. Metallography Principles and Practice. McGraw-Hill, Inc, New York. 1984
[29]陈锋.材料力学.武汉:华中理工大学出版社,1999
[30] Farzin M, Tehrani M S, Shameli E. Determination of buckling limit of strain in cold roll forming by the finite element analysis. Journal of Material Processing Technology, 2002, 125-126:626～632
[31] S.M. Panton, J.L.Duncan, S.D. Zhu. Longitudinal and shear strain development in cold roll forming. Journal of Materials Processing Technology,1996(60):219～224
[32]弗罗伊德,苏雷什著,卢磊等译.应力、缺陷的形成和表面演化.北京:科学出版社, 2007
[33]胡松林.板带连续辊式冷弯成型的喂入过程分析.钢管,1998 ,27(4):65～70
[34] R. Deltombe, M. Dubar, A. Dubois, etal. A new methodology to analyse iron fines during steel cold rolling processes. Wear ,2003 (254):211～221
[35]黄丽华,王家平.金相图像分析仪的现状及发展前景探讨.光学仪器,2003,25(6):50～53
[36] D.E.Laughlin, S.Kumar, Peng Yingguo,etal. Engineering the microstructure of thin films for perpendicular recording. Magnetics, 2005 ,41(2):719～723
[37] J.Villain, H.Steinberger. Reliability of microsystems from the material point of view. PROC. 23rd International Conference on Microelectronics, NI?, Yugoslavia,2002 (1):75～79
[38]张小川,陈庄,向勇等.基于PLC的磨加工生产线在线质量控制系统.轴承,2004(12):11～13
[39]刘海英.基于计算机技术的工序质量控制系统研究.中国机械工程, 2003,14(13):1118～1121
[40]黄丽华,王家平.金相图像分析仪的现状及发展前景探讨.光学仪器,2003, 25(6):50～53
[41] Hisaki Watari, Hiroshi Ona. Characteristic features of shape defects occurring in the cold roll forming of pre-notched products. Journal of Materials Processing Technology 1998(80–81):225～231
[42] Zhi-Wu Han, Cai Liu, Wei-Ping Lu etal. The effects of forming parameters in the roll-forming of a channel section with an outer edge. Journal of Materials Processing Technology ,2001 (116) :205～210
[43] Hiroshi Ona. Cold roll forming for high tensile strength steel sheet proposition on forming of thin spring steel sheet pipe. Journal of Materials Processing Technology, 2004 (153–154): 247～252
[44] M. Tajdaria, M. Farzin. Numerical analysis of cold roll forming of symmetrical open sections. Journal of Materials Processing Technology ,2002 (125-126): 633～637
[45]刘晗.应变电测技术在状态测试与评估中的应用研究.宝钢技术,2003(6):51～55
[46]徐晗,陈灼民,武松涛.电阻应变测量方法浅析.测控技术,2002,21(8):24～26
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