螺母与螺栓凸焊(翻译)

./I.GENERAL概述………………..………..I.1ScopeofEngineeringSpecification,GeneralStatement………….……….….总体说明,本规适用围I.2ProcessDescription……………….………..…….焊接过程描述I.3DesignGuidelines设计准则……………..….erSizeRelativetoBaseSheetMetalThickness紧固件对板材厚度的相对尺寸I.3.2HoleSizeinBaseSheetMetal板材上孔的尺寸I.3.3FastenerStrength紧固件强度I.3.4FlatnessofBaseSheetMetal板材的平面度I.3.5LocationofFastener紧固件的位置I.4ApplicableMaterials适用材料………I.5JointIdentificationSymbols焊接接头识……………………II.SUMMARYOFPRODUCTIONVALIDATIONANDIN-PROCESSTESTS……..生产验证及过程测试总述III.TESTPROCEDURESANDREQUIREMENTS………………试验过程及要求III.1ApplicabilityofTestProceduresforPV-andIP-TestPhases….PV试验阶段及IP试验阶段的适用性III.2WeldParameterMonitoring焊接参数监控……..…...…III.2.1Introduction简介III.2.1WeldingCurrentoverTime[A]焊接电流III.2.2ElectrodeForce[N]电极力III.3DimensionalandVisualInspectionoftheWeldedFastener……被焊紧固件的尺寸校核及目视检查III.3.1Introduction简介III.3.2GapbetweenFastenerandBaseSheetMetal紧固件与板材的间隙III.3.3BurnThroughintoBaseSheetMetal板材的烧穿III.3.4DeformationofFastenerBody紧固件的变形III.3.5Cracks破裂III.3.6FlashonThreads螺纹上的毛刺III.3.7Metalspatter金属飞溅III.3.8PositionofNutonComponent螺母在部件中的位置III.3.9PerpendicularityofBolt螺栓的垂直度III.4InspectionofSectionCuts剖面切割检查……………III.4.1Introduction简介III.4.2GapbetweenFastenerandBaseSheetMetal紧固件与板材之间的间隙III.4.3PenetrationintoBaseSheetMetal板材的焊透率III.4.4Porosity气孔III.4.5Cracks破裂III.4.6Inclusions夹杂III.4.7Hardness硬度III.5Destructive,Non-Destructive,andFunctionalTesting………….有损检测,无损检测及功能检测III.5.1Introduction简介III.5.2StaticTensileTest静态拉伸试验III.5.3TorqueTest扭矩试验III.TorqueTest<Destructive>扭矩试验〔有损III.TorqueTest<Non-Destructive>扭矩试验〔无损III.5.4PushOut/PullOutTest<Destructive>推出/剥落试验〔有损III.5.5Hammer/ChiselTest榔头/凿子试验III.5.6ThreadTest螺纹测试III.5.7LeakageTest密封性试验III.5.8Durability/FatigueTest寿命/疲劳测试III.6PermissibleRepairMethods……………...…...…允许的返修方法IV.REVALIDATIONREQUIREMENTS……再验证要求V.INSTRUCTIONSANDNOTES…………说明及注意事项VI.COMPILATIONOFREFERENCEDOCUMENTS……参考文件I.GENERAL综述I.1ScopeofEngineeringSpecification,GeneralStatement总体说明,本规适用围ThisEngineeringSpecificationisissuedtodefinedesignfactorsandperformancerequirementsapplicabletothejoiningofnutsandboltsusingtheprojectionweldingprocess.Itcoversmanualandautomatedprojectionweldingonsheetsteelhavingaminimumof0.5mmandamaximumof3.0mmthickness.ItcoversmetricdimensionsuptoM16andpropertyclass4.8and8.8fasteners,butnotfastenersofthepropertyclass10.9.本规用于规定螺母及螺栓凸焊的设计要素和焊接过程要求,它涉及厚度从0.5~3.0mm的钢板的手工凸焊和自动凸焊。本规囊括了公制M16以下的紧固件,其性能等级为4.8和8.8,而不包括性能等级为10.9的紧固件。ThisEngineeringSpecificationharmonizestherequirementsgloballyforFordMotorCompanyandisapplicabletonewmodelprograms.本工程规对全球的福特公司均有效并适用于新车型项目。ThisEngineeringSpecificationdoesnotreplacetherequirementsoftheFordworld-widefastenersstandards,whichfocusontheperformanceofthefasteneritself.Instead,itdefinestherequirementsfortheprojection-weldedjointbetweenthefastenerandthebasesheetmetal.Applicationsthatrequirespecialfastenersarenotdealtwithhereandrequireacase-by-caseapprovalbytheappropriateFastener,BodyandManufacturingEngineers.本工程规不替代全球通用的福特紧固件标准〔该标准主要讨论紧固件本身的性能,而是规定紧固件和板材之间的凸焊接头的各种要求。采用特殊紧固件的情况不在本规讨论之,如有采用需经紧固件工程师,车身工程师和制造工程师逐项批准。ThisEngineeringSpecificationisasupplementtothereleasedpartdrawing,andallrequirementshereinmustbemetinadditiontoallotherrequirementsofthepartdrawing.Eachsectionspecifiestheminimummeasuresnecessaryfordocumentingcompliancewiththisspecification.本工程规是所发放零件图纸的补充,除了要满足图纸的要求,也必须满足本规的要求。每部分规定了遵从本规的最基本的措施。ThisEngineeringSpecificationisintendedtoevaluatespecificcharacteristicsasasupplementtonormalmaterialinspections,dimensionalcheckingandin-processcontrols,andshouldinnowayadverselyinfluenceotherinspectionoperations.本工程规作为常规的材料检查,尺寸检查和过程控制的说明补充,而决不能反过来影响其它的检查操作。Preparationandsubmissionofanacceptablecontrolplanaretheresponsibilityofthemanufacturingsource.ThemanufacturingsourcewillretaintheoriginalcontrolplanandanylaterrevisionsperQS-9000andprovideacopytothedesignresponsibleProductEngineeringactivity.制造资源有义务准备与提交一份可接受的控制计划,制造资源保留原有的控制计划和任何之后经过QS-9000标准的修订版本,并且复制一份给负责设计的工程小组。I.2ProcessDescription过程描述Projectionweldingisaresistanceweldingprocessthatproducesaweldbytheheatobtainedfromtheresistancetotheflowoftheweldingcurrent.Theresultingweldsarelocalizedatpredeterminedpointsbylocalorannularprojections.Figure1showsthesequenceoftheprojectionweldingprocess.凸焊是一种利用电流流过电阻产生热量进行焊接的焊接方法。发生焊接的位置位于预制的环形凸点上。图1所示即为凸焊的焊接过程。Figure1:ExampleofProjectionWeldSequence图1.凸焊过程示例Figure2showstherepresentativeweldfastenerscoveredinthisdocument.Fastenersnotshownherearenotcoveredbythisengineeringspecificationandneedtobetreatedonacase-by-casebasis.图2所示为本规包含的代表性焊接紧固件。没有在图表中列出来的紧固件不在本规所涵盖的围,这些紧固件要采取"逐项原则"〔case-by-case原则对待。<a>Weldboltwiththreecircularprojection<a>Weldboltwiththreecircularprojections<b>Weldboltwith"banana"projections<c>Weldboltwithfourcircularprojections<NOTrecommendedfornewFORDdesigns><NOTrecommendedfornewFORDdesigns><d>Weldboltwithcontinuousringprojections<e>Squareweldnutwithfourprojections<NOTrecommendedfornewFORDdesigns>f>Pilotedweldnutwiththreecircularprojections<NOTrecommendedfornewdesigns>g>Flangedhexagonweldnutwiththree"banana"Projections带香蕉形凸块的六角法兰螺母<h>Flangedroundweldnutwiththree"banana"Projections<i>FlangedhexagonweldnutwiththreecircularProjections<j>FlangedroundweldnutwiththreecircularProjections<k>FlangedhexagonweldnutwithcontinuousringProjection<l>FlangedroundweldnutwithcontinuousringProjectionFigure2:ProjectionFastenersCoveredbythisSpecification图2.本规涵盖的凸焊紧固件I.3DesignGuidelines设计准则Thefollowingdesignguidelinesdescribethegenericconditionsfortheproperprojectionweldingapplicationofnutsandbolts.ItistheDesignEngineer'sresponsibilitytodeterminethedesignrequirementsfortheweldfastenernecessarytoachievethedesignobjective.以下设计准则描述了螺母和螺栓凸焊的一般情况。设计工程师负责决定焊接紧固件的设计要求及其所要达到的目标。Manyfactorsinfluencethechoiceoffastenertype,suchasloadingconditions,sheetthicknessandgrade,manufacturingpreferences,qualityassurance,etc.Ingeneral,weldnutsarepreferredoverweldbolts.Oneshouldthoroughlyconsiderthefunctionalityofthefastener,whetheritisintendedtocarryhighstaticand/orfatigueloads,oronlyserveasanattachmentpointforearthwirings<grounds>.Itisimportanttoestablishwhichpartofthefastenerjointsystemisthelimitingfactor<threadstrengthorthefastener'sattachmenttothesheetpart>inordertoavoidexpensiveover-dimensioning.紧固件类型的选择受多种因素的影响,比如加载状况,板料厚度及等级,制造偏好,质量保证等等。总的说来,焊接螺母优于焊接螺栓。我们必须彻底考虑紧固件的功能：它是否需要承受高的静态载荷和/或疲劳载荷,或者仅仅作为地线的一个附属点。为了避免采用过大尺寸的紧固件而造成更高的成本,确定焊接紧固件接头系统的限制性因素〔螺牙强度或者与板材的连接强度是很重要的。Forlowerloadsandsmallthreadsizes<M6andM8,>mechanicallyjoinedfastenersandweldfastenerscouldbeconsideredasequalintheirabilitytocarryload.Inwhichcase,themanufacturingprocessmaydictatethetypeoffastenertouse.对于小载荷和小螺纹尺寸〔M6和M8,,机械连接紧固件和焊接紧固件具有相同的承载能力。在这种情况下,制造过程决定所用的紧固件类型。Forhigherloadsandlargerthreadsizes,aweldedfastenerisrecommended.Fortheseconditions,itisalsoimportanttolocateaweldnutonthesideofthesheetcomponentwhichisoppositetotheloadingdirection.Withsuchadesign,theoccurrenceofwelddiscrepanciesareofminorimportancetotheperformanceofthejointasthefastenerhastobepulledthroughthesheetornutplate.Forhighfatigueloads,fastenerswithacontinuousringprojectionarethebestchoice,althoughthesearealsomoredifficulttoweld.对于大载荷和大尺寸螺纹,推荐使用焊接紧固件。对于这种情况,在板件上与载荷方向相反的另一边设置一个焊接螺母是很重要的。有了这种设计,焊接偏差的发生对于焊接接头性能的影响就不那么重要了,因为如果要产生破坏紧固件必须穿过板材或者螺母板。对于大的疲劳载荷,使用带有连续型环形凸块的紧固件是最好的,尽管这样也会增加焊接难度。I.3.1FastenerSizeRelativetoBaseSheetMetalThickness紧固件相对于板材厚度的尺寸大小TableI.3.1liststhepermissiblerangeofbasesheetthicknessfortherespectivesizeandtypeofnutandbolt.表I.3.1列出了各种螺母螺栓的类型尺寸及其对应的允许使用的板材厚度围。ThreadSize螺纹尺寸Minimum-MaximumSheetMetalThickness[mm]板材厚度围SquareNut方螺母Round/HexagonNutandBolt圆形/六角螺母和螺栓Round/HexagonNutandBolt圆形/六角螺母和螺栓Round/HexagonNutandBolt圆形/六角螺母和螺栓FourProjections四凸块ThreeBanana-ShapedProjections三个香蕉形凸块ContinuousRingProjection连续环状凸块ThreeCircularProjections三个环形凸块M61>0.5-1.50.75-1.250.5-1.52>0.5-0.8M80.75-2.50.9-2.00.75-2.52>0.8-2.0M100.75-2.51.25-2.50.75-2.52>1.25-2.07/16-20UNF1.5-3.01.5-3.0M121.0-3.01.5-3.01.0-3.02>1.5-2.2M141.5-3.03>1.5-3.03>1.5-2.4M161.5-3.03>1.5-3.03>注：1>ThesevaluescanbeusedforanM5threadappliedonanM6nutbody.这些值可用于采用M5螺纹M6螺母身的螺母2>Currentlyundervalidationintestprogram.Canbeuseduntilfurthernotice.目前正在测试验证当中,这些数据在下次通知之前有效。3>WeldNutsonly只对焊接螺母有效。TableI.3.1:MinimumandMaximumSheetMetalThicknessforVariousWeldFastenerSizes表I.3.1:各种焊接紧固件所对应的钣金厚度围Note:BananaprojectionsareassumedtomatchWE502sizerequirementsandcircularprojectionsareassumedtomatchWE500sizerequirements.注释：假设香蕉形凸块符合WE502尺寸要求；假设环状凸块符合WE500尺寸要求。DeviationsfromtheseguidelinesrequiretheapprovalofboththerelevantBodyandManufacturingEngineeringdepartments.采取与本准则有差异的方案需经与车身和制造有关的工程部门批准。Foroptimumperformanceofnon-standardfasteners:为了得到最佳性能,非标准紧固件采用如下原则：•Projectiondiameters/widthsshouldbeatleast2.5timestheattachingsheetthickness凸块直径/宽度至少要达到所焊板材厚度的2.5倍。•Projectionheightsshouldbeatleast0.5timestheattachingsheetthickness凸块高度至少要达到所焊板材厚度的0.5倍。I.3.2HoleSizeinBaseSheetMetal板材上孔的尺寸TableI.3.2liststheapplicablesheetholediameterforflangedandpilotedweldnutsandweldbolts.表I.3.2列出了焊接法兰螺母螺栓和带导向的螺母螺栓时板材上孔径的大小。Threadsize螺纹尺寸HoleDiameterforWeldNuts[mm]焊接螺母的板孔直径HoleDiameterforWeldBolts[mm]焊接螺栓的板孔直径FlangedNut1>法兰螺母PilotedNut导向螺母+0.5/-0.0+0.15/-0.0+0.5/-0.0M67.59.06.3M89.513.08.3M1011.415.010.37/16-20UNF11.410.3M1213.917.012.3M1415.919.0M1618.0Thecategory"FlangedNut"includesSquareNuts.法兰螺母包括了方螺母TableI.3.2:HoleSizeforVariousWeldFasteners表I.3.2:各种焊接紧固件对应的板孔直径I.3.3FastenerStrength紧固件强度Aftertheweldingprocess,weldboltsandnutsmuststillmeetthetensileand/orproofloadvaluesforthepropertyclassspecifiedintheWorldwideFastenerStandardsorontheindividualpartdrawings.焊接过程结束后,焊接螺栓和螺母的拉伸载荷和/或标准负荷值必须满足世界紧固件标准的规定或者图纸上的规定。•Actualproofloadvaluesforbolts-asreferencedintheGlobalFastenerStandardWA960–aretabulatedinISO898-1forvariouspropertyclasses.对不同性能等级的螺栓,其标准负荷数值在ISO898-1的列表中,亦可参考国际紧固件标准WA960。•Actualproofloadvaluesfornuts-asreferencedintheGlobalFastenerStandardWE960-aretabulatedinISO898-2.对于螺母,其标准负荷数值在ISO898-2的列表中,亦可参考国际紧固件标准WE960.Figure3illustratesthreepotentialloadingconditionsforfastenersthatneedtobeconsideredindesign.图3所示为三种潜在的紧固件负载情况,这需要在设计时加以考虑。Althoughthefigureshowsnormalloading,actualdesignmayrequireoff-normalloading.尽管图示的是常见的负载情况,实际设计中可能需要使用非常规的负载状况。<a>Push-Out推出式<b>Pull-Out拉出式<c>Pull-Through拉入式Figure3:PotentialLoadingConditionsforWeldedFasteners图3.紧固件潜在的加载情况I.3.4FlatnessofBaseSheetMetal板材的平面度Figure4outlinestheareaconditionneededtorobustlyweldafastenertotheparentsheetmetal图4画出了在母板金属上能稳固焊接紧固件的区域。Ry=Outerradiusoftheweldfastener<nutsizedependent,buttypically15mmforM5,M6,andM8nuts>Ry=焊接紧固件的外径〔由螺母尺寸决定,但对M5,M6和M8的螺母一般为15mmØ1=Functionalholediameter[mm]Ø1=作用的孔的直径[mm]根据表求得Ø2=AreawithflatnessrequirementswhereØ2=2x<Ry+2>[mm]Ø2=有平面度要求的区域直径Ø2=2x<Ry+2>[mm]Figure4:FlatnessRequirements平面度要求I.3.5WeldEquipmentClearance焊接设备间隙Theproductdesignshallprovidesufficientclearancefortheelectrodesoftheproductionweldequipment.Thetwozonestoconsiderareaboveandbelowtheweldedfastener.Theupperelectrodeisappliedonthesamesideasthefastener,whilethelowerelectrodeisappliedontheoppositesideofthefastener.Figure5illustratesvariousjointgeometries.TablesI.3.5-1and-2definetherequiredclearancesfordifferentfastenertypesandsizes.产品设计时要提供生产时电极所需要的足够的间隙。需要考虑的是紧固件上方和下方的两个区域。上电极作用在和紧固件相同的一侧,而下电极作用在与紧固件相反的另一侧。图5示意各种焊接接头结构。表和-2规定了不同类型和尺寸的紧固件所需的间隙。NOTE:Option3isNOTavailablewithWeldBolts.注：第三种情况不能用于焊接螺栓。Figure5:ElectrodeClearanceRequirementsforVariousConfigurations图5：各种情况下的电极间隙要求FastenerType紧固件类型A>B>C<D>H<I>SquareWeldNuts焊接方螺母30606018050140FlangedWeldNuts焊接法兰螺母38766020050140WeldBolts焊接螺栓306060NA50140+L1>1>L=NominallengthofboltL=螺栓公称长度TableI.3.5-1:RequiredweldequipmentclearancesfordimensionsA-D,H-I.Allvaluesinmm.表I.3.5-1:焊接设备要求的间隙尺寸A-D,H-I所有的数值单位为mm表I.焊接设备要求的间隙尺寸F和G所有的数值单位为mmDeviationsfromtherecommendedclearancesrequiretheapprovalofboththerelevantBodyandManufacturingEngineeringdepartments.Thepossibilityofusingspecialelectrodestogetintosmallerspacesmaybeconsidered,butthiswillleadtohigherequipmentoroperatingcosts.当采用不同于推荐的间隙值时需得到车身和制造相关工程部门的允许。也可以考虑采用特殊电极以达到小空间,但这会提高设备成本和操作成本。I.4ApplicableMaterials适用材料BaseSheetMetalSpecification金属板材规ThisEngineeringSpecificationcoverstheuseofthefollowingsteelscategoriesinuncoatedandcoatedcondition:本规包含以下种类的钢材〔有镀层或无镀层FORDMATERIALSPECIFICATIONNO福特材料规号CATEGORY类别TYPESOFSTEEL钢的类型ApplicabletoFordofEurope,VCC对欧洲福特和VCC适用ApplicabletoFordNorthAmerica对北美福特适用MSMildSteels,HotandColdRolled,LowCarbon低碳钢,热轧或冷轧WSS-M1A344-A1/A2WSS-M1A345-A1/A2/A3/A4WSD-M1A333-A1/A2/A3/A4DRDentResistantSteelsincludingBakeHardening,包括烘烤硬化HighStrengthIF,高强度IFIsotropicandRephosphorisedSteels各向同性钢和回磷钢WSS-M1A341-A1/A2/A3/A4/A5/A6/A7/A8/A9/A10WSS-M1A341-A1/A2/A3/A4/A5/A6/A7/A8/A9/A10HSLAHighStrengthLowAlloySteels高强度低合金钢WSS-M1A346-A1/A2/A3WSS-M1A347-A1/A2/A3WSB-M1A215-E1/F1DP1>DualPhaseSteels双相钢WSS-M1A348-A1/A2/A3/A4/A5/A6/A7/A8/A9WSS-M1A348-A1/A2/A3/A4/A5/A6/A7/A8/A9TRIP1>TRIPSteels相变诱发塑性钢WSS-M1A351-A1/A2/A3WSS-M1A351-A1/A2/A3MSW1>MartensiticSteels马氏体钢TBDWSS-M1A183-DBORON1>BoronSteels硼钢WSS-M1A322-A3WSB-M1A322-A1<Uncoated>WSS-M1A357-A1<Coated>2>WSS-M1A358-A1<Coated>2>1>DP,Trip,MSW,andBoronSteelsareincludedinthisEngineeringSpecificationwithinalimitedapplicability.UseofthesematerialsneedstobecheckedwiththerelevantBodyandManufacturingEngineeringDepartmentsonacase-by-casebasis.1>本规中DP,Trip,MSW,andBoron钢有限制的采用。这些材料的采用须经车身和制造相关工程部门的逐项确认。2>WSS-M99P39-A1/A2/A3/A4performancespecificationmustbecalledoutwiththeseBoronsteels.WSS-M99P39-A1/A2/A3/A4性能规必须遵从这些硼钢。TableI.4-1:ApplicableCategoriesofBaseSheetSteelsCoveredbythisSpecification表I.4-1:本规涵盖的适用的板材种类ThetextofthereferencedFordmaterialspecificationsisavailablefromthefollowingweblink.mats.ford./mats/scripts/spec_by_mtlCat.html,Metals1A-99A福特材料参考规可以参照以下：.mats.ford./mats/scripts/spec_by_mtlCat.html,Newsteeltypesareunderconstantdevelopment.InthecaseofsteeltypesnotcoveredbyTable7ofthisEngineeringSpecification,therelevantBodyandManufacturingEngineeringdepartmentsshallbecontacted.新的钢材种类正在持续的开发当中,如果使用超出本规中表7所示的钢材时,需经车身和制造相关工程部门确认。LaminatedsteelapplicationsarenotcoveredbythisEngineeringSpecificationandneedtobetreatedasspecialcase.Forsuchapplicationit’spreferredtousethepunchedfastenerratherthenaweldedone.本规未涉及层压复合钢板,如有使用应将其归入特殊钢板。并且在这种情况下使用冲压紧固件比焊接紧固件较好。StandardBaseSheetMetalCoatings标准板材镀层Projectionweldingoffastenerssupportsthefollowingcoatingsinallcombinations:紧固件的凸焊支持以下镀层SpecificationType规格种类SpecificationNo.规格牌号CoatingType镀层种类60G60GEL,50GWSS-M1P94-AElectro-galvanized电镀锌55A55AWSS-M1P94-AGalvannealed镀锌60G60GHD,50GWSS-M1P94-AHotDipGalvanized热镀锌AlSicoatingWSD-M1A295-A2HotDipAluminized热镀铝TableI.4-2:StandardBaseMetalCoatingsCoveredbythisSpecification表I.4-2:本规涉及的标准板材镀层TheuseofcoatingsnotlistedinTableI.4-2requirestheapprovalofboth,therelevantBodyandManufacturingEngineeringdepartments.使用未在表I.4-2中列出的镀层时需经车身部门和制造相关部门的同意。I.5JointIdentificationSymbols接头检测标识TheidentificationsymbolsshallbeinaccordancewiththeindividualrequirementsoftheFordMotorCompanybrandsasoutlinedbelow:检测标识必须与福特各品牌的要求保持一致,具体如下所示：•Ford福特ThecurrentFordEngineeringCADandDraftingStandardD-3<WeldingSymbolsandSpecifications>doesnotrequireaspecificidentificationofnutsandboltsweldedinaccordancewiththisengineeringspecification.现行的福特CAD和制图标准D-3〔焊接标识和规没有要求一个遵从本规的螺母螺栓检测规。•VolvoCarCorporation沃尔沃ThefastenersymbolsshallbeinaccordancewithVolvoCarCorporationstandardVCS5027,4,Indicationofsingleandcombinedjoints,availableat.紧固件标识必须与沃尔沃标准VCS5027,4保持一致。单个和组合的焊接接头标识可在以下查看.II.SUMMARYOFPRODUCTIONVALIDATIONANDIN-PROCESSTESTS生产验证和过程中测试综述ProductionValidation<PV>testsareusedtoobtainaninitialestimateoftheprocesspotentialtoproducepartsthatconformtoengineeringrequirements,andtoidentifycausalorpredictiverelationshipsbetweensignificantdesignandprocesscharacteristics<tobeusedforprocesscontrol>.ThetestsmustbecompletedsuccessfullyusinginitialpartsfromproductiontoolingandproductionprocessbeforePartSubmissionWarrant<PSW>approvalandauthorizationofproductionpartscanbeissued.SamplingplansforPVtestingmustbeincludedinthecontrolplan.生产验证〔PV测试的目的是获得按照工程要求生产的过程潜能的初始评价,并且识别有效设计和过程特性之间的因果关系〔用于过程控制。该测试必须使用生产工装上和生产过程中的首件,并且必须在PSW通过和产品流出之前。PV测试的抽样方法必须包含在控制计划中。Inaddition,testscanbedoneonprototypelevelpartsorvehiclestothesameextentasoutlinedforPV-testing.ThisdoesnotreplacethenecessitytorunPV-phasetestingasdescribedabove.此外,测试也可以在与PV测试同样大小的原型零件或汽车上进行。但这不能替代如上所述的PV阶段的测试。In-Process<IP>testsareusedtofurtherunderstandtherelationshipbetweensignificantdesignandprocesscharacteristicsandtoestablishabasisforcontinuingimprovement.Testsmustbecompletedwithproductionpartsonanongoingbasis.SamplingplansforbothIPtestingandevaluationofthesignificantprocesscharacteristicsmustbeincludedinthecontrolplan.Whentheprocessisfoundtobeoutofcontrolorthetestacceptancecriteriaarenotmet,thereactionplanapprovedinthecontrolplanshallbeinvoked.过程〔IP测试目的在于进一步了解有效设计和过程特性的关系并且确立改进方法。该测试必须使用在持续生产过程中的部件。对IP测试和重要的过程特征评估的抽样方法都需要包含在控制计划中。当过程失控时或者该测试无法满足接收标准时,必须采取控制计划允许的应对措施。WeldedfastenersthatdonotmeettherequirementsoutlinedinSectionII.,SummaryofProductionValidationandIn-ProcessTests,andSectionIII.,TestProceduresandRequirements,ofthisEngineeringSpecificationneedtoberepairedfollowingthereworkingprocedureasoutlinedinSectionIII.5.当焊接紧固件无法满足第II部分《生产验证测试和过程中测试综述》和第III部分《测试过程及要求》时,必须按第III.5部分的要求进行返修。ThetablesthatfollowsummarizethevariousPVandIPtestsandtheacceptanceparametersforeach.Theyformthebasisonwhichtodevelopacompletecontrolplanfortheseandtheirrelatedsignificantprocesscharacteristics.Thecontrolplanwillincludefrequencies,samplesizesandreactionplans;seeFordQualitySystemRequirements,QS-9000.以下表格概括了各种PV和IP测试及其可接受的数值。它们是形成完整的控制计划及相关过程特性的基础。控制计划包括测试频率,采样大小和应对措施。具体参考福特质量体系要求QS-9000。II.SUMMARYOFPRODUCTIONVALIDATIONANDIN-PROCESSTESTS<cont.>PV测试和IP测试综述WeldParameterMonitoring焊接参数监控TestNumberTestCharacteristic测试特征LowerToleranceLimit下限TargetValue目标值UpperToleranceLimit上限MinimumSampleSize最小采样大小MinimumSampleFrequency最小采样频率WeldingCurrentoverTime[A]焊接电流AsdeterminedinPVtesting根据PV测试结果AsdeterminedinPVtestingAsdeterminedinPVtestingsee1>参见注解1see1>参见注解1ElectrodeForce[N]电极力AsdeterminedinPVtestingAsdeterminedinPVtestingAsdeterminedinPVtestingsee1>参见注解1see1>参见注解11>Ford福特MinimumSampleSizeandFrequencytobedeterminedbythemanufacturingplantpersonnelresponsibleforthecontrolplaninconjunctionwiththedesignresponsiblebody-engineeringactivityandtherelevantqualitydepartmentsaswellasotherappropriatefunctions.Reference:FordofEurope:DocumentVOPQUE-612,availableatFordNorthAmerica:DocumentVOPSSN-008,availableat.vo.ford./ss/procedures/procd-files/ssn008c.pdf最小试样尺寸和最小检测频率由制造工厂的控制计划负责人与车身工程及质量工程相关部门协同确认,其它有关功能亦由此方法确定。参考欧洲福特文件VOPQUE-612,详见.voqoeu.ford.北美福特文件VOPSSN-008,详见.vo.ford./ss/procedures/procd-files/ssn008c.pdfVolvoCarCorporation:MinimumSampleSizeandFrequencytobedefinedbytherelevantmanufacturingunit.沃尔沃：最小试样尺寸和最小抽样频率由有关制造单元决定。II.SUMMARYOFPRODUCTIONVALIDATIONANDIN-PROCESSTESTS<cont.>PV测试和IP测试综述InspectionoftheVisiblePartoftheWeld焊接可见部分的检测TestNumberTestCharacteristic测试特征LowerToleranceLimit下限TargetValue目标值UpperToleranceLimit上限MinimumSampleSize最小样件尺寸MinimumSampleFrequency最小抽样频率GapBetweenFastenerandBaseSheetMetal紧固件与板材间的间隙Notapplicable不适用Afterwelding,thefastenermatchingsurfaceshalllieonthebasesheetmetal.焊接后紧固件配合面要贴合在板件上Maximumgap0.1mm最大间隙0.1mmsee1>见注解1see1>见注解1BaseSheetMetalBurnThroughNotapplicable不适用Notpresent未表述Notapplicable不适用see1>见注解1see1>见注解1DeformationofFastenerBody紧固件体的变形Notapplicable不适用Notpresent未表述Notapplicable不适用see1>见注解1see1>见注解1Cracks破裂Notapplicable不适用Notpresent未表述Notapplicable不适用see1>见注解1see1>见注解1FlashonThreads螺牙毛刺Notapplicable不适用Notpresent未表述Notapplicable不适用see1>见注解1see1>见注解1MetalSpatter金属飞溅Notapplicable不适用Notpresent未表述见第部分see1>见注解1see1>见注解1PositionofNutonComponent板件上螺母的位置Notapplicable不适用AsoutlinedonassemblyDrawing如装配图所示Asoutlinedonassemblydrawing.Shadowingofbasesheetmetalholeisnotpermissible.如装配图所示,不允许遮蔽板材上的孔see1>见注解1see1>见注解1PerpendicularityofBolt螺栓的垂直度-5degreesfromNormal垂直方向-5°AsoutlinedonassemblyDrawing如装配图所示+5degreesfromnormal垂直方向+5°see1>见注解1see1>见注解11>Ford福特MinimumSampleSizeandFrequencytobedeterminedbythemanufacturingplantpersonnelresponsibleforthecontrolplaninconjunctionwiththedesignresponsiblebody-engineeringactivityandtherelevantqualitydepartmentsaswellasotherappropriatefunctions.Reference:FordofEurope:DocumentVOPQUE-612,availableat.voqoeu.ford.FordNorthAmerica:DocumentVOPSSN-008,availableat.vo.ford./ss/procedures/procd-files/ssn008c.pdf最小试样尺寸和检测频率由制造工厂的控制计划负责人与车身工程及质量工程相关部门协同确认,其它相关功能亦由此方法确定。参考欧洲福特文件VOPQUE-612,详见.voqoeu.ford.北美福特文件VOPSSN-008,详见.vo.ford./ss/procedures/procd-files/ssn008c.pdfVolvoCarCorporation:MinimumSampleSizeandFrequencytobedefinedbytherelevantmanufacturingunit.沃尔沃：最小试样尺寸和抽样频率由有关制造单元决定。II.SUMMARYOFPRODUCTIONVALIDATIONANDIN-PROCESSTESTS<cont.>生产验证和过程测试总述〔续InspectionofSectionCuts剖切面的检验测试号测试特征公差下限目标值公差上限最小样本大小最小采样频率紧固件和主体金属件的间隙不适用无间隙最大0.1mm见1见1主体金属件的熔深初始焊脚高度的30%初始焊脚高度的50%基体金属厚度的90%见1见1气孔不适用未提供气孔面积不超过凸焊区域的25%见1见1裂纹不适用未提供裂纹长度不超过凸焊宽度的20%见1见1III.4.6夹杂不适用未提供夹杂区域不超过凸焊区域的20%见1见1III.4.7硬度不适用不适用具体见III.4.7章见1见11>Ford福特MinimumSampleSizeandFrequencytobedeterminedbythemanufacturingplantpersonnelresponsibleforthecontrolplaninconjunctionwiththedesignresponsiblebody-engineeringactivityandtherelevantqualitydepartmentsaswellasotherappropriatefunctions.Reference:FordofEurope:DocumentVOPQUE-612,availableat.voqoeu.ford.FordNorthAmerica:DocumentVOPSSN-008,availableat.vo.ford./ss/procedures/procd-files/ssn008c.pdf最小抽样尺寸和最小抽样频率及其他有关功能由制造工厂负责控制计划的工程师和负责车身设计及质量部门协同确定。参考：欧洲福特,VOPQUE-612www.voqoeu.ford.北美福特：VOPSSN-008.vo.ford./ss/procedures/procd-files/ssn008c.pdfVolvoCarCorporation:MinimumSampleSizeandFrequencytobedefinedbytherelevantmanufacturingunit.VCC：最小采样大小和采样频率由相关的制造单位制定。II.SUMMARYOFPRODUCTIONVALIDATIONANDIN-PROCESSTESTS<cont.>生产验证和生产进程测试总述〔续Destructive,Non-Destructive,andFunctionalTesting破坏性测试,非破坏性测试,和功能测试测试号测试特征公差下限目标值公差上限最小样本大小最小采样频率拉入试验〔破坏性不适用超过该紧固件的校验值不适用见1见1III.5.3推出试验和拉出试验〔破坏性对于凸点数≥3的凸焊,允许有1个凸点不符合要求；对于环状焊脚,连续的环形焊接区域至少为全长的70%对于凸点式焊脚,不能有不符合要求的凸点产生；对于环形焊脚,连续的环形焊接区域要达到100%。不适用见1见1III.5.扭矩测试〔破坏性不适用只能在刚好超过最小破坏性扭矩值时发生接头部分或全部分离不适用见1见1III.5.扭矩测试〔非破坏性不适用在超过最小非破坏性扭矩测试值之前不能发生接头的部分或全部分离和破裂。不适用见1见1III.敲打/凿击试验〔破坏性对于凸点≥3凸焊：允许有1个凸点不符合要求；对于环状焊脚,连续的环形焊接区域至少为70%对于凸点式焊脚,不能有不符合要求的凸点产生；对于环形焊脚,连续的环形焊接区域要达到100%。不适用见1见1III.5.5.敲打/凿击试验〔非破坏性不适用焊接接头没有发生部分或者全部的脱离。不适用见1见1III.5.6螺纹测试不适用通过测试不适用见1见1III.5.7密封测试不适用通过测试不适用见1见1III.5.8耐久性/疲劳测试不适用根据CETP00.00-R310,在整车PASCAR车第一阶段和PASCAR第二阶段阶段的50%完成时在焊接区域和热影响区不发生破裂和分离。不适用见1见11>Ford福特MinimumSampleSizeandFrequencytobedeterminedbythemanufacturingplantpersonnelresponsibleforthecontrolplaninconjunctionwiththedesignresponsiblebody-engineeringactivityandtherelevantqualitydepartmentsaswellasotherappropriatefunctions.Reference:FordofEurope:DocumentVOPQUE-612,availableat.voqoeu.ford.FordNorthAmerica:DocumentVOPSSN-008,availableat.vo.ford./ss/procedures/procd-files/ssn008c.pdf最小抽样尺寸和最小抽样频率及其他有关功能由制造工厂负责控制计划的工程师和负责车身设计及质量部门协同确定。参考：欧洲福特,VOPQUE-612www.voqoeu.ford.北美福特：VOPSSN-008.vo.ford./ss/procedures/procd-files/ssn008c.pdfVolvoCarCorporation:MinimumSampleSizeandFrequencytobedefinedbytherelevantmanufacturingunit.VCC：最小采样大小和采样频率由相关的制造单位制定。III.TESTPROCEDURESANDREQUIREMENTS测试过程和要求III.1ApplicabilityofTestProceduresforProductionValidation<PV>andIn-Process<IP>TestPhases生产确认〔PV和生产进程〔IP测试过程的适用性。测试号测试特征PV测试阶段IP测试阶段III.2焊接参数的监控强制的建立目标值和公差上下限强制的III.3焊点的外观检查和尺寸检查强制的强制的III.4对剖切面的检查可选的车身工程和制造工程部门决定是否需要进行剖面分析〔通常只需对与未知的主体板件结合时进行典型分析。可选的可用于对根本原因的分析III.5破坏性测试,非破坏性测试和功能测试强制的对于带开口环焊脚的螺母或螺栓：破坏性试验或非破坏性试验；对于带连续环焊脚的螺母或螺栓：不允许使用非破坏性试验。当可使用多种破坏性或非破坏性测试时,可以选其中一个作为最优的测试。这必须规定在其控制计划上。车身和制造工程部门决定是否进行密封测试强制的除III5.2的拉入试验,III5.7的密封测试和III5.8的耐久性/疲劳强度测试。对于带连续环焊脚的螺母或螺栓：不允许使用非破坏性试验。当多种破坏性或非破坏性测试存在于一种给定的紧固件中时,可以选其中一个作为最优的测试。这必须规定在其控制计划上。表III.1测试过程和要求的适用性III.2WeldParameterMonitoring焊接参数的监控III.2.1Introduction简介ProjectionweldingequipmentusedfortheproductionofpartsaccordingtothisEngineeringSpecificationshallbeequippedwithabuilt-inweldparametercontrolandmonitoringunit.ThetargetvaluesandtheupperandlowertolerancelimitsfortheparametersbelowshallbedeterminedinProductValidation<PV>testsindividuallyforeachprojectionweldingapplication.Theyshallbeincludedintheprocesscontrolplanandlaterbeappliedonthebasisofa100%samplingrateforInProcess<IP>conformancetesting.Non-conformingweldsshouldbemarkedandprocessedforadditionalinspectionandpossiblerework.用于零件产品生产的凸焊设备,根据工程说明书需要装备有嵌的焊接参数控制和监测的单元。以下参数的目标值和公差上/下限在每次进行凸焊时需要单独地在生产确认〔PV测试中制定。他们应该包含在过程控制计划中并且需要在随后的生产进