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Developed countries, casting the most important management features are: process control project specifications and detailed, process management, and control the scope of strict quantization; the implementation process the letter; focus on development and creativity, and continuously developing higher intangible value Technology castings.
steel casting foundryA process management and control projects, specification and meticulous process management, the scope of strict quantization
steel castings manufacturersThe goal of the casting production with the highest efficiency, lowest cost, production and quality standards, consistent quality castings. Quality standards is the casting size qualified, there is no surface and internal defects, material properties to meet the requirements. Consistent quality of each batch of castings as well as different batches of casting performance, quality, consistency.
investment casting1.1 Process management control
To a chieve this goal, you need a set of processes and a set of equipment. All the equipment for the process, the production process required process must be controlled. Foundry in developed countries for all science and technology has proven the need to control the production of the project, who can control the development of strict control range. The strict inspection and control of raw materials, components and specifications, including all kinds of metal materials, non-metallic materials. The same strict control of each parameter in the process, such as inspection and control of the compaction rate of wet sand, wet strength, dry strength, moisture, crushing the index, permeability, active clay content, volatile matter, burning reduction, dead clay content, temperature, sand hardness. Quite a few casting factory does not detect the active clay content and high clay content, and thus the moisture content is high, the sand, dead. For example, ductile iron chemical composition of the original liquid iron foundry in developed countries generally control range (mass fraction, the same below): ± 0.05% C and ± 0.1% Si.
steel castingsThe author examines other European non-ferrous metals and high temperature alloys, foundry, and its control processes and parameters for the same strict range. Without the competent department, and not to arbitrarily change the detection and control parameters. In addition, the execution of each process have the original documentation, the original file record is not allowed to tamper with them.
1.2 equipment selection and matching
Must have the appropriate equipment, apparatus, in order to achieve the control objectives. Smelting or melting of the duplex, the detection of carbon content and carbon-identification instrument, the spectrometer detection of the remaining dozen ingredients. Furnace and spectrometer rapid analysis o f foreign customers generally do not buy your product. Spheroidization rate test using a sample of diamond polishing paste, the quality of the sample close to the camera level; white depth model check; mechanical properties of the computer configuration used equipment, tensile strength, yield strength can be accurately measured; casting sample using CMM inspection station test; clean up after the casting special measuring tools, special fixtures test. Have the original documentation of each process. Ultrasonic testing ball rate, internal defects, x-ray detection of surface cracks. For inspection coupling agent coupling agent is used specifically for the test casting.
In short, all to ensure that the process equipment needed, compulsory purchase.
In order to achieve high efficiency, low-power production, the arrangement of the production shift as far as possible, production is continuous, reducing material and energy consumption. For example, the use of the cupola. Electric stove double enterprises, arrange 12 hours per class, four days a week work. The process should also consider the workers to operate a convenient, safe and efficient. For example, the production of high-temperature alloy precision casting wax mold is light green, to protect their eyesight, but also conducive to the production; table to select the most appropriate level of cleanup and Industry.
1.3 Quality Management
Because of the complexity of the production process, and then advanced quality certification, even the best management, and then strictly enforced, but also inevitably lead to waste. The problem is the attitude towards waste. Good quality system is that everyone is a quality member and never let one slip through the net of the waste from their own hands, and never let a scrap factory, nor will there be shoddy phenomenon. International quality certification (IS09000) and a variety of special certification, are very strict , does not allow fraud. Quality certification examination, is not whether to have a problem, but rather whether there is reputable. The problem can be through the efforts and improvements, to meet certification requirements. If fraud, discredited, will not be certified. Developed countries rarely seen casting manufacturers certification units and personnel of any special treatment, and there was little fraud phenomenon. Even so, some customers as required to a third party present to witness the inspection of mechanical properties, and to fill in the mechanical properties of inspection reports, showing that the strict requirements.
Any instrument can be used, the tools to control instruments, and tools to control. All the instrumentation is regularly inspected, calibrated to record.
In order to achieve high productivity, device configuration and management is necessary to pay attention to systematic and supporting. I visited many companies in Europe and America, the company s equipment is not each have advanced, but good supporting high reliability. This reduces the losses due to an equipment failure so that the entire line shutdown time, but the entire device system can meet the requirements of the production of high-quality castings. There are many manufacturers, many of the equipment is very advanced, world-class, but some equipment and poor, unreliable equipment for bad. For example, many domestic famous foundry is no CMM inspection, and other advanced detection equipment, resulting in even produce good castings do not have the testing equipment and data to support its product quality. U.S. and European companies have a strong maintenance team.
Some domestic peer-casting technology and management departments concerned, such a strict technical rules and the implementation of the letter whether because certain aspects of a problem resulting in the production to a standstill, takt time, affecting productivity. I n developed countries, not because of the strict technical rules and the implementation of the letter causing production to a standstill, affecting productivity.
In fact, the loose process specification, technical rules are not stringent enough to implement and can not increase productivity, but harmful to productivity and improving product quality. Contrary, it is so strict, detailed process specification and the implementation of the letter, the the castings energy consumption of developed countries is much smaller than China, while labor productivity and full output value is much higher than China s foundry.
Chinese manufacturing common problem is that the process management rules of order itself is more relaxed, process management, rules of order execution is far from satisfactory. For example, a British company imported from China carburant, packaging requirements per bag weight 25kg but each batch has a considerable number of bags are not allowed to re-phenomenon, less by 16 seven kilograms more than those 31 twelve kilograms. The foundry is also similar. It stands to reason through any kind of international quality certification, there should be a process management requirement is unreasonable, the process has not been executed. No wonder the Mr. Miao good, pointed out that the weight of international quality certification in international commodity markets soon know our plant manager, and now the domestic foundry to obtain this certification, has been quite a few, unfortunately, but if you These plants take a trip, you will find more than half of all enterprises regardless of casting quality, or production order, or management level, not like certified. Is no wonder that foreign firms need to casting foundry in China several field trips can start small quantities, or even send someone to supervise the production. It can be said, reasonable and optimization of process management procedures, as well as the strict imp lementation of the process specification, the current Chinese industrial production problems to be solved.
In this way, the strict implementation of each process will inevitably promote the strict control of the process. The pouring temperature, for example, strict control, to induce the smelting workers to strictly control the liquid metal temperature; modeling work, the stringent requirements of the sand, prompted the strict control of the sand work on the sand, but also to promote the careful maintenance and monitoring of the maintenance department equipment.
Therefore, if the product quality, process execution, process specification. Have to do is to improve the process, until the process to ensure high-quality castings. Once that s worked out an optimization process of order Once you have a strict implementation of the process, no matter who the implementation can produce quality products, and the movement of persons will not impact on production.< br />
German foundry through a rigorous process management system, the production of cast low temperature impact toughness of ductile iron without heat treatment. Attached cast test bars and castings body to reach the low temperature and high toughness ductile iron mechanical performance requirements. It is no exaggeration to say that the optimization process specification and its strict enforcement is actually developed countries, the entire industrial system to continuous production of the root causes of the high-quality products, or is the know-how.
1.4 staff development and job settings
Cultivate personnel pragmatic, need to develop anything. The main course (industry training courses, university courses), older workers and new workers between mentoring. The training is very focused, very practical. Not training for the Diploma, not for the certificate only for the work.
If mechanical process, and never will be the employer; a positi on requires a person will not be two people. For example: a worker in a foundry is responsible for two wet sand production line sand handling system, is responsible for feeding pulverized coal, new sand, water, etc., check the control sand performance, record data, in addition responsible for sample sorting; clean up the shop one hand responsible for inspection, including the dash test sample, casting dimensional inspection, ultrasonic inspection and nodularity, internal defects and surface cracks of x-ray detection, management, inspection tool library.
2 strict implementation process
The process has been regarded as the law of production. Once you have developed a process, from worker to management, technical staff, and personal responsibility for the implementation process. Workers although the education level is not high, but the quality of the implementation process, the implementation process provides an absolute letter. If you do not meet the proc ess conditions, the workers will never operate. For example, the temperature of the liquid metal, substandard ingredients, furnace workers never released; the pouring of the molten metal temperature exceeds the specified package temperature range, casting the work definitely not casting; would rather poured into ingots; sand temperature exceeds the specified temperature, the shape of workers are not modeling; hardness, size, surface quality, substandard products will not be release.
Equipment, raw materials and other technology services. In order to make the process to the implementation of the letter, at any cost. For example, the ball-rate testing of ductile iron, diamond polishing paste to polish the quality of the sample close to the camera level; casting kind of dimensional inspection using CMM inspection station, inspection and internal defects in other advanced detection equipment, x-ray, ultrasonic flaw detection everything necessary.
3 focus on the development and creativity, the development of high-tech castings with higher intangible value
Foundry in developed countries in recent years, efforts to improve customer service, active participation and development, design and production of high-tech castings, and with higher value-added high-profit castings. In recent years, casting continuously improve the performance of metallic materials and casting methods improve as well as the emergence of a new casting method to provide new opportunities for further development, the design of new castings and castings. Some metal castings or even replace plastic case parts.
Assemblies composed of from four competitors in steel castings in the production of automotive castings in Portland, Oregon the famous Intemational-Waukesha Foundry re-design, production and into ADI casting a production since 1991 ADI in 2003, has produced over 40,000 t ADI castings. 2003 truck after the spring seat to change the desi gn of ADI castings, weight reduction from 34 pounds to 27 pounds.
Smith foundry in Minneapolis the original design of 84 steel components assembled into track driving wheel an overall ADI driving wheel castings reduce the weight of 15%, cost reduced by 55% instead. Annual cost savings of $ 190,000. Eliminating the assembly time of 30 min, compared with the original assembly, wear resistance is increased, more beautiful appearance. This shows that: the great potential of casting design, casting design, innovation and improvement is endless.
According to my understanding: Europe and the United States there are many foundries are working with the user, the design of the casting, to innovate and improve, and some companies each year more than a dozen such projects. As the above examples illustrate, the use of new technology, new alloy development of new casting foundry and a combination of methods to achieve, but the developed countries, there have been cas ting design for business company these emerging computer solidification simulation technology, computer casting design and casting user and casting manufacturer, the fastest development of new castings. It can be said that the casting will be more features, better performance, cheaper. China s foundry industry should understand the development of the international foundry industry, to seize the opportunity to further develop and enhance China s foundry industry.
