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首先欢迎来我司考察并希望提出宝贵意见。现将贵司空运回的问题连杆做如下回答和解决。一、2-ICR6125-1R、3-ICR5700PR、2-ICR6000R、2-ICR63...
首先欢迎来我司考察并希望提出宝贵意见。
现将贵司空运回的问题连杆做如下回答和解决。
一、2-ICR6125-1R、3-ICR5700PR、2-ICR6000R、2-ICR6385-1R、3-10198922R,以上连杆属于毛坯存在缺陷。我公司和锻造厂沟通过,他们认为不影响使用,我司也认为材料费太贵,所以在这种情况下也过于理解他们。这种观点是绝对错误的。最近我公司又到锻造厂把存在的质量问题跟他们进行了沟通,现在锻造厂也承诺今后像这样的问题他们会把有质量问题的连杆严格选出。我司现在对库存连杆全面检查,凡是存在缺陷的连杆全部选出报废。为了保证今后生产的连杆不再有毛坯质量问题,我司采取了以下措施:(1)购进的毛坯进行全面检查,再经过喷瓦处理后再加工;(2)在加工过程中现也要严格把关,凡发现有缺陷的连杆全部报废。
二、3-10198922R、2-350-6125-2100-LR、2-454-6700-2200R,以上连杆属于钻工工序出现的质量问题:(1)3-10198922R和2-454-6700-2200R由于钻工钻定位孔和钢套孔时,可能是钻头磨偏,钻出的孔偏大而没有铰削余量,造成杆体杆盖合盖后,定位孔和定位钢套没有起到定位的作用;(2)2-350-6125-2100-LR连杆,螺栓旋不进去,主要原因是钻床工序在钻杆体螺纹底孔时,由于钻头磨损后,没有及时磨削,钻头阻力过大,发生偏移,造成杆体、杆盖、螺纹孔和定位钢套的不同轴度和不垂直度偏差过大,为了保证以后生产的连杆螺纹孔不再出现螺纹旋不进去的问题,及以上存在的问题,我公司与所有技术人员、生产管理人员和操作工人做了一次全面沟通,采取了下列措施:(1)加强对工装的检修,以工装精度来保证产品质量;(2)加强对钻工工序的严格检查和监督;(3)限制操作工人钻床转速和进合量,以保证杆体、杆盖、螺纹孔和钢套定位孔的同轴度和垂直度;(4)要求钻工勤磨钻头以保证钻头的锋利和切削顺畅;(5)现场技术检验人员和操作人员经常用量规检查螺纹孔和钢套定位孔的大小和同轴度。
三、2-ICR5400-927R、2-ICR5700R、2-454-6800-2200R,以上连杆属于螺纹孔过紧或螺纹孔清洗不干净,造成的螺栓卡死。现我们对库存的所有连杆进行全面清洗螺纹孔,然后用美制螺栓检查每支连杆螺纹孔,以保证每支连杆螺纹孔顺滑。为了保证以后生产的连杆螺纹孔不再出现螺纹孔过紧,螺栓旋不进去的质量问题,我们采取了以下措施:(1)加强对钻床工装的检修,以保证其精度要求;(2)加强对钻工工序的严格检查和监督限制钻床钻速和进给量,以保证杆体、杆盖螺纹孔和钢套定位孔的同轴度和垂直度;(3)经常用量规检查螺纹孔和钢套定位孔的大小和同轴度,以防止螺纹底孔过小而螺纹过紧;(4)加强对攻丝工序的严格检查,做到勤用螺纹塞规检查,以防止丝锥磨损而没有及时更换,造成螺纹孔过紧;(5)产品加工后,包装前用贵公司提供的美制螺栓检查每支连杆螺纹孔是否清洗干净。
四、2-454-6700-2200R、10256401-3,以上连杆属于螺栓座面倒角过大和螺栓座面倒角有波纹纹路。造成倒角过大的原因有:(1)操作工人疏忽大意机床没有限位;(2)用力过大,退刀过慢。造成波纹纹路的原因是:(1)倒角器过于锋利而没有及时处理;(2)倒脚时转速过高。现我司对库存连杆螺栓座面进行全面检查,凡发现螺栓座面倒角过大或者有波纹纹路的连杆,将重新加工螺栓座面。为了保证以后所有连杆螺栓座面倒角不再过大和出现波纹纹路,我们采取机床限位,使座面倒角不再过大,现已安排专人倒角保证螺栓座面倒角大小按要求一致,不再出现波纹纹路。
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现将贵司空运回的问题连杆做如下回答和解决。
一、2-ICR6125-1R、3-ICR5700PR、2-ICR6000R、2-ICR6385-1R、3-10198922R,以上连杆属于毛坯存在缺陷。我公司和锻造厂沟通过,他们认为不影响使用,我司也认为材料费太贵,所以在这种情况下也过于理解他们。这种观点是绝对错误的。最近我公司又到锻造厂把存在的质量问题跟他们进行了沟通,现在锻造厂也承诺今后像这样的问题他们会把有质量问题的连杆严格选出。我司现在对库存连杆全面检查,凡是存在缺陷的连杆全部选出报废。为了保证今后生产的连杆不再有毛坯质量问题,我司采取了以下措施:(1)购进的毛坯进行全面检查,再经过喷瓦处理后再加工;(2)在加工过程中现也要严格把关,凡发现有缺陷的连杆全部报废。
二、3-10198922R、2-350-6125-2100-LR、2-454-6700-2200R,以上连杆属于钻工工序出现的质量问题:(1)3-10198922R和2-454-6700-2200R由于钻工钻定位孔和钢套孔时,可能是钻头磨偏,钻出的孔偏大而没有铰削余量,造成杆体杆盖合盖后,定位孔和定位钢套没有起到定位的作用;(2)2-350-6125-2100-LR连杆,螺栓旋不进去,主要原因是钻床工序在钻杆体螺纹底孔时,由于钻头磨损后,没有及时磨削,钻头阻力过大,发生偏移,造成杆体、杆盖、螺纹孔和定位钢套的不同轴度和不垂直度偏差过大,为了保证以后生产的连杆螺纹孔不再出现螺纹旋不进去的问题,及以上存在的问题,我公司与所有技术人员、生产管理人员和操作工人做了一次全面沟通,采取了下列措施:(1)加强对工装的检修,以工装精度来保证产品质量;(2)加强对钻工工序的严格检查和监督;(3)限制操作工人钻床转速和进合量,以保证杆体、杆盖、螺纹孔和钢套定位孔的同轴度和垂直度;(4)要求钻工勤磨钻头以保证钻头的锋利和切削顺畅;(5)现场技术检验人员和操作人员经常用量规检查螺纹孔和钢套定位孔的大小和同轴度。
三、2-ICR5400-927R、2-ICR5700R、2-454-6800-2200R,以上连杆属于螺纹孔过紧或螺纹孔清洗不干净,造成的螺栓卡死。现我们对库存的所有连杆进行全面清洗螺纹孔,然后用美制螺栓检查每支连杆螺纹孔,以保证每支连杆螺纹孔顺滑。为了保证以后生产的连杆螺纹孔不再出现螺纹孔过紧,螺栓旋不进去的质量问题,我们采取了以下措施:(1)加强对钻床工装的检修,以保证其精度要求;(2)加强对钻工工序的严格检查和监督限制钻床钻速和进给量,以保证杆体、杆盖螺纹孔和钢套定位孔的同轴度和垂直度;(3)经常用量规检查螺纹孔和钢套定位孔的大小和同轴度,以防止螺纹底孔过小而螺纹过紧;(4)加强对攻丝工序的严格检查,做到勤用螺纹塞规检查,以防止丝锥磨损而没有及时更换,造成螺纹孔过紧;(5)产品加工后,包装前用贵公司提供的美制螺栓检查每支连杆螺纹孔是否清洗干净。
四、2-454-6700-2200R、10256401-3,以上连杆属于螺栓座面倒角过大和螺栓座面倒角有波纹纹路。造成倒角过大的原因有:(1)操作工人疏忽大意机床没有限位;(2)用力过大,退刀过慢。造成波纹纹路的原因是:(1)倒角器过于锋利而没有及时处理;(2)倒脚时转速过高。现我司对库存连杆螺栓座面进行全面检查,凡发现螺栓座面倒角过大或者有波纹纹路的连杆,将重新加工螺栓座面。为了保证以后所有连杆螺栓座面倒角不再过大和出现波纹纹路,我们采取机床限位,使座面倒角不再过大,现已安排专人倒角保证螺栓座面倒角大小按要求一致,不再出现波纹纹路。
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Welcome to our company for investigation and I sincerely hope you will give us some precious suggestions.
Now, we would like to make a response to your connecting rods by air.
1. There are some drawbacks existed in blank of connecting rods in the model 2-ICR6125-1R、3-ICR5700PR、2-ICR6000R、2-ICR6385-1R and 3-10198922R. And we discussed with the forging factory. They told us that it does not matter. Considering the expensive material fee, we didn’t blame them for these mistakes. But unfortunately, this view of point is absolutely wrong. We went to the forging factory again and had a communication with them about the existing quality problems. The forging factory turned their views and promised will strictly select the inferior connecting rod out next time. We are having an overall inspection for the stock connecting rods now. Once found the inferior ones, we declare them never being used. We take some measures as following for guarantee that we will get the superior connecting rods from now on. Firstly, the purchased blank needs to be overall inspected. The good ones are painted and then they are moved to the processing procedure. Secondly, being strict at selecting the inferior products in the processing procedure, once found, leave them along and never put them into production.
2. The drilling problems are found in the connecting rod model 3-10198922R、2-350-6125-2100-LR and 2-454-6700-2200R. The first problem exists in model 3-10198922R and 2-454-6700-2200R when drillers are drilling the locating hole and the steel hole. The reason might be that the drill did not polished on the right place so that makes the hole overlarge and when the body of rod and the top of rod are got together, the locating hole and steel lagging doesn’t play a role of positioning. The second problem exists in connecting rob model 2-350-6125-2100-LR. The bolt cannot whirl. The main cause is might be the abraded drill did not re-sharp in time and considering the resistance of drill, it shifted. Thus, it caused the deviation of different axiality and verticality oversized in body of rods, screwed holes and locating steel lagging. In order to avoid the problem of whirling problems and the problems mentioned above, our company together with the all technical, managerial personals and operators had a comprehensive communication and decided to take the following measures. First, strengthen the inspection to frock and guarantee the quality of products by frocking precision. Second, strengthen the strict inspection and supervision to drilling processing. Third, restrict the revolving speed and speed rates of drilling machine to operators and guarantee the axiality and verticality for body of rod, the top of rod, screwed holes and locating hole of steel lagging. Fourth, drillers are asked to polish drills so that they could be sharp and cut smoothly. Finally, technical inspector on the spot and operators are required to regularly use the measure gauge to check the size and axiality of screwed hole and locating hole of steel lagging.
3. The main problems for the model 2-ICR5400-927R、2-ICR5700R and 2-454-6800-2200R are the over-tightness or uncleanness in screwed holes, which lead to the bolt getting stuck. Now we need to clean all the connecting rods inside and outside. And then use the bolt made in America to check each piece of bolt of the connecting rod, in order to make sure that every bolt works smoothly. In order to avoid the problems mentioned above, we are going to take these measures. First, strengthen the examination and repair for drilling frock and guarantee the required precision. Second, strengthen the strict inspection to drilling processing, supervise and restrict the speed and feed rates of the drill, and guarantee the axiality and verticality of rods, screwed holes on the top of rods and locating hole of steel lagging. Third, regularly use the measure gauge to check the size and axiality of screwed hole and the locating hole of steel lagging for the sake of preventing thread’s bottom hole to be tight because of its undersize. Fourth, strengthen the strict inspection to screw’s processing. Frequently use the plug thread gauge to check whether the abraded screw taps are replaced. Finally, use the bolt made in America to examine whether every screwed hole of connecting rod is cleaned or not.
4. The problem in model 2-454-6700-2200R and 10256401-3 exists in chamfer oversize and having ripple in bolt base. The main cause for chamfer oversize might as following: First, the carelessness of operators made the machine tool unlimited. Second, overuse and retract slowness. The reasons for causing ripple in chamfer are as following: On one hand, didn’t deal with the hornwork in time. On the other hand, the high the revolving speed of the machine when deal with the chamfer. We are having an overall inspection for the stock connecting rods now. Once found the connecting rods existing in chamfer oversize and having ripple in bolt base, we will reprocess the bolt base. We will adopt the machine limited for the sake of the above problems never appeared. Now we are asking the particular person to take responsibility on the related jobs.
真的累啊,一个上午。希望能够帮到你,谢谢!
Now, we would like to make a response to your connecting rods by air.
1. There are some drawbacks existed in blank of connecting rods in the model 2-ICR6125-1R、3-ICR5700PR、2-ICR6000R、2-ICR6385-1R and 3-10198922R. And we discussed with the forging factory. They told us that it does not matter. Considering the expensive material fee, we didn’t blame them for these mistakes. But unfortunately, this view of point is absolutely wrong. We went to the forging factory again and had a communication with them about the existing quality problems. The forging factory turned their views and promised will strictly select the inferior connecting rod out next time. We are having an overall inspection for the stock connecting rods now. Once found the inferior ones, we declare them never being used. We take some measures as following for guarantee that we will get the superior connecting rods from now on. Firstly, the purchased blank needs to be overall inspected. The good ones are painted and then they are moved to the processing procedure. Secondly, being strict at selecting the inferior products in the processing procedure, once found, leave them along and never put them into production.
2. The drilling problems are found in the connecting rod model 3-10198922R、2-350-6125-2100-LR and 2-454-6700-2200R. The first problem exists in model 3-10198922R and 2-454-6700-2200R when drillers are drilling the locating hole and the steel hole. The reason might be that the drill did not polished on the right place so that makes the hole overlarge and when the body of rod and the top of rod are got together, the locating hole and steel lagging doesn’t play a role of positioning. The second problem exists in connecting rob model 2-350-6125-2100-LR. The bolt cannot whirl. The main cause is might be the abraded drill did not re-sharp in time and considering the resistance of drill, it shifted. Thus, it caused the deviation of different axiality and verticality oversized in body of rods, screwed holes and locating steel lagging. In order to avoid the problem of whirling problems and the problems mentioned above, our company together with the all technical, managerial personals and operators had a comprehensive communication and decided to take the following measures. First, strengthen the inspection to frock and guarantee the quality of products by frocking precision. Second, strengthen the strict inspection and supervision to drilling processing. Third, restrict the revolving speed and speed rates of drilling machine to operators and guarantee the axiality and verticality for body of rod, the top of rod, screwed holes and locating hole of steel lagging. Fourth, drillers are asked to polish drills so that they could be sharp and cut smoothly. Finally, technical inspector on the spot and operators are required to regularly use the measure gauge to check the size and axiality of screwed hole and locating hole of steel lagging.
3. The main problems for the model 2-ICR5400-927R、2-ICR5700R and 2-454-6800-2200R are the over-tightness or uncleanness in screwed holes, which lead to the bolt getting stuck. Now we need to clean all the connecting rods inside and outside. And then use the bolt made in America to check each piece of bolt of the connecting rod, in order to make sure that every bolt works smoothly. In order to avoid the problems mentioned above, we are going to take these measures. First, strengthen the examination and repair for drilling frock and guarantee the required precision. Second, strengthen the strict inspection to drilling processing, supervise and restrict the speed and feed rates of the drill, and guarantee the axiality and verticality of rods, screwed holes on the top of rods and locating hole of steel lagging. Third, regularly use the measure gauge to check the size and axiality of screwed hole and the locating hole of steel lagging for the sake of preventing thread’s bottom hole to be tight because of its undersize. Fourth, strengthen the strict inspection to screw’s processing. Frequently use the plug thread gauge to check whether the abraded screw taps are replaced. Finally, use the bolt made in America to examine whether every screwed hole of connecting rod is cleaned or not.
4. The problem in model 2-454-6700-2200R and 10256401-3 exists in chamfer oversize and having ripple in bolt base. The main cause for chamfer oversize might as following: First, the carelessness of operators made the machine tool unlimited. Second, overuse and retract slowness. The reasons for causing ripple in chamfer are as following: On one hand, didn’t deal with the hornwork in time. On the other hand, the high the revolving speed of the machine when deal with the chamfer. We are having an overall inspection for the stock connecting rods now. Once found the connecting rods existing in chamfer oversize and having ripple in bolt base, we will reprocess the bolt base. We will adopt the machine limited for the sake of the above problems never appeared. Now we are asking the particular person to take responsibility on the related jobs.
真的累啊,一个上午。希望能够帮到你,谢谢!
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