دانلود کتاب Total Quality Process Control for Injection Molding (Wiley Series on Polymer Engineering and Technology)

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Total Quality Process Control for Injection Molding: Second Edition......Page 2
Contents......Page 8
Preface......Page 20
1: Total Quality Process Control......Page 22
ISO 9001......Page 23
ESTABLISHING PROCESS OWNERSHIP......Page 26
IDEAS AND METHODS......Page 34
2: Implementing Total Quality Process Control (TQPC)......Page 36
QUALITY IMPROVEMENT PLAN......Page 38
CONTROLLING THE PROCESS......Page 40
CP THE CONTROL OF OPERATIONS......Page 41
CPK-CENTERED PROCESS CONTROL......Page 44
ESTABLISHING COMPANY QUALITY OBJECTIVES......Page 46
CUSTOMER QUALITY......Page 48
OBJECTIVES FOR MANAGING A QUALITY SYSTEM......Page 49
PROACTIVE PREVENTIVE ACTION......Page 50
Attitude......Page 51
Control of Change......Page 53
Improvement with Control of Change......Page 54
OBJECTIVES FOR MANAGING A QUALITY SYSTEM......Page 55
Parts to Print......Page 57
FORM, FIT, AND FUNCTION (FFF)......Page 60
EXISTING MOLD CONSIDERATIONS......Page 61
ESTABLISHMENT OF RESPONSIBILITY......Page 63
DEPARTMENT TQPC RESPONSIBILITY......Page 65
Program Development......Page 66
ESTIMATED PIECE PART PRICE......Page 67
MANUFACTURING CAPABILITY......Page 69
COMPUTER-INTEGRATED MANUFACTURE (CIM)......Page 70
EDI......Page 73
CONTROL OF OPERATIONS......Page 74
CONTROL CHARTING......Page 75
PROGRAM MONITORING — COMMUNICATION......Page 78
COMMUNICATIONS......Page 79
SURVEYS......Page 80
QUALITY FUNCTION DEPLOYMENT (QFD)......Page 82
QFD IN OPERATION......Page 83
CUSTOMER FEEDBACK......Page 84
CRITICAL TO QUALITY (CTQ)......Page 87
CHECKLISTS......Page 88
FISHBONE ANALYSIS......Page 90
FAILURE MODE AND EFFECTS ANALYSIS......Page 91
TYPES OF FMEAs......Page 92
FMEA TIMING......Page 94
FMEA DEVELOPMENT......Page 95
4: Customer Satisfaction......Page 100
VENDOR SELECTION......Page 101
VENDOR SURVEY......Page 102
CUSTOMER AND SUPPLIER AGREEMENTS......Page 103
PRODUCT REQUIREMENTS......Page 104
Contract Checklist......Page 105
5: Organization Responsibilities......Page 107
QUALITY OPERATIONS......Page 110
COMPLIANCE AUDITS......Page 112
SIX SIGMA INTRODUCTION......Page 113
PROCEDURE......Page 114
QUALITY PROBLEMS......Page 115
TQPC MANAGEMENT OPERATIONS......Page 117
PREVENTIVE ACTION......Page 124
6: Establishing the Limits for Quality Control......Page 126
TAGUCHI METHODS......Page 129
PROTOTYPING......Page 130
MOLD LIMITS......Page 132
MATERIAL SELECTION......Page 135
CALCULATION OF PLASTIC PART COST......Page 136
ESTIMATING PART CYCLE TIME......Page 137
MOLD PART CAVITY ESTIMATION......Page 139
INJECTION MOLDING MACHINE SELECTION......Page 140
MELT GENERATION......Page 142
MACHINE HOURLY RATE......Page 143
MACHINE SETUP CHARGES......Page 145
CALCULATING PRODUCT MANUFACTURING COST......Page 147
ESTABLISHING MANUFACTURING LIMITS......Page 150
IN-PROCESS INSPECTION......Page 152
ESTABLISHING TOTAL QUALITY PROCESS CONTROL......Page 153
ACCEPTABLE QUALITY LIMITS......Page 155
7: Material Selection and Handling......Page 156
THERMOSETS......Page 157
Crystalline Plastics......Page 158
PRODUCT CERTIFICATION......Page 159
MATERIAL SPECIFICATION......Page 161
INCOMING MATERIAL TESTING......Page 164
Types of Tests......Page 165
Analyzing the Tests......Page 166
Differential Scanning Calorimeter......Page 167
Thermogravimetric......Page 170
Gel Chromatography......Page 171
Test Methods......Page 174
RECORD ACCURACY......Page 184
BAR CODING: AN AID IN TOTAL QUALITY PROCESS CONTROL......Page 185
MATERIAL HANDLING AND STORAGE......Page 186
REGRIND USAGE......Page 187
PROCESSING AIDS......Page 189
8: The Mold......Page 190
COMPUTER-INTEGRATED MANUFACTURE......Page 191
Part Design......Page 193
Molding Machine Compatibility......Page 194
Fluid Flow in Mold......Page 195
Heat Transfer......Page 196
Abrasion Resistance......Page 197
Draft and Shut-off......Page 198
Part Drawings and Dimensional Stackup......Page 200
Maintenance/Repair/Operation......Page 201
Methods of Construction......Page 202
Reviewing Existing Tooling......Page 203
Prototype Tooling......Page 204
Production Tooling......Page 205
Pricing the Tool......Page 211
Tool Steel Selection......Page 213
Corrosion and Abrasion Resistance......Page 216
Thermal Conductivity......Page 217
Cavity Forming and Finishing......Page 219
Electric Discharge Machining......Page 220
Texturing......Page 224
Part Layout......Page 227
Cavity Selection Based on Molding Machine Size......Page 229
Mold Cavity Layout......Page 231
Runner System Design......Page 233
GATING THE PART......Page 236
Material Shrinkage......Page 237
Gate Location......Page 238
Gate Type......Page 241
Gate Control of Weld Lines......Page 244
Sprue Bushing and Nozzle Seating......Page 247
Complex Parting Line......Page 249
Side-Action Core Pull......Page 251
Delayed Side-Action Core Pull......Page 252
Slide Retainers......Page 253
Wedge Action Core Pull......Page 254
Unscrewing Cores......Page 255
PART EJECTION......Page 256
VENTING THE CAVITY......Page 258
Cavity Considerations......Page 263
Passive Vents......Page 264
CORE VENTING......Page 265
Insulating the Mold for Temperature Control......Page 266
Mold Temperature Control......Page 267
Cavity Temperature Control......Page 271
Cooling System Layout......Page 272
Core Cooling......Page 273
Coolant Channel Seals......Page 276
Mold Connection Types......Page 278
Cooling Time......Page 279
MOLD SHRINKAGE......Page 280
Post-Mold Shrinkage......Page 282
Calculating and Estimating Part Shrinkage......Page 285
Determining Cavity Dimensions......Page 288
HOT-RUNNER MOLDS......Page 292
Processing for Hot-Runner Molds......Page 293
MOLD MAINTENANCE......Page 299
MACHINERY SELECTION......Page 306
PROCESS CONTROL......Page 307
ELECTRIC INJECTION MOLDING MACHINES......Page 308
INJECTION MOLDING MACHINE NOMENCLATURE AND OPERATION......Page 309
RECIPROCATING SCREW INJECTION MOLDING MACHINE......Page 310
Injection Molding Cycle Operations......Page 311
Resin Melt Shot Capacity......Page 312
Machine Melt Plasticizing Capability......Page 313
Injection Rate and Pressure......Page 314
Back Pressure......Page 315
Injection Molding Cycle......Page 316
THE INJECTION MOLDING MACHINE......Page 318
The Barrel and Screw Assembly......Page 319
The Reciprocating Screw......Page 320
Nonreturn Valves......Page 326
Screw Tip......Page 328
Nozzles......Page 330
SELECTING BARREL HEATER CONDITIONS......Page 332
THERMOCOUPLES......Page 333
Hydraulic Clamp......Page 334
Toggle Clamp......Page 336
VENTED-BARREL MACHINES......Page 338
Preventive Maintenance......Page 342
Maintenance Checklist......Page 345
10: Auxiliary Equipment......Page 347
MATERIAL FEEDERS AND BLENDERS......Page 348
AUTOMATIC SYSTEM......Page 349
CENTRAL SYSTEMS......Page 350
MATERIAL FEED TO THE INJECTION MOLDING MACHINE......Page 352
MATERIAL BLENDING AT THE HOPPER......Page 353
COLOR CONCENTRATE BLENDING......Page 354
MATERIAL DRYING......Page 355
Material Drying Systems......Page 356
Dryer Analysis......Page 358
Material Drying......Page 360
Dryer Bed Analysis......Page 361
Desiccant Bed Analysis......Page 364
Dryer Problem Checklist......Page 366
Chiller Systems......Page 367
Mold Temperature Controllers......Page 371
Chiller Types......Page 372
Temperature Setting......Page 373
Maintenance Checks......Page 374
GRANULATORS OR GRINDERS......Page 376
Granulator Selection......Page 378
Press-Side Granulator......Page 379
Granulator Problems and Maintenance......Page 380
PART REMOVAL, CONVEYOR SYSTEMS, AND ROBOTS......Page 381
Conveyor and Part Separator Systems......Page 383
Robot Part Handling......Page 386
QUALITY INSPECTION EQUIPMENT......Page 387
QMC Requirements......Page 390
Implementing QMC......Page 391
PRODUCTION STARTUP FOR PROCESS CONTROL......Page 399
ACCEPTABLE QUALITY LEVEL LIMITS......Page 400
NETWORKING PRODUCTION......Page 403
THE INJECTION MOLDING PROCESS......Page 404
Mold Startup Procedure......Page 405
Setup Operator Responsibilities......Page 406
INJECTION MOLDING STARTUP......Page 410
Startup Procedure......Page 413
Shut-Down Procedure......Page 418
Plant Environment......Page 421
Cooling Systems......Page 422
Housekeeping......Page 423
Pyrometers for Temperature Readings......Page 424
Resin Melt Temperature......Page 425
FINE TUNING THE CYCLE......Page 426
Control by Part Weight......Page 427
REGRIND EFFECTS ON PART QUALITY......Page 428
DETERMINING THE MISSING VARIABLE......Page 429
PROCESS CONTROL CHARTING......Page 431
Manufacturing Limits......Page 432
Control Charts......Page 433
Measurement-Process Control-Chart Calculations......Page 434
Percent Control Chart Formulae......Page 443
Control Limit Calculations for Measurement Data......Page 444
MAINTAINING PROCESS CONTROL......Page 445
Precontrol......Page 446
Taking Measurements......Page 449
Shot-to-Shot Variations......Page 450
Cavity Melt Pressure Control......Page 458
PROCESS LINE INTEGRATION......Page 461
Process line Integration Benefits......Page 463
Process Line Integration Scheduling......Page 464
Selecting a System......Page 465
SELECTING THE TEST......Page 467
DESTRUCTIVE TESTS......Page 469
Gardner “Ball Drop” Impact Test......Page 470
Optical Comparators......Page 471
Polarized Light......Page 472
Aesthetic Part Checking......Page 473
Color Checks......Page 475
CONDITIONED PARTS......Page 478
PLANNING......Page 480
PART REMOVAL......Page 482
AUTOMATIC PART PACKAGING......Page 484
ROBOTS......Page 486
SELECTING THE CORRECT DESIGN PARAMETERS......Page 488
MATERIAL SELECTION......Page 489
PART DESIGN FOR END-USE APPLICATIONS......Page 490
Radii......Page 491
Nonuniform Part Thickness......Page 495
Ribs for Strength and Quality......Page 499
Weld-Line Considerations......Page 501
Surface Appearance Problems......Page 505
Bosses......Page 506
THREADS......Page 508
UNDERCUTS......Page 511
INSERTS......Page 514
INSERT LOADING......Page 516
INTEGRAL HINGES......Page 518
PLAN FOR ASSEMBLY......Page 520
AUTOMATED ASSEMBLY......Page 521
ASSEMBLY TECHNIQUES......Page 522
Press Fits......Page 523
Snap Fit......Page 524
Welding Assemblies......Page 527
Focused Infrared Melt Fusion......Page 550
Cold or Hot Heading......Page 552
Mechanical Fasteners......Page 554
Adhesive and Solvent Bonding......Page 559
CONTROL OF THE PROCESS......Page 564
DECORATING TECHNIQUES......Page 565
SURFACE PREPARATION......Page 566
MOLDED COLORS......Page 568
PAINTING......Page 573
Paint Systems......Page 574
Part Cleanliness......Page 576
Part Paint Specifications......Page 577
Graphics......Page 578
Pad Printing......Page 579
Hot Stamping......Page 580
TWO-SHOT MOLDING......Page 583
IN-MOLD DECORATING......Page 585
VACUUM METALLIZING......Page 586
ELECTROPLATING......Page 589
GRAVURE DECORATING......Page 591
17: Customer and Employee Satisfaction......Page 594
QUALITY AWARENESS......Page 595
Appendix A: Quality Management System (QMS) Control of Documents Procedure......Page 597
Appendix B: Design of Experiments (DOE): Statistical Troubleshooting Process Screening for Reducing the Number of Variables......Page 600
Appendix C: Checklists......Page 614
Appendix D: Supplier Evaluation Survey......Page 684
Appendix E: Mold Problem Solutions......Page 696
Appendix F: Decoration and Information on Parts......Page 704
Glossary......Page 713
Bibliography......Page 752
Index......Page 761