福特白光掃描要求教材課件

1、APA Tooling Supplier ConferenceMarch 21-22, 2013Larry Geng耿國濤 Die Surface Scanning Overview模具型面掃描概述 What is die surface scanning ? 什么是模具型面掃描 ？ Applications of scanning data in Ford 福特如何應(yīng)用模具的掃描數(shù)據(jù)？ Die surface scanning request items 模具掃描作業(yè)有什么要求？ Data surface scanning procedure 模具掃描工作的流程是什么？ Die Surfac

2、e Scanning OverviewWhat is die surface scanning ?什么是模具的掃描？白光掃描Optical equipment, 白光掃描設(shè)備Picture positioning technology 拍照定位技術(shù)Grating measurement technology 光柵測量原理Capture die key information before shipping dies 發(fā)運(yùn)前測量獲取模具的主要信息Scanning data stored in TCE Ford Data Base 掃描數(shù)據(jù)儲(chǔ)存在TCE-福特的數(shù)據(jù)庫Die Surface Scan

3、ning OverviewApplication of scanning data for Ford tooling shop 白光掃描技術(shù)在福特模具廠的應(yīng)用 Scanning was first used to improve machine performance on rough castings. 掃描技術(shù)最早應(yīng)用在改進(jìn)鑄件粗加工的加工工藝，提高加工效率 After successful implementation it expanded to many other applications; 成功應(yīng)用后，逐漸擴(kuò)展到很多其他的應(yīng)用領(lǐng)域。Die Construction 模具裝配Vir

4、tual die assembly to reduce press time 模具部件虛擬裝配，以減少在壓機(jī)上的研配時(shí)間Wear Plate dimensions were created from scan data and given to die makers to grind to size without ever assembling the dies. 通過掃描數(shù)據(jù)獲得導(dǎo)板的位置尺寸信息，無需裝配模具，即可完成導(dǎo)板的研配工作 - Able to align upper and lower die faces to reduce spotting ，凸凹模虛擬裝配，減少研合時(shí)間-

5、Eliminated sizing wear plates in the press to save press time，無需在壓機(jī)上調(diào)配導(dǎo)板，提高壓機(jī)利用率Tryout 調(diào)試Eventually formed the CSI process for correction loopsPanel scans for correction loops 根據(jù)鈑件掃描結(jié)果 制定整改方案Panels scans for CMM 鈑件全尺寸掃描作為檢測報(bào)告Die Buy-Off 驗(yàn)收Die Signatures 模具掃描數(shù)據(jù)作為驗(yàn)收確認(rèn)Perishable Steels 易損鋼塊數(shù)據(jù)備份，作為復(fù)制加工依

6、據(jù) Scanning technology was implemented in die manufacturing as an enabler to meet GPDS targets. 掃描技術(shù)作為得力工具保證模具制造周期滿足GPDS的目標(biāo) Die Signature Scanning OverviewApplication of scanning data for Ford tooling shop 白光掃描技術(shù)在福特模具廠的應(yīng)用 Improve machine performance on rough castings.改進(jìn)鑄件粗加工的加工工藝，提高加工效率 Operators run

7、 programs at 100% feeds and speeds.數(shù)控操作者執(zhí)行程序，100%的進(jìn)給量和進(jìn)給速度Roughing times are reduced 76% at the machine.鑄件粗加工時(shí)間降低76%100% accurate stock models result in safer programs 基于鑄件掃描數(shù)據(jù)編制的數(shù)控程序，加工量均勻 ，程序更安全The tooling is always engaged in metal removal.刀具始終處于切削狀態(tài)，無空走刀情況Die Surface Scanning OverviewFor Product

8、ion Plant 沖壓廠對(duì)模具最終狀態(tài)的驗(yàn)收確認(rèn) Die SignaturesThese are scans of the finished die surfaces of the completed dies at the Tryout source. 模具制造廠負(fù)責(zé)完成模具最終狀態(tài)的數(shù)據(jù)掃描 For Die Maintenance 模具維護(hù)及維修 Accidents in ProductionDie Surface is damaged beyond basic fixes.生產(chǎn)事故造成模具型面損壞，基本修復(fù)處理無法完成。For Rework Confirmation 模具修復(fù)工作前確認(rèn)

9、 Die Quality Guarantee Verify that the die has not been modified by the production die maintenance team is such a way that can void the warranty.模具出現(xiàn)異常時(shí)，確認(rèn)是否被沖壓廠的模具維修人員修改，如模具已不是發(fā)模前最終狀態(tài)，模具制造廠將不必承擔(dān)質(zhì)保責(zé)任。For Die Duplication 模具復(fù)制Same parts running in multiple regions Improve FPG quality for duplicate too

10、lsGo to a NO TRYOUT level of die manufacturing 相同制件在不同區(qū)域生產(chǎn)，需要模具復(fù)制，改善FPG鈑件質(zhì)量，模具無需調(diào)試即可出件Applications of scanning data for Ford stamping plant 福特沖壓廠對(duì)掃描數(shù)據(jù)的應(yīng)用 Die Surface Scanning OverviewApplication of scanning data in Ford福特對(duì)掃描數(shù)據(jù)的應(yīng)用 案例1 Signature, Duplication and study狀態(tài)確認(rèn)，復(fù)制，研究 Capturing quality impro

11、vements done in Tryout, for reverse engineering & ensuring a quick turn around in case of a crash. Scan is now the master.測量獲得模具調(diào)試后狀態(tài)的數(shù)據(jù)，作為逆向 復(fù)制及快速修復(fù)模具時(shí)的加工基準(zhǔn)。Analyzing data to better understand effects of spring back and to measure the success of compensation strategies.分析掃描數(shù)據(jù)以深入理解回彈對(duì)模具的影響，以及測量對(duì)比沖壓變

12、型補(bǔ)償策略的實(shí)際效果。Mapping the quality of the drawn stamping at the time of the buyoff模具驗(yàn)收時(shí) ，測量并分析所有成型模具的質(zhì)量情況 Die Surface Scanning OverviewDie maintenanceDSP requested lower front door hinge surfaces to be moved forward 1.5mm.Grinding Less減少打磨 Spotting Less減少研配Problem;No Cad Data exists for the P-221 doors

13、that were manufactured outside of the United States. 模具不是在北美制造，丟失CAD數(shù)據(jù)DSP does not have the press time for extensive tryout of changes in production tooling. DSP沒有大量的壓機(jī)工時(shí)來完成模具的調(diào)試工作ResolutionScan the die geometry and create new surfaces in Tebis using RSC (Rapid Surface Creation) 掃描模具型面，并用Tebis生成可加工用

14、型面數(shù)據(jù)。New surfaces were machined in the upper die half by using a material thickness offset, this ensured dimensional accuracy between the upper and lower dies.用于加工凹模側(cè)的型面數(shù)據(jù)偏置一倍料厚，以保證上下模之間間隙的尺寸精度Cutter path was being prepared while dies were in production. 模具沖壓生產(chǎn)的同時(shí)，制作機(jī)加編程數(shù)據(jù)DSP job was able to be adde

15、d to the machine schedule with no interruption to in house work load DSP的工作編入加工計(jì)劃，與廠內(nèi)模具任務(wù)無沖突ResultsDies were machined with a 2 day turn around. 模具在兩天內(nèi)輪班加工完成DSP polished change areas and was able to schedule a window for Tryout in the press. DSP拋光模具修改區(qū)域，安排計(jì)劃上壓機(jī)調(diào)試Die was brought to home position with

16、no interference and no grinding required. 模具無需打磨即可沖壓到底，且無干涉The first blank resulted in a split free panel. 第一張坯料即可打出不裂的鈑件The dies were ready for their next scheduled production run. 模具以具備生產(chǎn)狀態(tài)，可準(zhǔn)備下次生產(chǎn)計(jì)劃F-150 front door assembly issues due to lack of adjustment of lower door hinge.前門總成問題，與門下鉸鏈調(diào)整量不足App

17、lication of scanning data in Ford福特對(duì)掃描數(shù)據(jù)的應(yīng)用 案例2 Die maintenance The first blank resulted in a split free panel.整改模具，第一張坯料即可打出不裂的鈑件。Die Surface Scanning OverviewStamping Plant SupportDie maintenanceApplication of scanning data in Ford福特對(duì)掃描數(shù)據(jù)的應(yīng)用 案例3 Maintenance 維修scrap rate reduction from 2.4% to .6%廢

18、品率從2.4%降到0.6% DSP requested analysis on double attached F-150 Super Cab rear door outers to reduce production scrap rate. DSP要求分析后門外板雙槽模具狀態(tài)，發(fā)現(xiàn)并解決模具存在問題，以降低生產(chǎn)中廢品率Problem; RH door splits LH doesnt.右門鈑件裂Both Doors should be identical左右門應(yīng)該一致How can differences between the 2 doors be identified? 左右門為什么會(huì)有

19、差異？Analysis 分析The die was scanned and the LH data was mirrored in Tebis. (CAD/CAM Software) This produced a virtual RH die surface.掃描左側(cè)模具型面 ，在Tebis中鏡像為右側(cè)型面The virtual surface was compared to the actual surface. 比較虛擬右側(cè)型面與實(shí)際型面的差異Areas of concern were identified and DSP Tryout personnel were given a di

20、mensional road map for making improvements with zero risk for the assembly plant.問題區(qū)域，左右件的差異值報(bào)告以云圖形式提供給調(diào)試者，作為模具整改的依據(jù)，確保不會(huì)給裝配車間帶來任何風(fēng)險(xiǎn)。Results 結(jié)果The results were a reduction in scrap rate from 2.4% in January to .6% in April. 廢品率從一月份的2.4%降低到四月份的0.6%Improvements in performance to schedule 模具的整改工作按計(jì)劃完成

21、Die Surface Scanning OverviewDie surface scanning request items 模具型面掃描的基本要求From C489 Program 從C489 項(xiàng)目開始Finish at tryout source 由模具廠完成數(shù)據(jù)掃描Draw ,redraw and form dies 拉延，二次拉延等成型類模具Core body panel, critical underbody panel ,see below note from SOW 主要車身件及某些底盤件，具體以SOW所述為準(zhǔn)，見下圖注釋 Die items need scan 模具需要掃描的

22、項(xiàng)目Follow Ford die scanning procedure 遵照福特的掃描流程標(biāo)準(zhǔn)報(bào)價(jià)要求報(bào)價(jià)中應(yīng)該包含如下信息 要求掃描數(shù)據(jù)的模具為：主要車身鈑件的成型類模具，比如機(jī)蓋內(nèi)外板，翼子板，頂蓋，行李箱內(nèi)外板，門子內(nèi)外板，背門內(nèi)外板，側(cè)圍內(nèi)外板及地板，對(duì)于底盤類零件以報(bào)價(jià)單要求為準(zhǔn)Die Surface Scanning OverviewAll Die working surface 模具所有的工作型面 Any surface or area that was machined on the 5-axis. 所有在五軸機(jī)床上加工出的加工面或區(qū)域 All gaging or devic

23、e used to locate the blank within the die. 模具上所有用來鈑件定位的定位距或其他裝置All guiding components-wear plates, guide post and bushing 所有的導(dǎo)向部件，導(dǎo)板，導(dǎo)柱，導(dǎo)套 All stop blocks, bottom blocks ,balance blocks, cone blocks 所有的礅死塊，平衡塊，錐形定位快All tooling holes, datum surface ,key ways. 所有的基準(zhǔn)孔,基準(zhǔn)面，鍵槽 All items that was used to

24、find location during setup and machining of the dies 所有模具加工時(shí)需要用來定位的項(xiàng)目Items that need scanning模具需要掃描的項(xiàng)目 Die Surface Scanning OverviewDie scanning procedure模具基本掃描流程 Set up and make preparation 掃描前準(zhǔn)備工作 Scanning die surface with equipment 用設(shè)備掃描模具型面 Post procedure 掃描數(shù)據(jù)的后處理Die Surface Scanning OverviewDie

25、 scanning procedure set up and preparation 模具掃描流程設(shè)置及準(zhǔn)備 Good set ups will protect the integrity of the data 正確的設(shè)置及準(zhǔn)備工作能確保掃描數(shù)據(jù)的完整性Clean die to ensure all working and mounting surfaces are free of oil and dirt. 清潔模具，確保所有的工作面及安裝面無油無塵Place die on a flat surface or level table and make sure the flatness 模

26、具防置在平面或平板上，并保證平板的平面度 All lower and upper rings must be assembled with the punch in home position before scanning.掃描開始前，保證上下壓邊圈和凸模裝配在一起，并處于工作位置Level table 測量用平板，平板平面度可調(diào)Die Surface Scanning OverviewDie scanning procedurescanning模具掃描流程掃描過程 Make sure the environment light is strong enough 保證環(huán)境有足夠的光強(qiáng)，否則無法測量深腔部位Make sure the accuracy of scanning process-parameters set up in software and hardware calibration 保證掃描過程中精度的控制，軟件中精度參數(shù)設(shè)置，硬件標(biāo)定Make sure all the items are captured 保證獲得所有要求測量項(xiàng)目數(shù)據(jù)If the reflection of light is serious ,should spray developer to decrease reflection 對(duì)反光強(qiáng)烈區(qū)域，需要噴一層現(xiàn)象劑來降低反射 Die S