Method for evaluating manufacturing capability of casting and forging

Abstract

The invention relates to a casting and forging manufacturing capability evaluation method, which relates to the field of hot working manufacturing capability evaluation, carries out whole-process simulation verification on key process parameters through an analogue simulation platform, compares an output result with a product quality requirement, judges the rationality of a manufacturing process, and calculates the manufacturing capability of the casting and forging through comparing historical simulation data with historical actual production data. According to the method, the reliability of analogue simulation is determined, whether the standard is reached or not is determined through calculation and comparison of the process parameter deviation rate and the coincidence rate, all evaluation results are integrated, whether a manufacturer meets the qualification requirement or not is judged, and compared with a traditional evaluation method, the evaluation process can be effectively simplified, the evaluation period can be shortened, and the research and development cost and the purchase cost can be reduced.

Description

Technical Field

[0001] The invention relates to the technical field of thermal processing discrete manufacturing, and in particular to a method for evaluating the manufacturing capability of castings and forgings. Background Art

[0002] In the field of special castings and forgings manufacturing, the production and sales of castings and forgings require manufacturing qualifications recognized by relevant units. To obtain relevant qualifications, it is necessary to evaluate the production capacity of the manufacturer. At present, the evaluation of production capacity usually involves manufacturing equal-scale or scaled parts, and performing a series of tests and experiments such as flaw detection, dissection, sampling, physical and chemical testing, etc. At the same time, the manufacturing and inspection process requires supervision and witnessing. The evaluation process is complicated and cumbersome, with a long cycle and high cost, which is not conducive to the development and research of new products by the manufacturer and the purchaser's procurement cost control.

[0003] In the field of thermal processing such as casting, forging, and heat treatment, simulation technology has been developed for more than 30 years and can now simulate product manufacturing processes and product quality almost realistically. At the same time, after the development in recent years, the simulation of thermal processing can not only simulate a single process, but also simulate the entire process such as casting-heating, casting-forging-heating, etc., which improves the accuracy and credibility of the simulation results.

[0004] At the same time, the digital and intelligent development in the field of hot processing has also made great progress. Data acquisition systems have been widely used in various production processes of casting, forging and heat treatment. They can realize real-time collection, analysis and processing of production data, providing strong support for decision-making. Summary of the invention

[0005] In view of the defects of the prior art, the present invention provides a method for evaluating the manufacturing capability of castings and forgings, which combines simulation technology and digitization to realize the evaluation of the manufacturing capability of castings and forgings. The evaluation process is easy to implement and has a short cycle, which is conducive to reducing costs.

[0006] In order to achieve the above object, the technical solution adopted by the present invention is:

[0007] A method for evaluating the manufacturing capability of castings and forgings, the method comprising the following steps: Step 1: Determine the key process parameters for casting and forging manufacturing; Step 2: Use simulation to verify the whole process of key manufacturing process parameters, and evaluate the rationality of the manufacturing process by comparing the process simulation output results with product quality requirements; Step 3: Determine the reliability of the simulation based on the comparison between historical simulation data and historical actual production data; Step 4: Determine the deviation rate and compliance rate of process execution in historical manufacturing based on historical production data; Step 5: Establish different deviation rate and compliance rate standards according to different project requirements, and compare them with the results in step 4 to determine whether the manufacturer's deviation rate and compliance rate meet the standards; Step 6: Comprehensively evaluate the simulation reliability, manufacturing process rationality, process execution deviation rate and compliance rate to determine whether the manufacturer's manufacturing capabilities meet the qualification requirements.

[0008] Furthermore, manufacturers must have the ability to simulate the entire process of key process parameters and the ability to collect and store production data in real time and intelligently.

[0009] Furthermore, the simulation is realized through a simulation platform built by the manufacturer. The simulation platform should include at least a casting simulation module, a forging simulation module, and a heat treatment simulation module. Each module can independently set process parameters and the output result data of each module can be transmitted, identified and reprocessed to each other, and the simulation results are accurate and reliable.

[0010] Furthermore, key process parameters are defined as all process parameters that affect the final quality of the product. In the process of determining key process parameters, different process parameters are determined for different products, the production process parameters and result parameters that affect product quality are determined, and the number and standard values ​​of process parameters are clarified.

[0011] Furthermore, in step three, the reliability of the simulation is based on the following: the process parameters of the historical simulation data and the historical actual production data should be consistent, and the result parameters should be similar.

[0012] Furthermore, in step 4, the compliance rate and deviation rate of process execution should be updated in real time and historical data should be saved.

[0013] Furthermore, the calculation method of the key process parameter compliance rate is: The sum of key process parameters refers to the sum of the number of key process parameters.

[0014] Furthermore, the calculation formula for the deviation rate of key process parameters is: Wherein δ is the deviation rate of key process parameters, K is the number of key process parameters, M is the number of type I quality deviations, and N is the number of type II quality deviations; the type I quality deviation is the result deviation, and the type II quality deviation is the process deviation.

[0015] Beneficial effects:

[0016] The method proposed in the present invention can replace traditional production test pieces to evaluate production capacity, apply simulation technology and digital closed-loop implementation methods to achieve a comprehensive evaluation of the manufacturer's manufacturing capabilities, effectively simplify the evaluation process, shorten the evaluation cycle, and reduce R&D costs and procurement costs. DETAILED DESCRIPTION

[0017] The present invention is further described in detail below with reference to specific embodiments.

[0018] In order to solve the typical problems of long cycle and high cost in the traditional special casting and forging production qualification assessment process, the present invention proposes a casting and forging manufacturing capability evaluation method. The method uses full-process simulation technology and a closed-loop implementation method of discrete manufacturing digital transformation as a framework. Through the evaluation results of simulation reliability, manufacturing process rationality, process execution deviation rate and compliance rate, it is judged whether the manufacturer's production qualification or manufacturing capability meets the requirements.

[0019] Among them, the closed-loop implementation method of the digital transformation of discrete manufacturing is to divide the process data, process execution data, and process quality data into different subset databases, and determine the subset database into three categories: "key process parameter subset", "key process execution compliance rate subset", and "key process evaluation deviation rate subset". The digital transformation plan is built with the three subsets as the core. Focusing on the key process parameters, the process parameters, process parameter production execution, and process parameter quality evaluation are statistically analyzed and managed throughout the life cycle to achieve digital transformation of discrete manufacturing processes.

[0020] When conducting full-cycle management of products, the company's production equipment is digitally transformed based on the "key process parameter subset" to ensure that real-time production data can be collected and compared with process standard data in real time. Through the "key process execution compliance rate subset", real-time management and correction of production process non-conformities are carried out to reduce quality problems caused by inadequate process execution. After production is completed, production quality data is collected, and the deviation between process and quality is evaluated based on the "key process evaluation deviation rate subset", the rationality of the process is evaluated, and the data is deposited in the underlying database to provide data support for the next process formulation.

[0021] Under the framework of the above-mentioned digital transformation closed-loop implementation method, the casting and forging manufacturing capability evaluation method of the present invention includes the following steps:

[0022] Step 1: Determine the key parameters of the manufacturing process based on the key process parameter determination method;

[0023] Step 2: Use the simulation platform to conduct full-process simulation verification of key parameters of the manufacturing process, and evaluate the rationality of the manufacturing process by comparing the process simulation output results with product quality requirements;

[0024] Step 3: Determine the reliability of the simulation based on the comparison between historical simulation data and historical actual production data;

[0025] Step 4: Determine the deviation rate and compliance rate of the process execution in the historical manufacturing based on the method for determining the deviation rate and compliance rate of the key process parameters;

[0026] Step 5: Establish different deviation rate and compliance rate standards according to different project requirements, and determine whether the manufacturer's deviation rate and compliance rate meet the standards;

[0027] Step 6: Comprehensively evaluate the simulation reliability, manufacturing process rationality, process execution deviation rate and compliance rate to determine whether the manufacturer meets the qualification requirements.

[0028] The full-process simulation of key process parameters of special castings and forgings includes simulation of the entire process such as casting-heating, casting-forging-heating, etc. Therefore, when using the above evaluation method to evaluate the manufacturer's manufacturing capabilities, the manufacturer is required to have the ability to simulate the entire process of key process parameters and the ability to collect and store production data in real time and intelligently.

[0029] Manufacturers should first establish a casting-heat / casting-forging-heat full-process simulation platform. The full-process simulation platform should at least include a casting simulation module, a forging simulation module and a heat treatment simulation module. Each module can set process parameters independently; each module can transmit and identify relevant simulation results to each other, and at the same time, can select whether to continue the simulation results after identification as needed. That is, the casting, forging and heat treatment simulation modules used can not only set process parameters independently, but also the simulation results of each module can be transmitted, identified and reprocessed to each other.

[0030] The full-process simulation platform includes storage devices and computer equipment to ensure that production data can be collected and stored intelligently in real time.

[0031] Specifically, manufacturers can build a full-process simulation platform in the following ways. For example, by purchasing existing simulation software, conducting on-site collection of process parameters and setting parameters required by the simulation software, and revising and redeveloping the simulation through past production examples to make the casting, forging and heat treatment simulation results fit the actual production; and conducting secondary development of the simulation software so that the output results of the casting, forging and heat treatment modules can be transmitted and recognized to each other, thereby establishing a full-process simulation platform.

[0032] When implementing the evaluation method, key process parameter data for actual production should be collected as much as possible, the compliance rate and deviation rate of process execution should be updated in real time and historical data should be saved, and different manufacturing process evaluation standards and process execution compliance rate and deviation rate standards should be formulated according to the requirements of different projects.

[0033] The process parameters of historical simulation data and historical actual production data should be consistent, and the result parameters should be similar, only then can the simulation be considered reliable.

[0034] Among them, the key process parameters are defined as all process parameters that affect the final quality of the product. Different process parameters are determined for different products, the production process parameters and result parameters that affect product quality are determined, and the number and standard values ​​of process parameters are clarified. Specifically, the method for determining key process parameters is:

[0035] (1) Identify common quality problems by investigating quality problems existing in the production process of similar products;

[0036] (2) Determine the production process where the quality problem occurs based on the quality problem category;

[0037] (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;

[0038] (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;

[0039] (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.

[0040] The compliance rate mentioned above refers to the compliance rate of key process parameters, which is calculated as follows:

[0041]

[0042] The sum of key process parameters refers to the sum of the number of key process parameters. Any inconsistency between process parameters and standard requirements is considered a deviation.

[0043] The deviation rate is the key process parameter deviation rate, and its calculation formula is:

[0044]

[0045] Where δ is the deviation rate of key process parameters, K is the number of key process parameters, M is the number of type I quality deviations, and N is the number of type II quality deviations.

[0046] The first type of quality deviation is the result deviation. In the production and manufacturing process of hot-working parts, according to the basic technical conditions, after a process is completed, a quality inspection is carried out. If the inspection result does not meet the technical conditions, it is called a first-class quality deviation and is counted once;

[0047] The second type of quality deviation is process deviation. During the production and 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 the second type of quality deviation, and each time a work step exceeds the standard, it is counted once.

[0048] The present invention is further described below in conjunction with the manufacturing qualification process of a 100-ton large forging cylinder in the nuclear power field.

[0049] The method for evaluating the manufacturing capability of castings and forgings of the present invention comprises the following steps:

[0050] Step 1: Determine the key parameters of the manufacturing process based on the key process parameter determination method.

[0051] The key process parameters in the manufacturing process of 100-ton nuclear power cylinder are shown in Table 1 (excerpt): Table 1 Key process parameters for barrel manufacturing (excerpt)

[0052] Step 2: Use the simulation platform to conduct full-process simulation verification of key parameters of the manufacturing process, and evaluate the rationality of the manufacturing process by comparing the process simulation output results with product quality requirements;

[0053] Specifically, the key process parameters in Table 1 are simulated using the full-process simulation platform, and the output results are compared with the purchaser's process requirements to determine whether the manufacturer's manufacturing process is reasonable. If the output results meet the purchaser's requirements, then after comparison, it can be concluded that the relevant manufacturing process can produce products that meet the requirements and the process is reasonable.

[0054] Step 3: Determine the reliability of the simulation based on the comparison between historical simulation data and historical actual production data;

[0055] By comparing the key process parameter simulation data of cylinders of the same material, shape and different specifications that have been produced by the manufacturer with the key process parameter data collected during the production process, it is found that the process parameters are exactly the same and the result parameters are similar. It can be judged that the simulation results of this manufacturer are very reliable.

[0056] Step 4: Determine the deviation rate and compliance rate of the process execution in the historical manufacturing based on the method for determining the deviation rate and compliance rate of the key process parameters;

[0057] That is, the process parameter deviation rate and execution rate are calculated based on the relevant data collected during the historical manufacturing process.

[0058] Step 5: The purchaser shall formulate different deviation rate and compliance rate standards according to different project requirements, and determine whether the manufacturer's deviation rate and compliance rate meet the standards.

[0059] For example, nuclear power products require that the compliance rate of key process parameters should be close to 99% and the deviation rate should be close to 0.1%. The historical data collected by the manufacturer shows that the compliance rate of key process parameters of nuclear power products is 100% and the deviation rate is 0%, indicating that the standard requirements are fully met.

[0060] Step 6: Comprehensively evaluate the simulation reliability, manufacturing process rationality, process execution deviation rate and compliance rate to determine whether the manufacturer meets the qualification requirements.

[0061] According to the above evaluation results, the manufacturer's simulation results are credible, the manufacturing process is reasonable, and the process execution deviation and compliance rate meet the requirements, which means that it can produce products that meet the procurement requirements and obtain the manufacturing qualification for 100-ton nuclear power cylinders.

[0062] The present invention uses simulation technology to replace the traditional production test pieces to evaluate production capacity. During the evaluation process, it combines the closed-loop method of digital transformation and makes full use of process data, process execution data, and process quality data to evaluate the manufacturer's production qualifications from multiple aspects such as simulation reliability, manufacturing process rationality, process execution deviation rate and compliance rate, effectively shortening the cycle, reducing costs, and providing strong support for decision-making.

[0063] 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 evaluating the manufacturing capability of castings and forgings, characterized in that: The evaluation method comprises the following steps: Step 1: Determine the key process parameters for casting and forging manufacturing; Step 2: Use simulation to verify the whole process of key manufacturing process parameters, and evaluate the rationality of the manufacturing process by comparing the process simulation output results with product quality requirements; Step 3: Determine the reliability of the simulation based on the comparison between historical simulation data and historical actual production data; Step 4: Determine the deviation rate and compliance rate of process execution in historical manufacturing based on historical production data; Step 5: Establish different deviation rate and compliance rate standards according to different project requirements, and compare them with the results in step 4 to determine whether the manufacturer's deviation rate and compliance rate meet the standards; Step 6: Comprehensively evaluate the simulation reliability, manufacturing process rationality, process execution deviation rate and compliance rate to determine whether the manufacturer's manufacturing capabilities meet the qualification requirements.

2. A method for evaluating the manufacturing capability of castings and forgings according to claim 1, characterized in that: Manufacturers must have the ability to simulate the entire process of key process parameters and the ability to collect and store production data in real time and intelligently.

3. A method for evaluating the manufacturing capability of castings and forgings according to claim 2, characterized in that: The simulation is realized through a simulation platform built by the manufacturer. The simulation platform should include at least a casting simulation module, a forging simulation module, and a heat treatment simulation module. Each module can set process parameters independently and the output result data of each module can be transmitted, identified and reprocessed to each other, and the simulation results are accurate and reliable.

4. A method for evaluating the manufacturing capability of castings and forgings according to claim 1, characterized in that: Key process parameters are defined as all process parameters that affect the final quality of the product. In the process of determining key process parameters, different process parameters are determined for different products, the production process parameters and result parameters that affect product quality are determined, and the number and standard values ​​of process parameters are clarified.

5. A method for evaluating the manufacturing capability of castings and forgings according to claim 1, characterized in that: In step three, the reliability of the simulation is based on the following: the process parameters of the historical simulation data and the historical actual production data should be consistent, and the result parameters should be similar.

6. A method for evaluating the manufacturing capability of castings and forgings according to claim 1, characterized in that: In step 4, the compliance rate and deviation rate of process execution should be updated in real time and historical data should be saved.

7. A method for evaluating the manufacturing capability of castings and forgings according to claim 1, characterized in that: The calculation method of key process parameter compliance rate is: The sum of key process parameters refers to the sum of the number of key process parameters.

8. A method for evaluating the manufacturing capability of castings and forgings according to claim 1, characterized in that: The calculation formula for the deviation rate of key process parameters is: Wherein δ is the deviation rate of key process parameters, K is the number of key process parameters, M is the number of type I quality deviations, and N is the number of type II quality deviations; the type I quality deviation is the result deviation, and the type II quality deviation is the process deviation.

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