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عدد المساهمات : 19004 التقييم : 35512 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
| موضوع: كتاب Total Quality Process Control for Injection Molding الجمعة 25 أكتوبر 2019, 10:27 pm | |
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أخوانى فى الله أحضرت لكم كتاب Total Quality Process Control for Injection Molding Second Edition M. Joseph Gordon, Jr.
و المحتوى كما يلي :
Contents Preface xvii 1. Total Quality Process Control 1 ISO 9001 / 2 Documentation / 5 Establishing Process Ownership / 5 Ideas and Methods / 13 2. Implementing Total Quality Process Control (TQPC) 15 Quality Improvement Plan / 17 Statistical Process Control (SPC) / 19 Controlling the Process / 19 Cp the Control of Operations / 20 Cpk-Centered Process Control / 23 Establishing Company Quality Objectives / 25 Customer Quality / 27 3. Managing for Success, Commitment to Quality 28 Objectives for Managing a Quality System / 28 Proactive Preventive Action / 29 Total Quality Process Control / 30 Attitude / 30vi CONTENTS Control of Change / 32 Improvement with Control of Change / 33 Quality Decisions / 34 Principles for Quality Systems Engineering / 34 Objectives for Managing a Quality System / 34 Customer-Supplier Quality Agreements / 36 Captive Part Quality / 36 Product Quality Determination / 36 Parts to Print / 36 Form, Fit, and Function (FFF) / 39 Product Requirements / 40 Existing Mold Considerations / 40 Establishment of Responsibility / 42 Department TQPC Responsibility / 44 Program Development / 45 Estimated Piece Part Price / 46 Multifunctionality / 48 Assembly and Decorating / 48 Manufacturing Capability / 48 Computer-Integrated Manufacture (CIM) / 49 Tracking Manufacture / 52 RFID / 52 EDI / 52 Just-In-Time / 53 Control of Operations / 53 Process Control / 54 Control Charting / 54 International Organization for Standardization (ISO) Accreditation / 57 Program Monitoring—Communication / 57 Communicating Quality in Business / 58 Communications / 58 Surveys / 59 Quality Function Deployment (QFD) / 61 QFD in Operation / 62 Customer Feedback / 63 Critical to Quality (CTQ) / 66 Building on TQPC, Product Manufacture / 67 Checklists / 67 Quality Circles / 69CONTENTS vii Fishbone Analysis / 69 Failure Mode and Effects Analysis / 70 Types of FMEAs / 71 FMEA Timing / 73 Implementing an FMEA / 74 FMEA Development / 74 4. Customer Satisfaction 79 Manufacturing and Supplier Input / 80 Vendor Selection / 80 Vendor Survey / 81 Customer and Supplier Agreements / 82 Vendor Clinics / 83 Product Requirements / 83 Product Preproduction Review / 84 Contract Checklist / 84 5. Organization Responsibilities 86 Quality Operations / 89 Quality Uniformity / 91 Compliance Audits / 91 Six Sigma Introduction / 92 Procedure / 93 Quality Problems / 94 TQPC Management Operations / 96 Preventive Action / 103 6. Establishing the Limits for Quality Control 105 Preproduction Product Analysis / 108 Taguchi Methods / 108 Prototyping / 109 Mold Limits / 111 Material Selection / 114 Calculation of Plastic Part Cost / 115 Case Study of Product Cost Analysis / 116 Estimating Part Cycle Time / 116 Mold Part Cavity Estimation / 118 Mold Size Considerations / 119 Injection Molding Machine Selection / 119viii CONTENTS Melt Generation / 121 Molding Machine Screw-type Considerations / 122 Machine Hourly Rate / 122 Machine Setup Charges / 124 Calculating Product Manufacturing Cost / 126 Material Supplier Limits / 129 Establishing Manufacturing Limits / 129 Auxiliary Equipment / 131 In-Process Inspection / 131 Establishing Total Quality Process Control / 132 Acceptable Quality Limits / 134 7. Material Selection and Handling 135 Thermosets / 136 Thermoplastics / 137 Amorphous Plastics / 137 Crystalline Plastics / 137 Classifying the Polymers / 138 Product Certification / 138 Material Specification / 140 Product Variable Specification / 143 Incoming Material Testing / 143 Material Testing Equipment / 144 Types of Tests / 144 Analyzing the Tests / 145 Differential Scanning Calorimeter / 146 Thermogravimetric / 149 Gel Chromatography / 150 Test Methods / 153 Material Safety Data Sheets / 163 Record Accuracy / 163 Bar Coding: An Aid in Total Quality Process Control / 164 Regrind Control / 165 Material Handling and Storage / 165 Regrind Usage / 166 Processing Aids / 168 8. The Mold 169 Computer-Integrated Manufacture / 170 Pre-mold Design Checklist / 172CONTENTS ix Part Design / 172 Material Selection / 173 Shrinkage / 173 Molding Machine Capability / 173 Strength of Materials for the Mold / 174 Fluid Flow in Mold / 174 Venting the Mold / 175 Heat Transfer / 175 Thermal Conductivity / 176 Thermal Expansion of the Mold / 176 Coefficients of Friction / 176 Abrasion Resistance / 176 Corrosion Resistance / 177 Ejector System / 177 Draft and Shut-off / 177 Part Drawings and Dimensional Stackup / 179 Mold Setup / 180 Secondary Operations / 180 Maintenance/Repair/Operation / 180 Methods of Construction / 181 Tooling / 182 Processing / 182 Reviewing Existing Tooling / 182 Part Cost and Cavity Optimization / 183 Prototype Tooling / 183 Production Tooling / 184 Pricing the Tool / 190 Tool Scheduling / 192 Tool Steel Selection / 192 Selecting Materials for the Mold / 195 Corrosion and Abrasion Resistance / 195 Thermal Conductivity / 196 Cavity Forming and Finishing / 198 Electric Discharge Machining / 199 Polishing / 203 Texturing / 203 Cavity Selection / 206 Part Layout / 206 Cavity Selection Based on Molding Machine Size / 208 Mold Cavity Layout / 210x CONTENTS Runner Systems / 212 Cavity Runner Layout / 212 Runner System Design / 212 Gating the Part / 215 Material Shrinkage / 216 Gate Location / 217 Gate Terminology / 217 Gate Types / 220 Gate Control of Weld Lines / 223 Sprues and Nozzles / 226 Sprue Pullers / 226 Sprue Bushing and Nozzle Seating / 226 Parting Lines / 228 Cavity Parting Line Location / 228 Complex Parting Line / 228 Side Core Pulls / 230 Side-Action Core Pull / 230 Delayed Side-Action Core Pull / 231 Slide Retainers / 232 Wedge Action Core Pull / 233 Core Selection / 234 Collapsible Cores / 234 Unscrewing Cores / 234 Part Ejection / 235 Positive Early Ejector Return / 237 Accelerated Ejectors / 237 Venting the Cavity / 237 Cavity Shutoff / 242 Cavity Considerations / 242 Passive Vents / 243 Porous Metal Vents / 244 Core Venting / 244 Positive Cavity Venting / 245 Blowback System / 245 Temperature Control / 245 Insulating the Mold for Temperature Control / 245 Mold Temperature Control / 246 Cavity Temperature Control / 250CONTENTS xi Cooling Systems / 251 Cooling System Layout / 251 Core Cooling / 252 Coolant Channel Seals / 255 Mold Cooling Line Connections / 257 Mold Connection Types / 257 Cooling Time / 258 Mold Shrinkage / 259 Post-Mold Shrinkage / 261 Calculating and Estimating Part Shrinkage / 264 Determining Cavity Dimensions / 267 Hot-Runner Molds / 271 Processing for Hot-Runner Molds / 272 Mold Maintenance / 278 9. Manufacturing Equipment 285 Machinery Selection / 285 Process Control / 286 Electric Injection Molding Machines / 287 Injection Molding Machine Nomenclature and Operation / 288 Reciprocating Screw Injection Molding Machine / 289 Injection Molding Cycle Operations / 290 Machine Selection for the Molding Cycle / 291 Resin Melt Shot Capacity / 291 Machine Melt Plasticizing Capability / 292 Injection Rate and Pressure / 293 Packing Pressure / 294 Back Pressure / 294 Time Variables and Controls / 295 Injection Molding Cycle / 295 The Injection Molding Machine / 297 The Barrel and Screw Assembly / 298 The Reciprocating Screw / 299 Nonreturn Valves / 305 Barrel Adaptor / 307 Screw Tip / 307 Nozzles / 309 Selecting Barrel Heater Conditions / 311 Pyrometer / 312xii CONTENTS Thermocouples / 312 Mold Fit and Support / 313 Machine and Mold Clamping Systems / 313 Hydraulic Clamp / 313 Toggle Clamp / 315 Vented-Barrel Machines / 317 Maintenance of Machinery / 321 Preventive Maintenance / 321 Maintenance Checklist / 324 10. Auxiliary Equipment 326 Material Feeders and Blenders / 327 Automatic System / 328 Central Systems / 329 Material Feed to the Injection Molding Machine / 331 Material Blending at the Hopper / 332 Blending Quality Checks / 333 Color Concentrate Blending / 333 Regrind Usage / 334 Material Drying / 334 Material Drying Systems / 335 Dryer Analysis / 337 Material Drying / 339 Dryer Bed Analysis / 340 Desiccant Bed Analysis / 343 Dryer Problem Checklist / 345 Dielectric Closed-loop Moisture Analysis / 346 Microwave Dryers / 346 Plant Equipment Cooling Systems / 346 Chiller Systems / 346 Mold Temperature Controllers / 350 Chiller Types / 351 Mold Heaters / 352 Temperature Setting / 352 Maintenance Checks / 353 Granulators or Grinders / 355 Granulator Selection / 357 Press-Side Granulator / 358CONTENTS xiii Central Granulator / 359 Granulator Problems and Maintenance / 359 Part Removal, Conveyor Systems, and Robots / 360 Conveyor and Part Separator Systems / 362 Robot Part Handling / 365 Quality Inspection Equipment / 366 Quick Mold Change / 369 QMC Requirements / 369 Key Factors / 370 Implementing QMC / 370 11. Processing 378 Production Startup for Process Control / 378 Acceptable Quality Level Limits / 379 Networking Production / 382 The Injection Molding Process / 383 Mold Startup Procedure / 384 Monitoring Mold Setup and Startup Procedures / 385 Setup Operator Responsibilities / 385 Injection Molding Startup / 389 Setting the Cycle / 392 Startup Procedure / 392 Shut-Down Procedure / 397 Other Molding Variables / 400 Plant Environment / 400 Electrical Power / 401 Cooling Systems / 401 Plant Airflow / 402 Housekeeping / 402 Pyrometers for Temperature Readings / 403 Mold Temperature Balance / 404 Resin Melt Temperature / 404 Machine Pressure Settings / 405 Fine Tuning the Cycle / 405 Control by Part Weight / 406 Regrind Effects on Part Quality / 407 Determining the Missing Variable / 408 Taguchi Problem-Solving Techniques / 410 Process Control Charting / 410xiv CONTENTS Manufacturing Limits / 411 Control Charts / 412 Measurement-Process Control-Chart Calculations / 413 Percent and Fraction Control Charts / 422 Percentage Control Chart Formulae / 422 Control Limit Calculations for Measurement Data / 423 Maintaining Process Control / 424 Precontrol / 425 Taking Measurements / 428 Quality Maintenance / 429 Solutions to Typical Molding Problems / 429 Shot-to-Shot Variations / 429 Cavity Melt Pressure Control / 437 Controlling and Monitoring Process Variables / 440 Process Line Integration / 440 Process Line Integration Benefits / 442 Process Line Integration Scheduling / 443 Selecting a System / 444 12. Part Testing at the Machine 446 Selecting the Test / 446 Verifying Molding Conditions / 448 Destructive Tests / 448 Gardner “Ball Drop” Impact Test / 449 Nondestructive Tests / 450 Optical Comparators / 450 Stress/Strain Part Evaluation / 451 Polarized Light / 451 Aesthetic Part Checking / 452 Color Checks / 454 Testing of Plated Parts / 457 Post-Mold Shrinkage Testing / 457 Conditioned Parts / 457 13. Part Handling and Packaging 459 Planning / 459 Part Removal / 461 Part Handling and Packaging / 463CONTENTS xv Automatic Part Packaging / 463 Robots / 465 14. Part Design Influence 467 Selecting the Correct Design Parameters / 467 Material Selection / 468 Part Design for End-Use Applications / 469 Radii / 470 Nonuniform Part Thickness / 474 Ribs for Strength and Quality / 478 Weld-Line Considerations / 480 Surface Appearance Problems / 484 Bosses / 485 Threads / 487 Undercuts / 490 Inserts / 493 Insert Loading / 495 Integral Hinges / 497 15. Assembly Techniques 499 Plan for Assembly / 499 Automated Assembly / 500 Automated Inspection / 501 Assembly Techniques / 501 Press Fits / 502 Snap Fit / 503 Welding Assemblies / 506 Hot-Plate Welding / 529 Focused Infrared Melt Fusion / 529 Cold or Hot Heading / 531 Mechanical Fasteners / 533 Adhesive and Solvent Bonding / 538 16. Decorating Considerations 543 Control of the Process / 543 Decorating Techniques / 544 Surface Preparation / 545 Molded Colors / 547 Surface Finish / 552xvi CONTENTS Painting / 552 Paint System / 553 Part Cleanliness / 555 Part Paint Specifications / 556 Graphics / 557 Silk Screen / 558 Pad Printing / 558 Hot Stamping / 559 Heat Transfer / 562 Spray and Wipe / 562 Two-Shot Molding / 562 In-Mold Decorating / 564 Vacuum Metallizing / 565 Electroplating / 568 Flocking / 570 Gravure Decorating / 570 17. Customer and Employee Satisfaction 573 Quality Awareness / 574 Appendix A. Quality Management System (QMS) Control of Documents Procedure 576 Appendix B. Design of Experiments (DOE): Statistical Troubleshooting Process Screening for Reducing the Number of Variables 579 Appendix C. Checklists 593 Appendix D. Supplier Evaluation Survey 663 Appendix E. Mold Problem Solutions 675 Appendix F. Decoration & Information Solutions 683 Glossary 692 Bibliography 731 Index
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