Some standard content:
Mechanical Industry Standard of the People's Republic of China
Forging Process Quality Control Specification
1. Subject Content and Scope of Application
This standard specifies the general principles and requirements for the whole process quality control of forging process. This standard is applicable to the forging process quality control of forging plants (including forging workshops, hereinafter omitted). 2 Reference standards
GB12361 General technical conditions for steel die forgingsGB12362 Tolerances and machining allowances for steel die forgingsG1313318 General rules for safety in forging workshopsGB/T 12363
JB4249
JB4385wwW.bzxz.Net
Functional classification of forgings
Machining allowances and tolerances for steel self-forgings on hammerGeneral technical conditions for steel free forgings on hammerGeneral technical requirements for heating of steel free forgingsJB/T 6052
JB/T6055
Environmental protection guidelines for forging workshops
ZB J32 001
General technical conditions for free forgings on hydraulic presses ZBJ32003.1003.8 Machining allowance and tolerance of free forgings on hydraulic presses 3 Classification of forgings
The classification of forgings involved in the quality control of this standard shall be implemented in accordance with GB/T12363. 4 Control of environment
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The working environment of the forging plant, including the floor of the plant, skylight, temperature, ventilation, lighting, noise, passages, pipelines, and the storage of bad materials, forgings and work clamps and dies, shall be formulated in accordance with the requirements of Chapter 3 of GB13318 and Chapters 3 and 4 of JB/T6055 and the relevant national laws and regulations to formulate specific implementation requirements for the enterprise.
5 Control of equipment, instruments and tooling
5.1 Equipment, instruments
5.1.1 All types of equipment must be in good condition and have operating procedures and maintenance and verification systems. 5.1.2 All types of main equipment in use must be hung with a good equipment label, and have the inspection validity period and the next inspection date. Unqualified equipment and equipment that has exceeded the validity period of the inspection must be hung with a "disabled" label. 5.1.3 The control system and detection display instruments of the equipment should be checked regularly to ensure that the displayed values of the instruments and their accuracy are accurate. 5.1.4 The temperature display and measurement point layout of the heating equipment should correctly reflect the furnace temperature and furnace temperature uniformity of the heating zone. 5.1.5 All equipment used must be archived, and the specific contents include: a. Equipment instruction manual; b. Machine hour record; c. Fault record; d. Repair record; 5. Calibration reports and calibration certificates over the years.
5.2 Moulds and other tooling
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5.2.1 New moulds shall be manufactured according to the requirements of the mould drawing, and after passing the inspection, they shall be tested. Only after confirming that they meet the design and manufacturing requirements can they be put into production.
5.2.2 At the end of each batch of forging production, the forged tail pieces shall be marked and the moulds shall be returned to the warehouse for continued use after the size is inspected and qualified.
5.2.3 The tools used for forging must be selected according to the provisions of the process documents and can only be used after being inspected and in good condition. 5.2.4 A "mould resume" must be established for each set of moulds (including pre-forging moulds, trimming moulds, etc.), and a strict mould management system must be established. 6 Raw material control
6.1 Raw materials for forgings (including steel ingots) shall have quality certificates and meet the material grade, size specifications and performance requirements specified in the process documents. 6.2 Raw materials and ring materials must be re-inspected by the material inspection department after entering the factory. The bars and forged parts used for forging must have a re-inspection report. The re-inspected raw materials should have a re-inspection mark, and the unqualified materials should be clearly marked. 6.3 Qualified materials, materials to be inspected, and unqualified materials should be clearly marked, and should be stored in different areas. Mixing is strictly prohibited. 6.4 There must be a strict management system for the storage and delivery of qualified materials. 7 Document and data control
7.1 Necessary technical documents
Forging production should have technical documents such as part drawings, forging drawings, process drawings, mold drawings, technical standards, production instructions, and process regulations. 7.2 Technical document requirements
7.2.1 The expression of the content of the technical documents should be accurate, concise, easy to understand and logical, and should meet the requirements of standardization. Various technical documents must be unified and complete.
7.2.2 All technical documents shall be approved and signed according to the prescribed procedures before they can take effect. If there is any change in the technical documents, the approval procedure is the same as that of the original documents.
7.2.3 All technical documents should be classified and archived. 7.3 Original records
All original records, process parameters, test reports and other technical data involved in Chapter 8 should be archived. The preservation period depends on the importance of the forgings, generally within 1 to 10 years.
8 Control of production process
8.1 Cutting
8.1.1 Before cutting, the material brand, specification, quantity, melting furnace (batch) number should be verified according to the process regulations and process cards, and the surface quality should be checked. If there are special requirements, the head and tail marks should also be checked. 8.1.2 Cutting must be carried out in batches according to the forging number, material brand, specification and melting furnace (batch) number, and the number of cuts should be indicated on the process card to prevent foreign materials from mixing. In case of material substitution, the substitution procedures must be strictly followed in accordance with the provisions of the material substitution system before cutting. 8.1.3 When cutting materials, the "three inspections of the first piece" (self-inspection, mutual inspection and special inspection) system should be strictly implemented. After passing the inspection and making obvious marks, it can be put into production.
8.1.4 The weight, dimensional tolerance, surface and end face quality of the bad materials shall comply with the requirements of the process regulations. 8.1.5 During the process of cutting materials, if the material is found to have visible defects, the cutter should report it to the inspection personnel or process personnel in time. The work can be continued only after processing.
8.1.6 The cutting site should be kept clean. It should be placed according to the material brand, smelting furnace (batch) number, and specifications. After the bad materials are checked and confirmed by the inspector 314
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and marked, they should be packed and managed, and no mixing is allowed. 8.1.7 The remaining materials should be marked with the material brand and smelting furnace (batch) number and returned to the warehouse in time, and strictly classified and managed. 8.2 Heating
8.2.1 Before heating the raw materials, check whether the material brand, smelting furnace (batch) number, size specifications, and quantity are consistent with the process card. 8.2.2 Before loading the scraps into the furnace, the debris in the furnace must be cleared. The surface of the raw materials heated in the electric furnace must not be contaminated with oil. 8.2.3 When the scraps are put into the furnace, they should be placed in the working area. To ensure that the scraps are heated evenly, large scraps should be added with pads. There should be a certain distance between the scraps. If necessary, they should be arranged in order
8.2.4 Cold chain heating should be heated in accordance with the corresponding *General Technical Requirements for Heating of Forgings". 8.2.5 When heating in a diffuse flame furnace, the flame is not allowed to spray directly on the surface of the scrap. 8.2.6 When heating in an electric furnace, the scrap should be kept at a certain distance from the heating element, or shielding measures should be taken to prevent overburning of the metal. 8.2.7 For the heating of scraps of precision forgings, non-oxidizing or low-oxygen heating should be used. Chemical heating method. 8.2.8 The heating temperature and heating time of the bad material shall be carried out in accordance with the requirements of the corresponding forging process regulations. The heating record of the whole process of bad material heating shall be kept for archiving and future reference.
8.2.9 When heating the bad material, the thickness of the oxide scale and the depth of the decarburization layer shall meet the forging process requirements. The heating of the bad material is not allowed to produce overheating, overburning and internal cracks. If the bad material cannot be forged on time for some reason, it can be treated by cooling or taking it out of the furnace, but it must meet the requirements of the process regulations.
8.2.10 When different bad materials with the same heating specifications are heated in the furnace, they must be placed in different areas in the furnace, and mixing is strictly prohibited. . 8.2.11 In principle, materials with different heating specifications shall not be heated in the same furnace. If they must be heated in the same furnace, materials with similar heating specifications must be selected and heated in the same furnace, but technical guarantee measures must be taken. 8.2.12 Precautions for heating different types of alloys: Equipment that has heated copper alloys should be cleaned before heating steel and other alloys; a.
When heating aluminum alloy blanks, the furnace atmosphere is not allowed to contain sulfur and water vapor: b.
When heating titanium alloy blanks, the furnace is not allowed to have a reducing atmosphere. 3 The material temperature during blank heating should be detected by a temperature measuring instrument, and heating records should be kept. Record and file for future reference. 8.2.13
8.3 Forging
8.3.1 Select the appropriate forging equipment according to the material, shape, size and process requirements of the forging. Forgings must be forged on the equipment specified in the process documents.
8.3.2 Operators should be familiar with the forging drawings and process documents before forging. 8.3.3 Before forging, the tools and dies used must be preheated to the specified temperature using the correct method. 8.3.4 Select appropriate lubricants according to the complexity, material and process requirements of the forging. 8.3.5 Before forging and during forging, the oxide scale of the bad material should be removed. 8.3.6 During forging, the initial forging overflow, final forging temperature, deformation degree and deformation speed must be strictly controlled. 8.3.7 During the forging operation, it must be carried out strictly in accordance with the process regulations and process cards. And pay attention to whether the deformation of the bad material is normal at any time. If defects such as folding and cracks are found, they must be immediately removed by appropriate methods. Forging can be continued only when the quality of the forging is not affected. 8.3.8 The cooling of the forgings shall be carried out according to the cooling method specified in the forging process regulations. 8.3.9 The heat treatment after forging shall be carried out according to the relevant process documents. It can be carried out according to the process regulations of the manufacturer or according to the process requirements proposed by the user, but it must be indicated when signing the contract. 8.3.10 For Class I forgings, a special process description shall be proposed when necessary, and the initial production process and tooling tests shall be carried out. Only after verification can it be put into production. Class II forgings shall establish quality files according to the forging drawing number. 8.3.11 The trimming, punching and correction temperature of forgings shall be carried out according to the relevant regulations of the forging process regulations. 8.3.12 The surface of forgings shall be cleaned as follows: a. Surface cleaning shall be carried out by sandblasting, shot blasting, roller, pickling or other methods according to the process requirements. The surface quality of the forgings after cleaning shall meet the requirements of the technical documents;
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b. Forging surface defects are allowed to be cleaned, and the cleaning depth and depth-to-width ratio shall be in accordance with the relevant forging technical standards; ℃. When pickling is used for cleaning, the pickling solution shall be regularly tested and replaced according to the relevant technical documents. Forgings are not allowed to be over-pickled. 8.4 Forging Inspection
8.4.1 Process Inspection
8.4.1.1 Each batch of forgings must undergo the "first piece three inspections" system, and can only be officially put into production after passing the inspection. Self-inspection, mutual inspection and special inspection shall be strictly implemented in production.
8.4.1.2 The process inspector shall conduct a patrol inspection on the production site, conduct on-site control of the temperature of the forging heating furnace and the forging operation, and regularly scan and inspect the external dimensions and surface quality of the forgings. 8.4.1.3 After the forgings (or returned materials) have passed the inspection, the inspector shall sign on the process card or record card before transferring to the next process. 8.4.2 Final inspection of forgings
8.4.2.1 Final inspection of die forgings shall be carried out in accordance with the forging drawings and relevant provisions of GB12361, GB12362 or contracts. 8.4.2.2 Final inspection of free forgings shall be carried out in accordance with the forging drawings and relevant provisions of JB4249.JB4385, ZBJ32003.1~~003.8, ZB3J32001 or contracts.
8.4.2.3 Inspection marks (or labels) or other marks may be made on the specified forging parts. 8.4.3 Certificate of Conformity
The certificate of conformity shall be issued by the inspection department in accordance with the relevant technical standards or contract requirements to fill in and issue the forging certificate of conformity. 8.4.4 Unqualified products
Forgings that are confirmed to be unqualified after inspection by the inspection department. They shall be stored in isolation and handed over to the unqualified product handling organization of the quality assurance system for processing. 9 Processing of forging quality and information feedback
9.1 During the production process, if quality problems are found, production shall be stopped immediately and analysis shall be organized in a timely manner to find out the causes and propose solutions or improvement measures. Production may be resumed only after the product is confirmed to be qualified through production verification. 9.2 Regularly conduct visits to users (or the next process), and timely study and handle the opinions and feedback information raised by users during the visits.
10 Personnel quality control
10. Operators and quality control managers in various positions of forging production should have certain professional theoretical knowledge and practical experience.
10.2 Forging operators, instrument operators, inspectors, etc. must undergo technical training and assessment of corresponding professions and obtain operating licenses before they can take up their posts.
10.3 The technical requirements for various types of operators shall be trained and assessed in accordance with the "What to know and what to do forging in the technical level of mechanical industry workers". Training and assessment shall be carried out in accordance with relevant regulations.
11 Preparation of enterprise process quality control specifications
The enterprise forging process quality control specifications shall be carried out under the guidance of this specification. Enterprises are encouraged to formulate enterprise quality control specifications that are higher than this specification, but the level of enterprise quality control specifications shall not be lower than the basic requirements of this specification. Additional notes:
This standard is proposed and managed by the National Forging Standardization Technical Committee. This standard is drafted by the Beijing Electromechanical Research Institute of the Ministry of Machinery Industry and the 621 Institute of the Aviation Industry Corporation. The main drafters of this standard are Cai Fulin and Tang Longzhang.
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