Method for determining key process parameters of whole hot working process
By investigating and analyzing the process parameters of quality problems in the thermal processing production process, key process parameters were determined, and the problems of difficult correspondence between process and quality in the thermal processing industry were solved, and the product quality stability was improved and the digital development of the thermal processing industry was achieved.
Patent Information
- Application Number
- CN202411789360.4
- 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
In the thermal processing industry, long production cycles and numerous processes make it difficult to establish a clear correspondence between process and quality. One process parameter may lead to multiple mass deviations, and one mass deviation may be affected by multiple process parameters and is difficult to directly map.
By investigating the quality problems existing in the production process of similar products, clarifying the categories of common quality problems, sorting out the corresponding process control points under the corresponding processes of the target product quality problems, analyzing the key process parameters that may affect quality deviations in each process, and finally determining the key process parameters that have a greater impact on quality results.
The correspondence between the final quality and the process parameters of the entire process are clarified, and a digital means of quality control for hot processing production is formed, the direction of process optimization is clarified, and the stability of product quality is improved, providing a technical direction for the digital development of the mechanical manufacturing hot processing industry.
Smart Images
Figure CN119721834A_ABST
Abstract
Description
Technical Field
[0001] The present invention belongs to the technical field of digital heat treatment, and in particular relates to a method for determining key process parameters of the entire heat treatment process. Background Art
[0002] Due to the discrete, single-piece, and small-batch manufacturing characteristics of hot-processed products in the machinery industry, unlike the direct connection and transmission from "process control" to "quality deviation" in cold processing, the following problems often exist: 1. The long production cycle, numerous production processes, opacity and delayed quality results detection make it difficult to establish a clear correspondence between process and quality; 2. The results of "process parameters" and "quality deviation" in the hot processing industry often show that one process parameter may lead to multiple quality deviations, and one quality deviation may be jointly affected by multiple process parameters, which cannot be directly mapped through process and quality.
[0003] 3. A single production process has dozens or even hundreds of process control points. Usually, process deviations occur in one or more control links, which does not affect the final quality of the product. There are situations where there are no process deviations in the manufacturing process but quality deviations occur.
[0004] Therefore, how to determine the key process parameters of the thermal processing and clarify the correspondence between process and quality are technical problems that need to be solved. Summary of the invention
[0005] In view of the defects of the prior art, the present invention proposes a method for determining the key process parameters of the entire hot working process. Through this method, the corresponding relationship between the final quality and the process parameters of the entire process can be clarified, and the key process parameters of each process that are closely related to the quality can be determined, which is helpful to form a digital evaluation method for process control of the entire hot working process. It can not only clarify the direction of process optimization and improve product quality stability, but also provide a technical direction for the digital development of the mechanical manufacturing hot working industry.
[0006] In order to achieve the above object, the technical solution adopted by the present invention is: A method for determining key process parameters of the entire hot working process mainly includes the following steps: (1) Identify common quality problem categories by investigating quality problems existing in the production process of similar products; (2) Determine the production process where the quality problem occurs based on the quality problem category; (3) Targetedly sort out the corresponding process control points of the target product quality problems in the corresponding process, and combine the product hot processing production and manufacturing process to sort out the key process parameters of each process in the production process; (4) For the key process parameters that may affect quality deviation in each process step, analyze whether one process parameter may cause multiple quality deviations or whether one quality deviation may be jointly affected by multiple process parameters; (5) Based on the above quality problem analysis, the key process parameters of the key processes that have a greater impact on the quality results are finally sorted out.
[0007] Furthermore, the quality problems include two aspects: quality problems that affect the "shape" of the product and quality problems that affect the "property" of the product.
[0008] Furthermore, quality issues that affect the product's external "shape" include: out-of-tolerance size, dark skin and missing meat, concave core, and pits.
[0009] Furthermore, quality issues that affect the intrinsic "properties" of the product include: unqualified chemical composition, excessive flaw detection defect equivalent, cracks, coarse grains, unqualified hardness, unqualified tensile properties, and unqualified impact properties.
[0010] Beneficial effects: The method for determining the key process parameters of the entire hot working process of the present invention investigates quality problems, analyzes the key process parameters of each process in the production process that may cause quality problems, sorts out and determines the key process parameters, clarifies the correspondence between the final quality and the process parameters of the entire process, and forms a digital means of hot working production and manufacturing quality control, which can clarify the direction of process optimization and improve product quality stability. BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Figure 1 A simplified flow chart for determining key process parameters of the present invention. DETAILED DESCRIPTION
[0012] The present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.
[0013] Due to the opacity of the thermal processing process and the lag in quality result detection, it is often difficult to establish a clear correspondence between process and quality. The present invention provides a method for determining key process parameters of the entire thermal processing process, such as Figure 1 As shown, it mainly includes the following steps: (1) First, based on the evaluation method of "shape" and "property" of the hot processing production process in the machinery industry, the quality problems existing in the production process of similar products are investigated to identify the problem categories.
[0014] (2) Based on the quality problem category, analyze the processes that may cause abnormal "shape" or "quality" and determine whether the root cause of the quality problem is a single process or a coupled effect of multiple processes.
[0015] (3) Targetedly sort out the corresponding process control points under the corresponding process of the target product quality problem, and combine the product hot processing production and manufacturing process to sort out the key process parameters of each process in the production process.
[0016] (4) For the key process parameters that may affect quality deviation in each process step, analyze whether one process parameter may cause multiple quality deviations or whether one quality deviation may be affected by multiple process parameters.
[0017] (5) Finally, the key process parameters of the key processes that have a greater impact on the quality results are sorted out, and a method for evaluating the process quality of the hot working process is formed. This method serves as a digital means of product quality control and improvement, and ultimately achieves a clear direction for process optimization and improves product quality stability.
[0018] Based on the key process parameters determined by the above method, a machine learning algorithm is used in the later stage to establish a neural network that shows the strength of the influence relationship between process and quality. It is adjusted autonomously based on the subsequent compliance rate and deviation rate as a digital means of product quality control and improvement, and ultimately achieves a clear direction for process optimization and improves product quality stability.
[0019] The steps of the method of the present invention in a specific application are as follows: (1) Investigate the quality problems existing in the production process of similar products and identify the types of problems.
[0020] Taking the characteristic products of the casting-forging-heat process as an example, we first investigate the common quality problems of similar forgings, such as: size tolerance, black skin and lack of meat, concave heart, pits, etc., which are aspects that affect the external "shape" of the product. Unqualified chemical composition, excessive equivalent of flaw detection defects, cracks, coarse grains, unqualified hardness, unqualified tensile properties, unqualified impact properties, etc., are aspects that affect the internal "properties" of the product.
[0021] (2) Determine the process that may cause quality problems and the main process parameters included in the process. For example, the main smelting process includes primary smelting, LF refining, VD treatment, LF reheating, VC pouring, etc.
[0022] (3) Targetedly sort out the corresponding process control points under the corresponding process of quality problems, such as: the main process of VC pouring includes: the number of times the riser is used, the riser baking time, the pouring temperature, the pouring time, the riser pouring height and other key process control points.
[0023] (4) For the key process parameters that may affect the quality deviation in each process, analyze whether one process parameter may cause multiple quality deviations or one quality deviation may be affected by multiple process parameters. For example, the flaw detection crack problem may be caused by shrinkage and shrinkage in the smelting process, or by unreasonable reduction in the forging process, and micro cracks formed by rapid cooling in the heat treatment process.
[0024] (5) Based on the analysis of quality problems, the key process parameters of key processes that have a greater impact on quality results are sorted out, and a digital evaluation method for the whole process control of hot working is formed. Ultimately, it can not only clarify the direction of process optimization and improve product quality stability, but also provide a technical direction for the digital development of the mechanical manufacturing hot working industry.
[0025] The main effects of the process parameter determination method of the present invention are: 1. Proposing a digital control method for quality control in the long-process and multi-process manufacturing process of hot-working castings and forgings. 2. Through data accumulation, it is possible to systematically control quality risks, clearly observe the influencing factors of quality fluctuations, and dig out some influencing parameters that cannot be directly verified by experiments.
[0026] 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 key process parameters of the entire hot working process, characterized in that: The main steps include: (1) Identify common quality problem categories by investigating quality problems existing in the production process of similar products; (2) Determine the production process where the quality problem occurs based on the quality problem category; (3) Targetedly sort out the corresponding process control points of the target product quality problems in the corresponding process, and combine the product hot processing production and manufacturing process to sort out the key process parameters of each process in the production process; (4) For the key process parameters that may affect quality deviation in each process step, analyze whether one process parameter may cause multiple quality deviations or whether one quality deviation may be jointly affected by multiple process parameters; (5) Based on the above quality problem analysis, the key process parameters of the key processes that have a greater impact on the quality results are finally sorted out.
2. The method for determining key process parameters of the entire hot working process according to claim 1, characterized in that: The quality problems mentioned include two aspects: quality problems that affect the "shape" of the product and quality problems that affect the "property" of the product.
3. The method for determining key process parameters of the entire hot working process according to claim 2, characterized in that: Quality issues that affect the product's external "shape" include: out-of-tolerance size, dark skin and missing meat, concave core, and pits.
4. The method for determining key process parameters of the entire hot working process according to claim 2, characterized in that: Quality issues that affect the intrinsic "properties" of the product include: unqualified chemical composition, excessive flaw detection defect equivalent, cracks, coarse grains, unqualified hardness, unqualified tensile properties, and unqualified impact properties.