Method for determining deviation ratio of key process parameters of part in hot working process
By defining and evaluating the quality deviations of the first and second categories in the hot processing process and calculating the deviation rate of key process parameters, the problem of unclear correspondence between process and quality in the hot processing process is solved, and effective evaluation and control of the key process parameters of the hot processing process is achieved, production efficiency is improved and production costs are reduced.
Patent Information
- Application Number
- CN202411789358.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-06
- Publication Date
- 2025-03-28
AI Technical Summary
During the hot processing process, it is difficult to directly map the quality results through process parameters, which makes it difficult to establish a clear correspondence between process and quality, and it is impossible to effectively control process deviations and quality deviations.
Define the first-class quality deviation and the second-class quality deviation, and judge the results and quantity of the two-class quality deviation through data acquisition and comparison, and calculate the deviation rate of key process parameters to evaluate the implementation compliance of key process parameters in the thermal processing process.
The correspondence between quality data and key process parameters is clarified, and the effective evaluation and control of key process parameters of the thermal processing process is achieved, which improves production efficiency and reduces production costs.
Smart Images
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Abstract
Description
Technical Field
[0001] The invention relates to the technical field of thermal processing in the machinery industry, and in particular to a method for determining a deviation rate of key process parameters of a part in a thermal processing process. Background Art
[0002] Due to the discrete, single-piece, and small-batch manufacturing characteristics of hot-processed parts in the machinery industry, unlike the direct connection and transmission from "process control" to "quality deviation" in cold processing, the "process parameters" and "quality deviation" in the hot processing industry result in one process parameter leading to multiple quality deviations, and one quality deviation may be jointly affected by multiple process parameters. It is impossible to directly map process and quality, and it is impossible to complete stable process iteration.
[0003] The opacity of the hot working process and the delayed detection of quality results make it difficult to establish a clear correspondence between process and quality. Usually, process deviation occurs in one or more control links, which does not affect the final quality of the product, while there is no process deviation in the manufacturing process, but there is a quality deviation. Therefore, it is urgent to determine a new method that can judge the execution of key process parameters in the hot working process through quality deviation results. Summary of the invention
[0004] In view of the defects of the prior art, the present invention provides a method for determining the deviation rate of key process parameters of parts in a thermal processing process.
[0005] In order to achieve the above object, the technical solution adopted by the present invention is:
[0006] A method for determining the deviation rate of key process parameters of parts in a hot working process is mainly implemented by the following steps:
[0007] Step 1: Definition of Class I and Class II quality deviations:
[0008] In the manufacturing process of hot-processed parts, according to the basic technical requirements, quality inspection is carried out after one process is completed. If the inspection result does not meet the technical requirements, it is called a type of quality deviation;
[0009] In the manufacturing process of hot-working parts, when a process is carried out, if the number of steps executed according to the standard cannot meet the requirements of size, performance, etc., it is necessary to execute the number of steps beyond the standard definition and perform rework and repair to meet the relevant requirements. This is called the second type of quality deviation.
[0010] Step 2: Build basic product technical information:
[0011] According to the standard requirements of each test item in the definition of Class I quality deviation and Class II quality deviation, establish a data archive of technical conditions for various products, and build product quality control standards and process control standards;
[0012] Step 3: Obtaining the first and second quality deviations:
[0013] During the hot working manufacturing process of parts, after each process is completed, the quality result data of each type of first-class quality deviation test item is obtained, and the results are compared with the technical conditions and requirements to judge the result-type quality deviation of the parts. The number of first-class quality deviations is recorded as M;
[0014] In each process of the hot working production of parts, the execution data of the second-class quality deviation inspection items of each process is obtained, compared with the standard data, and the process quality deviation of the parts is judged. The number of second-class quality deviations is recorded as N;
[0015] Step 4: Definition and calculation of key process parameter deviation rate:
[0016] The calculation formula for the number of key process parameters is:
[0017] Among them, n0 is the number of key processes, Ki is the number of key process parameters of the i-th key process;
[0018] Step 5. Definition and calculation of key process parameter deviation rate:
[0019] After the hot working of parts is completed, the deviation rate of key process parameters is calculated based on the number of first-class quality deviations, second-class quality deviations and key process parameters in the whole process, and the execution compliance of key process parameters in the hot working process is evaluated through result-type quality data and process-type quality data;
[0020] The calculation formula for the deviation rate of key process parameters is:
[0021]
[0022] Where δ is the deviation rate of key process parameters, M is the number of type I quality deviations, and N is the number of type II quality deviations;
[0023] K is the number of key process parameters.
[0024] Specifically, one type of quality deviation inspection items includes: size inspection, appearance inspection, magnetic particle inspection, ultrasonic inspection, hardness inspection, mechanical property inspection, and metallographic structure inspection.
[0025] Among them, the calculation method of the quantity M of a type of quality deviation is: Where n is the number of times each type of inspection item is performed during the parts manufacturing process, M sizei is the result of the i-th size detection, M apperancei is the result of the i-th appearance inspection, M MTi is the result of the i-th magnetic particle inspection, M UTi is the result of the i-th ultrasonic flaw detection, M har"nessi is the result of the i-th hardness test, M pr#per$％i is the result of the i-th mechanical property test, M me$a”(rgicali is the test result of the metallographic structure for the i-th time. When the actual test result meets the technical requirements, M i When it is 0 and does not meet the technical requirements, M i is 1.
[0026] Specifically, the second category of quality deviation detection items include: smelting alloying rework, post-casting heat treatment rework, cast steel blank rework, performance heat treatment rework, forging process cleaning, forging rework, and post-forging heat treatment rework.
[0027] The calculation formula for the number of type II quality deviations is: Among them, i=1 represents the rework result of smelting alloying, i=2 represents the rework result of cast steel blank, i=3 represents the rework result of post-casting heat treatment, i=4 represents the rework result of performance heat treatment, i=5 represents the result of forging process cleaning, i=6 represents the rework result of forging, and i=7 represents the rework result of post-forging heat treatment; Represents the actual number of executed steps. Represents the standard number of work steps.
[0028] Furthermore, data of each type of first-class quality deviation detection item and second-class quality deviation detection item are obtained by OPC protocol, Modbus protocol, reading configuration software ACCESS database, and PDA entry.
[0029] Beneficial effects:
[0030] The present invention is applicable to the production and manufacturing process of discrete hot-working manufacturing parts. By utilizing the definitions and acquisition methods of the first-class quality deviation, the second-class quality deviation, and the deviation rate of key process parameters in the present invention, the deviation of product quality and process execution can be characterized by product process deviation and result deviation data, and the corresponding relationship between quality data and key process parameters can be clarified, so as to achieve the goal of controlling stable process quality, improve production efficiency and reduce production costs. DETAILED DESCRIPTION
[0031] The present invention is further described in detail below with reference to specific embodiments.
[0032] The method for determining the key process deviation rate of parts in a hot working process of the present invention defines a type I quality deviation and a type II quality deviation, and constructs basic technical condition information of the product. During and after the hot working production process, data are collected and compared to judge the results and quantities of the two types of quality deviations. Finally, based on the quality deviation results and the number of key process parameters, the key process parameter deviation rate is calculated to evaluate the execution compliance of the key process parameters of the hot working process. This is specifically achieved through the following steps.
[0033] (1) Definition and acquisition method of a type of quality deviation:
[0034] 1) Definition of a type of quality deviation: In the production and manufacturing process of hot-processed parts, according to the basic technical conditions, quality inspection is carried out after the completion of one process and before the next process. If the inspection result does not meet the technical conditions, it is called a type of quality deviation (also called result-type deviation). The inspection items include: size inspection, appearance inspection, magnetic particle inspection, ultrasonic inspection, hardness inspection, mechanical property inspection, and metallographic structure inspection.
[0035] 2) Method for obtaining Class I quality deviation: Each type of Class I quality deviation detection item obtains quality result data through relevant detection equipment and detection methods, and collects and pushes quality data through OPC protocol, Modbus protocol, reading configuration software ACCESS database, PDA input, etc., compares the results with technical conditions requirements, and judges the result-type quality deviation of parts.
[0036] 3) The calculation method of the quantity of the first-class quality deviation is: Where n is the number of times each type of inspection item is performed during the parts manufacturing process; M sizei is the result of the i-th size detection, M apperancei is the result of the i-th appearance inspection, M M6i is the result of the i-th magnetic particle inspection, M 76i is the result of the i-th ultrasonic flaw detection, M 8249n1 / / i is the result of the i-th hardness test, M 34:314；<u is the result of the i-th mechanical property test, M ＝1；2>>u4@i52>i is the test result of the metallographic structure for the ith time. When the actual test result meets the technical requirements, Mi is 0, and when it does not meet the technical requirements, Mi is 1.
[0037] (2) Definition and acquisition method of Class II quality deviation:
[0038] 1) Definition of Class II quality deviation: During the manufacturing process of hot-working parts, when a process is carried out and the number of work steps executed according to the standard cannot meet the requirements of size, performance, etc., it is necessary to execute work steps exceeding the number defined in the standard and perform rework and repair to meet the relevant requirements. This is called Class II quality deviation (also called process deviation), including: smelting alloying rework, post-casting heat treatment rework, cast steel blank rework, performance heat treatment rework, forging process cleaning, forging rework, and post-forging heat treatment rework.
[0039] 2) Method for obtaining Class II quality deviation: During the hot processing production process of parts, each process obtains the execution data of each Class II deviation inspection item through OPC protocol, Modbus protocol, reading configuration software ACCESS database, PDA input, etc., and compares it with the standard data to judge the process quality deviation of the part.
[0040] 3) The calculation method for the number of Class II quality deviations is: Among them, i=1 represents the rework result of smelting alloying, i=2 represents the rework result of cast steel blank, i=3 represents the rework result of post-casting heat treatment, i=4 represents the rework result of performance heat treatment, i=5 represents the result of forging process cleaning, i=6 represents the rework result of forging, and i=7 represents the rework result of post-forging heat treatment. Represents the actual number of executed steps. Represents the standard number of work steps.
[0041] (3) Construction of basic technical condition information of products:
[0042] Build basic product technical information, including the standard requirements for each test item in the definition of Class I quality deviation and Class II quality deviation, define the source method of Class II deviation comparison standard data for different product categories, connect with the system individually, complete the quality control fields, establish a data archive of technical conditions for various products, and build product quality control standards and process technology control standards.
[0043] (4) The calculation method of key process parameters is: Among them, n0 is the number of key processes, K i is the number of key process parameters of the i-th key process.
[0044] (5) Definition and calculation of key process parameter deviation rate:
[0045] After the hot working production of parts is completed, the key process parameter deviation rate is calculated based on the number of Class I quality deviations, Class II quality deviations and key process parameters in the whole process, and the execution compliance of the key process parameters of the hot working process is evaluated through result-type quality data and process-type quality data.
[0046] The calculation formula for the deviation rate of key process parameters is: Where δ is the deviation rate of key process parameters, M is the number of type I quality deviations, N is the number of type II quality deviations, and K is the number of key process parameters.
[0047] Through the calculation of the above-mentioned key process parameter deviation rate, a set of evaluation methods for the correspondence between process execution and production quality is provided. The execution of key process parameters in the hot working process is judged by the quality deviation results, and the correspondence between quality data and key process parameters is clarified, which helps to stabilize the control of process quality, improve production efficiency and reduce production costs.
[0048] In the following, a cast steel gear of a grinding mill is selected as the application object. According to the production process, the number of first-class quality deviations, the number of second-class quality deviations and the deviation rate of key process parameters in the hot working production process of the gear are calculated to evaluate the product quality and the execution of key process parameters.
[0049] Step 1: The gear material is ZG40CrNi2Mo. According to the technical requirements of the gear drawing and the process production flow, the basic technical information of the gear is constructed as follows:
[0050] The following types of inspection items need to be carried out during the manufacturing process: 2 size inspections, 1 appearance inspection, 6 magnetic particle inspections, 3 ultrasonic inspections, 3 hardness inspections, and 1 mechanical property inspection. Among them, the size inspection is carried out after the blank and rough processing, and the inspection standard is the size requirements of the drawing; the appearance inspection is carried out after the finished product is finely processed, and the appearance is required to be free of surface defects such as pores and slag inclusions; the magnetic particle inspection is carried out at the blank stage and after each part is processed, and the inspection standard is QHM1257-2019 standard; the ultrasonic inspection is carried out after rough turning, semi-finishing milling, and semi-finishing turning, and the inspection standard is Q / HM1257-2019 standard; the hardness inspection is carried out after quenching and tempering, semi-finishing turning, and tooth opening, and the hardness value is required to be HB 310-350. After quenching and tempering, the mechanical property inspection requires tensile strength ≥840Mpa, yield strength ≥650Mpa, elongation ≥10%, cross-sectional shrinkage ≥20%, and impact energy ≥27J.
[0051] The comparison standard for Class II quality deviation is: 3 times of smelting and alloying, 0 times of reworking of cast steel blanks, 1 time of post-casting heat treatment, 1 time of performance heat treatment, 0 times of forging cleaning, 0 times of forging rework, and 0 times of post-forging heat treatment.
[0052] Step 2: In the gear manufacturing process, a quality inspection is carried out after the process is completed. The system obtains the following inspection results based on the OPC protocol, Modbus protocol, reading the configuration software ACCESS database, PDA input, etc.: 1) The size inspection failed twice, and the thickness of the combined plate exceeded the size requirements of the drawing; 2) The magnetic particle inspection failed once, and the tooth surface was loose; the remaining 5 times were qualified; 3) The ultrasonic inspection was qualified; 4) The hardness test result was HB323-337, which met the technical requirements; 5) The tensile strength was 1100Mpa, the yield strength was 960Mpa, the elongation was 17%, the cross-sectional shrinkage was 39%, and the impact energy was 58-79J, all of which met the technical requirements in step 1. Based on the above results, the number of quality deviations of the first category is calculated as M=1*3+0*13=3.
[0053] Step 3: In the gear production process, the system obtains the number of work step executions according to the OPC protocol, Modbus protocol, reading the configuration software ACCESS database, PDA input, etc. as follows: smelting alloying times: 4 times; cast steel blank repair times: 1 time; post-casting heat treatment times: 1 time; performance heat treatment times: 1 time; forging cleaning times: 0 times; forging rework times: 0 times; post-forging heat treatment times: 0 times. Based on the above results, the second type of quality deviation times are calculated as: N = (4-3) + (1-0) + (1-1) + (1-1) + (0-0) + (0-0) + (0-0) = 2.
[0054] Step 4. There are three key processes for the gear: smelting, casting, and heat treatment. The smelting process has 6 key process parameters, the casting process has 21 key process parameters, and the heat treatment process has 8 key process parameters. Therefore, the number of key process parameters K=6+21+8=35.
[0055] Step 5: Deviation rate of key process parameters of the gear This characterizes deviations in product quality and process execution.
[0056] The present invention defines a type I quality deviation and a type II quality deviation of hot-processed parts in the machinery industry, and utilizes the OPC protocol, Modbus protocol, reading the configuration software ACCESS database, PDA input and other methods to construct basic technical condition information, collect type I quality deviation data and type II quality deviation data of the entire process of hot processing smelting, casting, forging and heat treatment, and calculates the deviation rate of key process parameters of castings and forgings based on the key process parameter definition method; characterizes the deviation of product quality and process execution through product process deviation and result deviation data, clarifies the corresponding relationship between quality data and key process parameters, and achieves the goal of controlling stable process quality, improving production efficiency and reducing production costs.
[0057] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Although the present invention has been disclosed as a preferred embodiment as above, it is not used to limit the present invention. Any technician familiar with this profession can make some changes or modify the technical contents disclosed above into equivalent embodiments without departing from the scope of the technical solution of the present invention. However, any simple modification, equivalent change and modification made to the above embodiments according to the technical essence of the present invention without departing from the content of the technical solution of the present invention still fall within the scope of the technical solution of the present invention.
Claims
1. A method for determining the deviation rate of key process parameters of parts in a hot working process, characterized in that: The method is mainly implemented by the following steps: Step 1: Define the first-class quality deviation and the second-class quality deviation: the first-class quality deviation is the result-type deviation, and the second-class quality deviation is the process-type deviation; Step 2: Build basic product technical condition information: According to the standard requirements of each test item in the definition of Class I quality deviation and Class II quality deviation, establish a data archive of technical conditions for various products, and build product quality control standards and process control standards; Step 3: Acquisition of first-class quality deviation and second-class quality deviation: During the hot working and manufacturing process of parts and after the completion of each process, obtain various types of first-class quality deviation data and second-class quality deviation data; Step 4: Definition and calculation of key process parameter deviation rate: After the hot working production of parts is completed, the key process parameter deviation rate is calculated based on the number of type I quality deviations, type II quality deviations and the number of key process parameters in the whole process. The key process parameter deviation rate is the percentage of the sum of the two types of quality deviations and the number of process parameters. This is used to evaluate the compliance of the execution of the key process parameters in the hot working process.
2. The method for determining the deviation rate of key process parameters of parts in a hot working process according to claim 1 is characterized in that: In the manufacturing process of hot-processed parts, according to the basic technical requirements, quality inspection is carried out after one process is completed. If the inspection result does not meet the technical requirements, it is called a type of quality deviation; During the manufacturing process of hot-working parts, when a process is carried out and the number of work steps executed according to the standard cannot meet the requirements of size, performance, etc., it is necessary to execute a number of work steps exceeding the standard definition and perform rework and repair to meet the relevant requirements. This is called Class II quality deviation.
3. The method for determining the deviation rate of key process parameters of parts in a hot working process according to claim 1 is characterized in that: The calculation formula for the number of key process parameters is: Among them, n0 is the number of key processes, K i is the number of key process parameters of the i-th key process.
4. The method for determining the deviation rate of key process parameters of parts in a hot working process according to claim 3 is characterized in that: In step 4, the calculation formula for the deviation rate of key process parameters is: Where δ is the deviation rate of key process parameters, M is the number of type I quality deviations, N is the number of type II quality deviations; K is the number of key process parameters.
5. The method for determining the deviation rate of key process parameters of parts in a hot working process according to claim 1 is characterized in that: The first category of quality deviation inspection items includes: size inspection, appearance inspection, magnetic particle inspection, ultrasonic inspection, hardness inspection, mechanical property inspection, and metallographic structure inspection.
6. The method for determining the deviation rate of key process parameters of parts in a hot working process according to claim 5, characterized in that: in, The calculation method of the quantity M of a type of quality deviation is: Where n is the number of times each type of inspection item is performed during the parts manufacturing process, M sizei is the result of the i-th size detection, M apperancei is the result of the i-th appearance inspection, M MTi is the result of the i-th magnetic particle inspection, M UTi is the result of the i-th ultrasonic flaw detection, M hardnessi is the result of the i-th hardness test, M propertyi is the result of the i-th mechanical property test, M metallurgicali is the test result of the metallographic structure for the i-th time. When the actual test result meets the technical requirements, M i When it is 0 and does not meet the technical requirements, M i is 1.
7. The method for determining the deviation rate of key process parameters of parts in a hot working process according to claim 1 is characterized in that: The second category of quality deviation detection items include: smelting alloying rework, post-casting heat treatment rework, cast steel blank rework, performance heat treatment rework, forging process cleaning, forging rework, and post-forging heat treatment rework.
8. The method for determining the deviation rate of key process parameters of parts in a hot working process according to claim 7, characterized in that: The calculation formula for the number of type II quality deviations is: Among them, i=1 represents the rework result of smelting alloying, i=2 represents the rework result of cast steel blank, i=3 represents the rework result of post-casting heat treatment, i=4 represents the rework result of performance heat treatment, i=5 represents the result of forging process cleaning, i=6 represents the rework result of forging, and i=7 represents the rework result of post-forging heat treatment; Represents the actual number of executed steps. Represents the standard number of work steps.
9. The method for determining the deviation rate of key process parameters of parts in a hot working process according to claim 1, characterized in that: The data of each type of first-class quality deviation detection item and second-class quality deviation detection item are obtained by OPC protocol, Modbus protocol, reading configuration software ACCESS database, and PDA entry.