CQI15_特殊过程：焊接系统评估t

1、ProcessTABLED-SolidStateWeldingProcesses流程表D-固态焊接流程Allcontrolofvariablesgivenbelowaresubordinatetocustomerspecificrequirements.以下歹U出的所有控制变量均要Item#项目RelatedCategory/ProcessSteps类别/流程步骤Inertia编号WSAFrictionQuestionWelding#相关WSA(FRW-I)惯性问题编号摩擦焊41.7,1.8Weldingspecificessentialvariableswhichshallbeaddress

2、edintheFMEA,controlplanandweldingprocedures具体的基本焊接变量，应在FMEA、控制计划和焊接工艺中列出D4.1Tolerancesonaxialalignmen轴对齐公差XD4.2Fayingsurfacearea接合面区域XD4.3Fayingsurfacecleanliness接合面清洁XD4.4Initialspindalspeed起始轴转速XD4.5Weldingspindalspeed焊接轴转速D4.6Spindaltorque-tonotdamageequipment轴扭矩-不损坏设备XD4.7Flywheels;totalmomentof

3、inertia飞轮：总惯性力矩XD4.8Spindleclamppressure轴钳压力XD4.9Fixtureclamppressure夹钳压力XD4.10Partstickout零件外伸长度Preheat(Firstfrictionphase)ifneeded预热(第一摩擦阶段)如果需要的话XD4.11-Projectiononfayingsurface接合面投射X1D4.12-Preheatforce预热力X1D4.13-PreheattimeorRPM预热时间或RPMX1D4.14Preheatburnofflength-amountofdimensionlossduringprehe

4、at预热摩擦变形量-预热期间尺寸损失量WeldHeat(Secondfrictionphase)焊接热(第二摩擦阶段)D4.15-Frictionweldforce摩擦焊力XD4.16-Frictionspeedatwhichforgingbegins锻造开始时的摩擦速度ForgingStage锻造阶段XD4.17-Forgingspeed锻造速度XD4.18-Forgeforce锻造力XD4.19-Forgetime锻造时间D4.20-Forgelengthiflimitedupsetisused使用有线电阻对焊时的顶锻变形量D4.21-Forgedelay锻造延迟D4.22-Upsetdi

5、stanee接头距离D4.23-Upsetremoval/management接头去除/管理XD4.24-Upsetholdtime接头保持时间XD4.25-Upsetrate对焊速率XD4.26-Frictionupsetdistaneeandtime摩擦焊接头距离和时间D4.27Brakesettingorstoppingtimedimensionsandtolerences制动设置或停止时间维度和公差D4.28Brakeforce制动力D4.29Brakedelaypriortoupset对接冃u的制动延迟D4.30Finalposition最终位置D4.31Postweldheattr

6、eatmentifneededbasedonmaterialsjoined焊后热处理(根据连接材料类型考虑是否需要)D4.32Protectiveatmosphereifnecessaryforthebasematerial基础材料保护气（如需要）D4.33l/lvkis|-liId久yTotalburnoff-amountofdimensionlossduringtotalprocess整个流程过程中尺寸损失的总变形量FSWD4.34Primarycontrol（positionorforce）主要控制（位置或力）D4.35Tooltoweldjointalignmentduringleng

7、thoftrave1整个运动过程中的焊缝校准工具Tool工具D4.36-Pintoshoulderratio管脚与肩比D4.37-Pinlength管脚长度D4.38-Includedangleforpin包括管脚夹角D4.39-Includedangleforshoulder包括肩夹角D4.40-Threadonpinsurface止推面螺纹D4.41-Pinmaterial管脚材料PlungePractice螺柱送进方法D4.42-Speedofplunge螺柱送进速度D4.43-Spindalspeedduringplunge螺柱送进过程中的轴转速D4.44-Preheatdwellti

8、meafterplunge螺柱送进后的预热停留时间D4.45-Plungeforce螺柱送进力Weld焊接D4.46-Weldforce焊接力D4.47-Travelspeed运动速度D4.48-Tooltiltangle工具倾斜角D4.49-Weldspindalspeed焊接轴速度Weldtermination焊接终止D4.50-Exitmotionoftoolsuchastiltanglerotation工具退出模式，如倾斜角度旋转D4.51-Spindalspeedattoolextraction工具萃取时的轴速度D4.52-Dwellatendoftravel运动结束时的停留D4.5

9、3Electrodedesign-eliminatedieburns电极设计-消除焊接缺陷D4.54Electrode/Diecleanliness电极/模具清洁D4.55Electrode/Dieclampingpressure电极/模具夹紧压力D4.56Partcleanlinessandscaleremoval零件清洁和除垢D4.57Partalignment零件校准D4.58Jointgeometrypreporation接头形状制备D4.59Initialmartialstickoutorextensionbeyondelectrodes起始材料外伸长度或伸出电极的部分Preheat

10、预热D4.60-Preheatforce预热力D4.61-Tapselection丝锥选择D4.62-Percentheat热量百分比D4.63-Offtimeduringinitialdieopening最初开模期间的停止时间InitialFlashing初步闪光D4.64-Initialdieopening初步开模D4.65-Initialflashingrate初步闪光频率D4.66-Typeofplattenmovement（linearorparabolic）运动类型（直线或抛物线）D4.67-Voltage电压D4.68-Initialflashingdistanceortime初

11、步闪光距离或时间D4.69-Percentheat热的百分比D4.70-Tapselection丝锥选择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闪光-Flashingrate闪光频率-Typeofplattenmovement(linea

12、rorparabolic)运动类型(直线或抛物线)-Voltage电压-Flashingdistaneeortime闪光距离或时间-Percentheat热的百分比-Tapselection丝锥选择WeldStage1焊接阶段1-Percentheat热的百分比-Tapselectionvoltage丝锥选择电压#NAME?-Pulsation(on,offandnumberofpulses)脉冲(脉冲开、关和脉冲数)-Offtimebeforestagechange阶段改变前的停止时间WeldStage2(canbemultiplestageswithdifferentparameters)

13、焊接阶段2(可以是具有不同参数的多个阶段)-Percentheat热的百分比-Tapselectionvoltage丝锥选择电压-Force力-Pulsation(on,offandnumberofpulses)脉冲(脉冲开、关和脉冲数)Forge/Upset锻造/顶锻-Forgerate锻造速率-Forgeforce锻造力-Forgedistanee/totalupset锻造距离/总接头-Upsettime顶锻时间-Upsetcurrent顶锻电流-Flashingvoltagecutoff闪光电压保护阈值-Flashingremoval/management闪光去除/管理Postweldh

14、eattreatmentifneeded焊接后热处理(如需要)-Heattreatmentclampingdistanee热处理夹紧距离-Quenchtime淬火时间-Tapselection丝锥选择-Precentheat热的百分比-Tempertime回火时间Finaldieopening最终开模UltrasonicMetalweld超声波金属焊接Tapselection/designofribbonstructure带状结构的丝锥选择/设计Frequencyofpowersupplyforapplication(40/30/20kHz)应用电源频率(40/30/20kHz)Fixture

15、&partdesignwithmaxdimensiondeviationandmaterialspecs固定装置及零件设计，最大尺寸偏差和材料规格UpsetandMonitoring(windowing)顶锻与监测(开窗)Welding-Energy焊接-能量Welding-Time焊接-时间Welding-Amplitude焊接-幅度Welding-Force焊接-力Welding-Current焊接-电流WeldingpreHeightandtravel(compaction)焊接前高度和运动(压实)D4.108Energywithheightcompensation高度补偿能量D4.10

16、9WeldHeadCooling焊头冷却D4.110Environmentalconditionscontrol(i.e.,temperature,humidity,dust,etc.环境条件D4.111控制/Di即，el度neS湿度攻灰尘清洁D4.112TAP/Dieclampingpressure丝攻/模具夹紧压力D4.113Partcleanlinessandscaleremoval零件清洁和除垢D4.114Partalignment零件校准x1:Ifrequiredtoachieveheatbalance.Examplethinparttothickpartorvarioushardnesses.如果需要达到热平衡。例如薄零件与厚零件或各种硬度零件