CQI-27第二版中英文 工艺表G-铝金属模具2019.8.27

Observations / Comments about Actual Condition 对实际情况的观察/评论
G1.4
Casting Simulation 铸造模拟
1. The casting plant must use solidification modeling software such as MagmaSoft, AnyCasting, ProCast, EKK, FLOW-3D or similar software approved by the customer Product Engineering on the casting as part of the design process for the gating and feeding system prior to tooling construction and prototype part submission. Simulation must include both fill and solidification analysis. 2. Results must be reviewed with the Customer Product Engineering. 3. At any high stress features in the FEA, the simulation should avoid hot spots, air entrapment, multiple metal fronts converging. 1. 铸件厂必须使用MagmaSoft、AnyCasting、ProCast、EKK、FLOW-3D或客户产品工程师认可的铸件凝固建模软件，作为浇注和进料系统设计过程的一部分， 然后才能进行模具施工和原型部件提交。模拟必须包括填充和凝固分析。 2. 结果必须与客户产品工程师一起评审。 3.在有限元分析中的任何高应力特征下，模拟应避免热点、空气滞留、多个金属前沿会聚。
Conforming 符合/ Non-Conforming 不符合 Not Applicable 不适用
Casting Process 铸造工艺
This Process Table is for aluminum semi-permanent mold and permanent mold castings (except Cylinder Heads which has its own Table). Includes pistons, aluminum alloy wheels. Cast processes include different types of equipment such as: gravity die casting, tilt pour, rotary, low pressure die cast, and pressure counter pressure. 该工艺表用于铝的半永久性模具和永久性模具铸件（钢瓶头除外，钢瓶头有自己的表）。包括活塞、铝合金车轮。浇铸工艺包括不同类型的设备，如：重力压 铸、倾斜式浇铸、旋转式、低压压铸、压力反压式浇铸。
G1.1Design SoftwFra bibliotekre 设计软件
1. Casting plant must be compliant to customer specific software requirements. 2. Casting plant must have and maintain customer specific requirements for math data transfer for the tooling and for part Drawings / Models. 1. 铸造车间必须符合客户特定的软件要求。 2. 铸造工厂必须有并维护客户对模具和零件图纸/模型的数学数据传输的特定要求。
What is the scope covered by this audit? The entire foundry? A specific product line? A specific part number? Other? 本次审计涵盖的范围是什么？整个铸造厂？特定的产品线？特定的零件号？其他？
G1.2
FEA Analysis - Part One 有限元分析-第一部分
1. The design responsible party must complete an FEA (Finite Element Analysis) for the casting. The ultimate tensile strength, yield strength, and percent elongation used in the FEA must be over the lower limit of engineering requirement for the specified alloy for similar applications. 2. The foundry should know the specific features of the casting where maximum stresses exceed 50% of the Yield Strength. For purposes of this assessment, the expression "high stress" refers to any feature exceeding 50% of the Yield Strength. 3. Yield Strength as used in this discussion is the x-bar (mean value) minus 3s (three sigma) statistical calculation from tensile bars pulled at the casting source. 4. Any high stress features identified in the FEA must be evaluated when casting simulations are reviewed, and when establishing product audits such as wall thickness, microstructure, hardness, x-ray, crack inspections. 1、设计负责方必须完成铸造工艺的的FEA分析（有限元分析）。 FEA中的抗拉强度，屈服强度和延伸率必须高于特定合金的最低工程要求值。 2、当最大应力超过屈服强度的50%，铸造方应该了解铸造特定特征。为了这一评价目的，表达“高应力”指的是任何超过屈服强度50%的特征。 3、此处讨论的屈服强度是铸造试棒拉断数据，X-Bar （平均值）减去3s(3 sigma) 统计计算。 4、当铸造模拟和开始产品审核，比如壁厚，微观组织，硬度，X光，裂纹检查时，FEA中的任何高应力特征必须被评价。
Describe the scope of the audit: 描述审核范围:
Item Category/Process Step 类
条款
别/过程步骤
1.0
Casting Design and Tooling 铸造设计和模具
Requirement 要求
Observations / Comments about Actual Condition 对实际情况的观察/评论
第 1 页，共 17 页
Item Category/Process Step 类
条款
别/过程步骤
Requirement 要求
G1.3
FEA Analysis - Part Two 有限元分析-第二部分
5. If there are any features on the casting which would have an Extreme Load Maximum Stress greater than 75% of the Yield Strength of the alloy, then Limit Testing at Extreme Load conditions is appropriate. The foundry may not be responsible for this testing, however, the foundry is responsible to provide worst-case parts for this testing. Customer Product Engineering will define the worst-case conditions, such as internal porosity, for Limit Testing. 6. If there are any features on the casting which would have an Extreme Load Maximum Stress greater than 75% of the Yield Strength of the alloy, Customer Product Engineering may restrict shipment of castings for serial production only to the extent of what was provided for Limit Testing. This may be tighter than stated Product Engineering acceptance criteria if the worst-case parts provided were not at the extremes of the permissible acceptance criteria. In other words, if it was not Limit Tested, it cannot be shipped. This is a decision to be made by customer Product Engineering. 5、如果铸件有任何最大极限负载超过屈服75%的特征，那么，需要进行极限负载条件下的极限试验。铸造可以不负责试验，然而，铸造方有责任提供最差条件 的产品用于试验。客户产品工程师会定义最差条件，比如内部气孔，做极限试验。 6、如果极限负载最大应力大于合金屈服75%，铸件是否会有任何特征。客户产品工程师可能对于连续生产的铸件控严到只有提供了极限试验的程度。如果最差 条件的产品不再可接受标准的限度内，这个可能比产品工程师接收标准更加严格。换而言之，如果没做极限试验，不允许发运。这个决定由客户产品工程师下 。
PROCESS TABLE G - Aluminum Metal Mold 工艺表G-铝金属模具
All requirements given below are subordinate to customer specific requirements. When performing the CQI-27 Casting Assessment the auditor shall verify foundry is conforming to customer requirements; including a customer approved Control Plan defining the agreed upon inspection testing and frequencies. *If minimum requirements are not met, provide supporting records to justify actual conditions. 以下所有要求均服从于客户的具体要求。 在进行CQI-27铸件评估时，审核员应验证铸件是否符合客户要求;包括客户批准的控制计划，确定双方同意的检验、测试和频率。*如未能符合最低要求，须提供证明实际情况的证明文件。