CQI15_特殊過程：焊接系統(tǒng)評估t

1、ProcessTABLED-SolidStateWeldingProcesses流程表D-固態(tài)焊接流程Allcontrolofvariablesgivenbelowaresubordinatetocustomerspecificrequirements.以下歹U出的所有控制變量均要Item#項目RelatedCategory/ProcessSteps類別/流程步驟Inertia編號WSAFrictionQuestionWelding#相關WSA(FRW-I)慣性問題編號摩擦焊41.7,1.8Weldingspecificessentialvariableswhichshallbeaddress

2、edintheFMEA,controlplanandweldingprocedures具體的基本焊接變量，應在FMEA、控制計劃和焊接工藝中列出D4.1Tolerancesonaxialalignmen軸對齊公差XD4.2Fayingsurfacearea接合面區(qū)域XD4.3Fayingsurfacecleanliness接合面清潔XD4.4Initialspindalspeed起始軸轉速XD4.5Weldingspindalspeed焊接軸轉速D4.6Spindaltorque-tonotdamageequipment軸扭矩-不損壞設備XD4.7Flywheels;totalmomentof

3、inertia飛輪：總慣性力矩XD4.8Spindleclamppressure軸鉗壓力XD4.9Fixtureclamppressure夾鉗壓力XD4.10Partstickout零件外伸長度Preheat(Firstfrictionphase)ifneeded預熱(第一摩擦階段)如果需要的話XD4.11-Projectiononfayingsurface接合面投射X1D4.12-Preheatforce預熱力X1D4.13-PreheattimeorRPM預熱時間或RPMX1D4.14Preheatburnofflength-amountofdimensionlossduringprehe

4、at預熱摩擦變形量-預熱期間尺寸損失量WeldHeat(Secondfrictionphase)焊接熱(第二摩擦階段)D4.15-Frictionweldforce摩擦焊力XD4.16-Frictionspeedatwhichforgingbegins鍛造開始時的摩擦速度ForgingStage鍛造階段XD4.17-Forgingspeed鍛造速度XD4.18-Forgeforce鍛造力XD4.19-Forgetime鍛造時間D4.20-Forgelengthiflimitedupsetisused使用有線電阻對焊時的頂鍛變形量D4.21-Forgedelay鍛造延遲D4.22-Upsetdi

5、stanee接頭距離D4.23-Upsetremoval/management接頭去除/管理XD4.24-Upsetholdtime接頭保持時間XD4.25-Upsetrate對焊速率XD4.26-Frictionupsetdistaneeandtime摩擦焊接頭距離和時間D4.27Brakesettingorstoppingtimedimensionsandtolerences制動設置或停止時間維度和公差D4.28Brakeforce制動力D4.29Brakedelaypriortoupset對接冃u的制動延遲D4.30Finalposition最終位置D4.31Postweldheattr

6、eatmentifneededbasedonmaterialsjoined焊后熱處理(根據(jù)連接材料類型考慮是否需要)D4.32Protectiveatmosphereifnecessaryforthebasematerial基礎材料保護氣（如需要）D4.33l/lvkis|-liId久yTotalburnoff-amountofdimensionlossduringtotalprocess整個流程過程中尺寸損失的總變形量FSWD4.34Primarycontrol（positionorforce）主要控制（位置或力）D4.35Tooltoweldjointalignmentduringleng

7、thoftrave1整個運動過程中的焊縫校準工具Tool工具D4.36-Pintoshoulderratio管腳與肩比D4.37-Pinlength管腳長度D4.38-Includedangleforpin包括管腳夾角D4.39-Includedangleforshoulder包括肩夾角D4.40-Threadonpinsurface止推面螺紋D4.41-Pinmaterial管腳材料PlungePractice螺柱送進方法D4.42-Speedofplunge螺柱送進速度D4.43-Spindalspeedduringplunge螺柱送進過程中的軸轉速D4.44-Preheatdwellti

8、meafterplunge螺柱送進后的預熱停留時間D4.45-Plungeforce螺柱送進力Weld焊接D4.46-Weldforce焊接力D4.47-Travelspeed運動速度D4.48-Tooltiltangle工具傾斜角D4.49-Weldspindalspeed焊接軸速度Weldtermination焊接終止D4.50-Exitmotionoftoolsuchastiltanglerotation工具退出模式，如傾斜角度旋轉D4.51-Spindalspeedattoolextraction工具萃取時的軸速度D4.52-Dwellatendoftravel運動結束時的停留D4.5

9、3Electrodedesign-eliminatedieburns電極設計-消除焊接缺陷D4.54Electrode/Diecleanliness電極/模具清潔D4.55Electrode/Dieclampingpressure電極/模具夾緊壓力D4.56Partcleanlinessandscaleremoval零件清潔和除垢D4.57Partalignment零件校準D4.58Jointgeometrypreporation接頭形狀制備D4.59Initialmartialstickoutorextensionbeyondelectrodes起始材料外伸長度或伸出電極的部分Preheat

10、預熱D4.60-Preheatforce預熱力D4.61-Tapselection絲錐選擇D4.62-Percentheat熱量百分比D4.63-Offtimeduringinitialdieopening最初開模期間的停止時間InitialFlashing初步閃光D4.64-Initialdieopening初步開模D4.65-Initialflashingrate初步閃光頻率D4.66-Typeofplattenmovement（linearorparabolic）運動類型（直線或拋物線）D4.67-Voltage電壓D4.68-Initialflashingdistanceortime初

11、步閃光距離或時間D4.69-Percentheat熱的百分比D4.70-Tapselection絲錐選擇D4.71D4.72D4.73D4.74D4.75D4.76D4.77D4.78D4.79D4.80D4.81D4.82D4.83D4.84D4.85D4.86D4.87D4.88D4.89D4.90D4.91D4.92D4.93D4.94D4.95D4.96D4.97D4.98D4.99D4.100D4.101D4.102D4.103D4.104D4.105D4.106D4.107Flashing閃光-Flashingrate閃光頻率-Typeofplattenmovement(linea

12、rorparabolic)運動類型(直線或拋物線)-Voltage電壓-Flashingdistaneeortime閃光距離或時間-Percentheat熱的百分比-Tapselection絲錐選擇WeldStage1焊接階段1-Percentheat熱的百分比-Tapselectionvoltage絲錐選擇電壓#NAME?-Pulsation(on,offandnumberofpulses)脈沖(脈沖開、關和脈沖數(shù))-Offtimebeforestagechange階段改變前的停止時間WeldStage2(canbemultiplestageswithdifferentparameters)

13、焊接階段2(可以是具有不同參數(shù)的多個階段)-Percentheat熱的百分比-Tapselectionvoltage絲錐選擇電壓-Force力-Pulsation(on,offandnumberofpulses)脈沖(脈沖開、關和脈沖數(shù))Forge/Upset鍛造/頂鍛-Forgerate鍛造速率-Forgeforce鍛造力-Forgedistanee/totalupset鍛造距離/總接頭-Upsettime頂鍛時間-Upsetcurrent頂鍛電流-Flashingvoltagecutoff閃光電壓保護閾值-Flashingremoval/management閃光去除/管理Postweldh

14、eattreatmentifneeded焊接后熱處理(如需要)-Heattreatmentclampingdistanee熱處理夾緊距離-Quenchtime淬火時間-Tapselection絲錐選擇-Precentheat熱的百分比-Tempertime回火時間Finaldieopening最終開模UltrasonicMetalweld超聲波金屬焊接Tapselection/designofribbonstructure帶狀結構的絲錐選擇/設計Frequencyofpowersupplyforapplication(40/30/20kHz)應用電源頻率(40/30/20kHz)Fixture

15、&partdesignwithmaxdimensiondeviationandmaterialspecs固定裝置及零件設計，最大尺寸偏差和材料規(guī)格UpsetandMonitoring(windowing)頂鍛與監(jiān)測(開窗)Welding-Energy焊接-能量Welding-Time焊接-時間Welding-Amplitude焊接-幅度Welding-Force焊接-力Welding-Current焊接-電流WeldingpreHeightandtravel(compaction)焊接前高度和運動(壓實)D4.108Energywithheightcompensation高度補償能量D4.10

16、9WeldHeadCooling焊頭冷卻D4.110Environmentalconditionscontrol(i.e.,temperature,humidity,dust,etc.環(huán)境條件D4.111控制/Di即，el度neS濕度攻灰塵清潔D4.112TAP/Dieclampingpressure絲攻/模具夾緊壓力D4.113Partcleanlinessandscaleremoval零件清潔和除垢D4.114Partalignment零件校準x1:Ifrequiredtoachieveheatbalance.Examplethinparttothickpartorvarioushardnesses.如果需要達到熱平衡。例如薄零件與厚零件或各種硬度零件