发动机铝铸件PFMEA分析中英文

PotentialFailureModeandEffectsAnalysis(ProcessFMEA),,,,,,,,,,,,,,,,,,

过程失效模式及后果分析,,,,,,,,,,,,,,,,,,

System系统,,"Enginesubsystems/

发动机分系统/",,,ProcessResponsibility过程责任,,,,,,FMEANumber编号,,,,,,,

Subsystem子系统,,,,,,,,,,,Page页码,,,共2页第1页,,,,

Component零部件,,,,,KeyDate关键日期,,,,,,PrepareBy编制,,,,,,,

ModelYear(s)/Vehicle(s)车型年/车辆类型,,,,,,,,,,,Date(Orig.)日期（最初）,,,,,,,

CoreTeam核心小组成员,,,,,,,,,,,Rev.（修订）,,,,,,,

"Serialnumber

序号","Item/Function

项目/功能",Requirements要求,PotentialFaisureMode潜在失效模式,PotentialEffect(s)ofFailure潜在失效后果,Sev.严重度,CLASS级别,PotentialCause(s)/Mechanism(s)ofFailure潜在失效的起因/机理,Occr.频度,"CurrentProcessControl

现行控制过程",Detec探测度,"RPN

风险度

",RecommendedAction(s)建议措施,Responsibility&TargetCompletionDate责任和目标完成日期,ActionResults措施结果,,,,

,,,,,,,,,,,,,,ActionsTaken采取的措施,Sev严重度,Occ频度,Det探测度,Rpn风险度

0--1,"ChemicalcompositionInspectionofrawmaterials(ADC12)

检验原材料化学成份（ADC12）","FollowtheincomingchemicalcompositionstandardproceduresofADC12

符合铝合金ADC12的进料化学成份标准","1Mistakenjudgments:

1.1qualifiedasunqualified;

1.2unqualifiedasqualified;

1误判断：

1.1合格判为不合格；

1.2不合格判为合格。

","1Purchasecostincreas(thepurchasepriceofdifferentgradesofaluminumaredifferent);

2Mechanicalpropertiesdifferent(mechanicalpropertiesofdifferentgradesofaluminumarebigdifferenct).

1采购成本增加（不同牌号铝材的采购价格有差价）；

2力学性能差异（不同牌号铝材的机械性能差异大）。",6,,"1.1theWIofinspectionequipmentisunclear;

1.1检验设备操作书不明细;",2,"definetheoperationprocedure;

制订操作规程;",3,36,无,,,,,,

,,,,,5,,"1.2inspectortakeanwrongbatchofsamples

1.2检验人员取错批次样品",3,"definespecimenbatchmanagementprocedure

试块的批次管理",3,45,无,,,,,,

,,,,,3,,"1.3inspectionequipmenterror;

1.3检验设备误差;",2,"1.3.1regularcheck

1.3.2equipmentcheck

1.3.1定期校检

1.3.2设备点检",2,12,无,,,,,,

,,,,,3,,"1.4theenvironmenttemperatureandhumidityofinspectionequipmentisunstable

1.4检验设备使用环境温度湿度不稳定",2,"humidityandtemperaturemetercontrol

温度湿度计控制",2,12,无,,,,,,

,,,"2.Missinginspection

2.漏判","(Ibid.)

（同上）",5,,"Noinspectionrequestnote/notcheckallsample

未报检/少检",2,"incominginspectionprocedure

进料检验流程",4,40,无,,,,,,

0--2,"Ingotsstorage

铝锭入库","Seperatedqualifiedincomingaluminiumingot(Black)

合格铝锭用标识分开","1.notlabeledmaterial

1.未标示材质","materialwasmixedinmeltingoperation

混用",5,,"warehousekeeperforgetidentity

库管员忘记做标识",2,"checkingthelabelwhendrawing

领料时检查材料标识",3,30,无,,,,,,

,,,"2.surfacehalogenated

2.表面卤化","baddegassandmaycauseexcessiveinternalporosity

精炼效果不良，可能引起内部气孔超标",5,,2.1Humidityexceeded2.1环境湿度超标,2,"extendthedryingtimeofmelting

熔炼延长烘干时间",2,20,无,,,,,,

,,,,,,,"2.2Longtimestorage

2.2存放时间超长",,,,,无,,,,,,

0--3,"Transferfromstoragetofurnace

移送材料至熔炼炉","TankbowlwithblacktagfortransportationADC12

用有标记的铝缸来运ADC12","Errorgrade

牌号错误","mechanicalpropertiesofunquaified

力学性能不合格",5,,"Mixingdifferentbrandsofmaterial

物料混料",2,"requestorcheckthematerial

领用人核对",2,20,无,,,,,,

10--1,"melting

temperature:700~720℃

material:ADC12

熔炼

温度:700~720℃

材料：ADC12

","

60%ingot(Min)40%recycle(Max)ADC12.(ColorCode:Black)

75%铝锭(Min)25%回收铝(Max)ADC12.","1.Chemicalcompositionunqualified

1.化学成份不合格","Mechanicalpropertiesofunqualified

力学性能不合格",6,,"1.1Mixingdifferentbrandsofrecyclematerial

1.1不同牌号的回炉料混",3,"1.1.1recyclematerialmanagement

1.1.2chemistryinspection

1.1.1回炉料管理

1.1.2化学成份分析",2,36,无,,,,,,

,,,,,,,"1.2cleansingdidnotdoagoodjobrefiningfurnace

1.2熔炼炉未清理干净",3,"Cleanfurnacebeforedegass,Cleanfurnaceafterwork

精炼前清扫精炼炉，下班后清扫精炼炉",,,无,,,,,,

,,,"2.Temperatureoutofcontrol1

2.温度失控","2.1Thetemperatureistoohigh,causemoreinteralcastingdefects(porosityandshrinkage)

2.2Thetemperatureistoolow,causemoreexteralcastingdefects(coldshut)

2.1温度过高,铸件内部存在缺陷(气孔和缩孔)

2.2温度过低,铸件外部存在缺陷（冷隔）",6,,"2.1Equipmentfailure

2.1设备故障",3,"inspection:inspecttheAltemperature

点检:测铝水温度",2,36,无,,,,,,

,,,,,,,"2.2Extendeduseofcrucible

2.2钳锅超期使用",3,"replacethecrucibleregularly

定期更换坩埚",,,无,,,,,,

10--2,"reservemeltonanddegassing

精炼、除气","

用氮气除气机每炉进行一次.

","1.residualforeignsubstance

1.杂质残留","castingtrachoma

铸件沙眼",5,,"temperatureissetedtoolow

温度设置过低",3,"Requirements/Inspectionofequipment

规定/点检设备",3,45,无,,,,,,

,,,"2.degassingisnotfull

2.除气不充分","castingpore

铸件气孔",5,,"temperatureissetedtoolow

温度设置过低",3,"Requirements/Inspectionofequipment

规定/点检设备",3,45,无,,,,,,

,,,"3.Thetemperatureistoohigh

3.温度过高","Castingshrinkage

铸件缩孔",5,,"temperatureissetedtoohigh

温度设置过高",3,Requirements/InspectionofEquipment规定/点检设备,3,45,无,,,,,,

,,,"4.thetemperatureistoolow

4.温度过低","Castingscoldshut

铸件冷隔",4,,Furnacefailure电炉故障,2,"Requirements/Inspectionofequipment

规定/点检设备",3,24,无,,,,,,

,,,"5.reservetimeistoolong

5.静置时间过长","elementsisburned,segregation

元素烧损,偏析",4,,"Productioninterruption

生产中断",2,"re-degass

重新精炼",3,24,无,,,,,,

20--1,Insulation保温,MoltenAltemperatureintheHoldingfurnaceis620~660℃.铝液在保温炉温度620~660℃,1.Atemperaturetoohigh1.温度过高,"castingshrinkage

铸件缩孔",5,,"temperatureissetedtoohigh

温度设置过高",3,Requirements/PointInspectionEquipment规定/点检设备,4,60,无,,,,,,

,,,2.thetemperatureistoolow2.温度过低,castingscoldshut铸件冷隔,4,,"Furnacemalfunction

电炉故障",2,Requirements/PointInspectionEquipment规定/点检设备,4,32,无,,,,,,

,,,"3.standingtoolong

3.静置时间过长","elementsinburning,segregation

元素烧损,偏析",4,,"Productioninterruption

生产中断",2,"Ingots

铸锭",2,16,无,,,,,,

20--2,"die-casting

压型","Noseriousdefectsuchascracks,coldlap,deformationnonfills,porosityetc.

没有严重的缺陷,如开裂,冷格变形,压铸砂孔等","1.Appearancedefects

1.1notch

1.2dragmark,deformation,

1.3porosity

1.4ProductsCrack

2.Mechanicalpropertiesoutofspec

1.外观缺陷

1.1欠铸

1.2拉伤、变形

1.3气孔、

1.4产品裂纹

2.机械性能及功能能达不到要求",,8,,"1aluminumwater(moldtemperature)islow;

2Shotpressureislower.

1铝水(模温)度偏低;

2压射力低。",2,"Verifyprocessrationality,checksbeforeoperation;Scrapstandardnumberofpiecesmangement

验证工艺合理性,作业准备检查;冷模件管理",4,64,无,,,,,,

,,,"1.dimensionisoutofspec

1.尺寸不合格.

2.productdeformation.

2.产品变形。",,8,,"1cavitydeformation,

2coolingtimeisnotenough

1型腔变形,

2冷却时间不够",2,"1.checkthecavity

2.checktheprocessparametersbeforeoperation

1.模具型腔点检

2.作业前核对工艺参数",2,32,无,,,,,,

,,,"1.porosity.

1.气孔

2.notchdeformation

2.欠铸",,8,,"1Exhaustpoor

2Excessivespraying

1.排气不畅

2.喷涂过量",2,"1Regularlycleanuptherowoverflowtank;

2inspectasrequired

1定期清理排溢槽;

2按要求检查",4,64,无,,,,,,

,,,"1.porosity.

1.气孔.

",,8,,"1Aluminumwater(mold)temperatureistoohigh

2Productstructureisirrational

1铝水(模具)温度偏高

2产品结构不合理",2,"1checktheprocess

2measuretheALtemperatureregularly

1核对工艺

2定时测铝水温度",2,32,无,,,,,,

,,,"1.porosity

2.Mechanicalpropertiesoutofspec

1.气孔

2.机械性能及功能能达不到要求",,8,,"1Aluminum(mold)temperatureistoohigh

2risingpressureisplummeted

1铝水(模温)度偏高

2保压压力骤减",4,"1Checktheprocessbeforeoperation.

2Regularlycheckthetemperatureofaluminum.

1作业前对工艺进行点检.

2定时测铝水温度.",2,64,无,,,,,,

,,,"1.Appearancedefects

1.外观缺陷.",,8,,"Coldprocesspartsweremixedin

冷模件混入合格品中",4,Scrapstandardnumberofpieces规定开班前的冷模件数量,2,64,无,,,,,,

,,,"1.Appearancedefects

1.1notchdeformation,

1.2porosity

2.Mechanicalpropertiesoutofspec

1.外观缺陷

1.1欠铸

1.3气孔、

2.机械性能及功能能达不到要求",,8,,Castingparametersweresetedincorrectly压铸参数设置不正确,4,Checktheprocessbeforeoperation.开班根据压铸工艺校验压铸参数,2,64,无,,,,,,

,,,"2.dimensionisoutofspec

2.尺寸不合格","零件报废

Partsscrap",6,,"2.1diewear

2.2Revisedmodelbymistake

2.1模具磨损

2.2修模失误",2,"measuretherelateddimensionsby1/10000

1次/万件关重尺寸检测",2,24,无,,,,,,

30,"Trimmingbyhand

手工敲冒口",不能敲伤外观,"1.notchongate

2.Appearancehurt

1.去浇口溢料口缺料

2.外观敲伤","1.Partsscrap

2.badappearance,customercomplaints

1.零件报废

2.外观不良，客户不满",6,,"knockdirection,strength,location,tool

敲击方向,力量,位置,工具",3,"Operationinstructions(visual)

mastersample操作指导书(可视化),样件对比度",3,54,无,,,,,,

40,"Deburring

去毛刺",不能有挫伤,1.fileinjury1.锉伤,"1.impactthelocation2.customerdissatisfaction1.影响定位

2.客户不满意",5,,"Anoperator'soperationandtoolswerewrong

操作者操作工具及方法不对",2,"Operationinstructions(visual),mastersample

操作指导书(可视化),样件对比度",4,40,无,,,,,,

,,必须定置放置,2.missdeburrs2.漏去毛刺,"1.impactthelocation2.customerdissatisfaction1.影响定位

2.客户不满意",,,"partsbemixinprocess

产品流转时箱子混放",3,"Set-management,inspection定置管理,检查",,60,无,,,,,,

50,"roughcastinspection

毛坯检验",,"1Mistakenjudgments:

1.1qualifiedasunqualified;

1.2unqualifiedasqualified;

误判断：

1.1合格判为不合格；

1.2不合格判为合格。","Affecttheappearanceandmachineprocess

影响外观和后续的加工",5,,Burrisoutofspec毛刺不符合工艺要求,3,"Trainandevaluatetheinspector

对巡检员进行培训及考核",4,60,无,,,,,,

60,"roughcaststore

毛坯入库",,quantitydidnotconfrontwiththesheet数量与入库单不一致,"Cannotguaranteequantityinaccountsisthesamewithactualproducts

无法保证账本与实际产品相同数量",2,,"wrongAcceptance

验收错误",3,"Storagesheets,visualinspect

入库记录单,目测",3,18,无,,,,,,

70,Millingplane铣底平面,粗糙度在Ra3.2,"1.surfaceroughnessoutoftolerance

1.表面粗糙超差","themillingplaneandthecorrespondingsurfacecannotcompletelycloseafterassembly

基准A、C与相对应的装配面不能完全紧贴",6,,"1.1Cutterwear

1.1铣刀磨损",3,LifeManagement使用寿命管理,3,54,无,,,,,,

,,,,,,,"1.2Lowspeed

1.2转速低",3,"Confirmedbeforetheoperation

开班前转速确认",3,,无,,,,,,

,,,,,,,"1.3Fastfeed

1.3进给量快",3,confirmvalveoffeedbeforeoperation开班前进给量确认,3,,无,,,,,,

,,,,,,,"1.4bigdepthofcut

1.4切削深度大",3,Confirmedthedepthofcut开班前切削深度确认,3,,无,,,,,,

,,,,,,,"1.5Productsarenottightclamping

1.5产品装夹不紧",3,Checkwhethertheproductisqualified检查产品是否合格,3,,无,,,,,,

,,24mm±0.15,"2.24mm±0.15outofspec.

2.距离基准面A的高度24mm±0.15不合格

","Affectassemblyquality

影响装配质量",7,SC4,"theforeignmaterialonthesurfaceofFixtureandproduct

夹具，产品定位面有异物",3,"blowtheforeignmaterialonthesurfacebeforeclamping

装夹前气枪清除定位面异物.",4,84,无,,,,,,

,,,"3.MachinedsurfaceandthebaseB,A,C0.3degreeoutline

3.加工面与基准B、A、C的轮廓度0.3","Affectassemblyquality

影响装配质量",7,SC5,"theforeignmaterialonthesurfaceofFixtureandproduct

夹具，产品定位面有异物",3,"blowtheforeignmaterialonthesurfacebeforeclamping

装夹前气枪清除定位面异物.",4,84,无,,,,,,

,"drillingΦ22.2±0.15hole

镗Φ22.2±0.15孔",φ22.2±0.15,"1.holediameteroutofspec.

1.孔径不合格","Affectassemblyquality

影响装配质量",7,,"1.1wrongdrillbrand

1.1镗刀型号错误",4,CheckdiameterwithcalipersbeforeopeningandFirstpieceInspection开班前用卡尺检查直径大小和首件检查,3,84,无,,,,,,

,,,,,7,,"1.2thebladeofdrillwear

1.2镗刀磨损",4,Toollifemanagement:checkwhethertheproductisqualified刀具寿命管理:检查产品是否合格,3,84,无,,,,,,

,,,"2.位置度不合格

2.positionoutofspec.","Affectassemblyquality

影响装配质量",7,,"2.1wrongdrillbrand

2.1镗刀型号错误",3,CheckdiameterwithcalipersbeforeopeningandFirstpieceInspection开班前用卡尺检查直径大小和首件检查,3,63,无,,,,,,

,,,,,7,,2.2clamptheproductstiltlypositionisincorrect2.2装夹产品倾斜，位置不正确,5,Checkwhethertheproductisqualified检查产品是否合格,3,105,无,,,,,,

,,,,,7,,"2.3theforeignmaterialonthesurfaceofFixtureandproduct

2.3夹具，产品定位面有异物",3,"blowtheforeignmaterialonthesurfacebeforeclamping

装夹前气枪清除定位面异物.",4,84,无,,,,,,

,"drilling2-φ7.5±0.15hole

钻2×φ7.5±0.15孔",φ7.5±0.15,"1.holediameteroutofspec.

1.孔径不合格","Affectassemblyquality

影响装配质量",7,SC1,"1.1wrongdrillbrand

1.1钻花型号错误",4,CheckdiameterwithcalipersbeforeopeningandFirstpieceInspection开班前用卡尺检查直径大小和首件检查,3,84,无,,,,,,

,,,,,7,,"1.2thebladeofdrillwear

1.2钻花磨损",4,Toollifemanagement:checkwhethertheproductisqualified刀具寿命管理:检查产品是否合格,3,84,无,,,,,,

,,,"2.positionoutofspec.

2.位置度不合格","Affectassemblyquality

影响装配质量",7,SC2/SC3,"2.1wrongdrillbrand

2.1钻花型号错误",3,CheckdiameterwithcalipersbeforeopeningandFirstpieceInspection开班前用卡尺检查直径大小和首件检查,3,63,无,,,,,,

,,,,,7,,2.2clamptheproductstiltlypositionisincorrect2.2装夹产品倾斜，位置不正确,5,Checkwhethertheproductisqualified检查产品是否合格,3,105,无,,,,,,

,,,,,7,,"2.3theforeignmaterialonthesurfaceofFixtureandproduct

2.3夹具，产品定位面有异物",3,"blowtheforeignmaterialonthesurfacebeforeclamping

装夹前气枪清除定位面异物.",4,84,无,,,,,,

80,"Chamfer

倒角","partshavebevisualinspecteddoneaferimpregnation

产品补漏后进行目视检查","漏序

missingchamfer","Affectassemblyquality

影响装配质量",7,,Mixedproducts(processedandunprocessedproducts)混产品(加工与未加工产品),4,"定置管理

fixationmanage",4,112,无,,,,,,

90,Cleaning清洗,"Nogreaseandslagonproduct,partsnoscratch

产品上无油和铝屑,产品不可碰伤,划伤","1.productsaredirtandforeignmatteronit

1.产品有污垢和异物","Affectassemblyquality

影响装配质量",7,,cleaningisnotthorough清洗不彻底,2,"Comparedwiththemastersample

与样件比较",4,56,无,,,,,,

,,,"2.theproducthassurfacescratches

2.产品机加面有碰划伤","Affectproductappearanceandassemblyquality

影响产品外观和装配质量",7,,"bumpincleaningandtransferingprocess

周转和清洗过程中碰伤",3,"definethelayoutofthepart

产品规定摆放方式",3,63,无,,,,,,

100,"FinalInspection

终检",按照成品检验指导书进行检测,"1Mistakenjudgments:

1.1qualifiedasunqualified;

1.2unqualifiedasqualified;

误判断：

1.1合格判为不合格；

1.2不合格判为合格。

","1.Manufacturingcosts

2.Productisnotavailable

1.产品无法使用

",5,,"1.1usewrongcheckfixtur

1.1检具使用错误",3,"checkfixtureidentitymanagement

检具标识管理",3,45,无,,,,,,

,,,,,5,,1.2checkfixturewear1.2检具磨损,3,"Regularcalibration

定期校检",3,45,无,,,,,,

,,,,,5,,1.3Thespecisnotclear1.3检验标准不明确,3,"visualsample

可视标准",3,45,无,,,,,,

,,,"2.missedinspection

2.漏检,不合格品流出厂",2.theproductcannotbeused2.产品无法使用,7,,"SettingManagementisnotclear

定置管理混乱",3,"identificationininspectionarea

检验工位区域标识",3,63,无,,,,,,

110--1,Packingpart包装,"AccordingtoProductstructuralchart&packinginstruction

符合产品结构报表和包装指引",Wrongpartwaspacked包错工件,Customercomplain