Quality Management and Quality Control Material...
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Quality Management and Quality Control in the Powder Injection Moulding Process Dr.-Ing. Henri Cohrt Marschallstrasse 2a D-35444 Biebertal Germany terial Engineering nri Cohrt Germany Tel.: +49 151 2290 1386 Fax: +49 6409 804970 [email protected] powdercon Mat Dr.-Ing. Hen
Transcript of Quality Management and Quality Control Material...
Quality Management and Quality Controlin the
Powder Injection Moulding Process
Dr.-Ing. Henri CohrtMarschallstrasse 2aD-35444 Biebertal
Germany
Mate
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Ing
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Germany
Tel.: +49 151 2290 1386Fax: +49 6409 804970
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rtThe powder injection moulding process is widely used to produce highprecision structural parts of very high complexity in shape. The variety ofmaterials ranges from ceramics and hard metals to stainless steels andlow alloyed steels. As a near net shape process the entire process is verycomplex and needs the full attention of all the people incorporated. Theearly design activities are influencing the quality of the final product aswell as the tool design and fabrication, the selection of raw material andbinder system, and all single production steps and the secondaryoperations. For that, a well designed quality management and controlsystem is necessary to control the powder injection moulding process inall the details. Such a system should incorporate a carefully organizedsystematic Failure Mode and Effect Analysis (FMEA). The combination of
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systematic Failure Mode and Effect Analysis (FMEA). The combination ofa high performance process monitoring system with the extensiveapplication of statistical procedures creates the basis for a StatisticalProcess Control (SPC) system that meets all the requirements to producemulti-functional structural parts of high complexity in shape and of highperformance materials. The paper will discuss such a qualitymanagement and control system in detail.
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1. Introduction
2. What is possible
3. Principle problems
4. How to realize improvements with respect to technicalcharacteristics and economy?
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5. Design of a Quality Management system
6. Closing remarks
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Metal / Powder Injection Molding is
the combination of design features of plastic injection molded parts with
the properties of high performance metals, hard metals or ceramics
in a (near)-net-shape process
Characteristics of the Process
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Source: Schunk Sintermetalltechnik GmbH
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1. Introduction
2. What is possible
3. Principle problems
4. How to realize improvements with respect to technicalcharacteristics and economy?
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5. Design of a Quality Management system
6. Closing remarks
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Clamping device for a breaking system ( 3 MIM parts)
Functions
� Guiding
� Adjusting
� Clamping
Functional IntegrationSource: Schunk Sintermetalltechnik GmbH
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� Clamping
� Connecting
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Connector
Reduction of process steps
� Production of a forged and drilled bronze head
� Production of a steel tube
� Production of a spike
Reduction of production stepsSource: Schunk Sintermetalltechnik GmbH
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� Elimination of a bracing operation
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Elimination of electro-erosion machining
Simplification of ProductionSource: Schunk Sintermetalltechnik GmbH
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machining
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Combination of complex shape and high strength steel
Realization of new Design FeaturesSource: Schunk Sintermetalltechnik GmbH
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and high strength steel
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Production quantity of 1,5 Mil.gears per year
Large Scale ProductionSource: Schunk Sintermetalltechnik GmbH
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gears per year
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Wide Range of Secondary Operations Available Source: Schunk Sintermetalltechnik GmbH
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Lever for a sun roof
Substitute for Precision Casting
Substitution of Existing Processes for Economic ReasonsSource: Schunk Sintermetalltechnik GmbH
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Carbonyl IronPowder
Micro-Structure Engineering – Development of Pure Iron Carbon Steel
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25 µm
10 µm
Pure Iron Carbon Steel with 0,6 % C
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12,5 µm10 µm
Carbonyl IronPowder
Chromium Carbide Powder
Micro-Structure Engineering – Development of 100 Cr 6 Bearing Steel
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2,5 µm
100 Cr 6 Bearing SteelAs Sintered
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Inert Gas AtomizedStellite 6 Powder
7,5 µm
Micro-Structure Engineering – Development of Stellite 6 Wear Resistant Steel
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Stellite 6 wear resistant steel
5 µm
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Hardened
Str
ess [
MP
a]
Effect of Heat Treatment on Fe 2.5%Ni 0,6%C Steel
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Total Stain [%]
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Forging,Die CastingPM (Die Pressing)
Metal / Powder Injection Molding(MIM / PIM)
Med
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Hig
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Co
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ity o
f G
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Competition of Processes
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Machining
Precision Casting
Low Medium High
Lo
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Complexity of Geometry
Co
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1. Introduction
2. What is possible
3. Principle problems
4. How to realize improvements with respect to technicalcharacteristics and economy?
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5. Design of a Quality Management system
6. Closing remarks
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rtMetalHard Metal- PowderCeramic-
Organic Binder
MixingHomogenizing and
Granulating
Shaping usingInjection Molding
Removal of Binder
~ 40 vol-%
~ 60 vol-%
Process Schematic
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Sintering
Secondary Operations
Complex Structural PartsReady to Use
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Typical Defects
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Shell-like arranged porosity due to sheer-induced separation processes in the feedstock during mold filling
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(green condition)
De-bound(brown condition)
Typical Defects
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Shrinkage hole due to sheer-induced separation processes in the feedstock during mold filling
(Visualization by means of micro-focus X-raying)
(brown condition)
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Material Specification: AISI 316L
Pla
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[%
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Round Robin Tests (Working Group MIM, Germany 1997)
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Code of Supplier
Pla
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[%
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1. Introduction
2. What is possible
3. Principle Defects
4. How to realize improvements with respect to technicalcharacteristics and economy?
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5. Design of a Quality Management system
6. Closing remarks
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Visualization of Process Optimization by means of Statistical Process Control Procedures
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Test
1E
xtr
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Test
2P
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acu
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Sin
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3P
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acu
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Sin
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Test
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Belt
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Belt
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Dim
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,94
±0
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Comparison of Different De-binding and Sintering Conditions
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Test
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o2 -
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ir ,
N2-P
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Specimen No.
Dim
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,94
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1. Introduction
2. What is possible
3. Principle Defects
4. How to realize improvements with respect to technicalcharacteristics and economy?
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5. Design of a Quality Management system
6. Closing remarks
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Quality Control ���� Quality Management
Quality control means: To find errors.
Quality management means: To avoid errors!
What is the Focus of Quality Management?
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From the economic point of view
avoiding errors has the priority
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Co
st
Co
st
Co
st
Co
st
Co
st
Co
st
Co
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Co
st
Co
st
Co
st
Pro
ce
ss D
esig
n,
Ro
w M
ate
ria
l a
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Eq
uip
me
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Se
lec
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Pro
du
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Pro
ce
ss
Fin
al In
sp
ec
tio
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Sh
ipm
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t to
th
e C
us
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er
As
se
mb
ly a
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In
sta
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tio
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Wa
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Tim
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Aft
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Cost of Quality Control and Lack of Quality
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Cost of QM & QC
Progress of the Process
Cost of QM & QC
Progress of the Process
Cost of QM & QC
Progress of the Process
Cost of QM & QC
Progress of the Process
Cost of QM & QC
Progress of the Process
Cost of QM & QC
Progress of the Process
Cost of QM & QC
Progress of the Process
Cost of QM & QC
Progress of the Process
Cost of QM & QC
Progress of the Process
Cost of QM & QC
Progress of the Process
Ro
w M
ate
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l a
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Eq
uip
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Se
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Wa
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Tim
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DefectQuote
Project Definition
Design &Development
ProductionPlanning
Quality Control
Product inOperation
Defect Generation and Setting of its
Pre-Conditions
Defect Detection
Schedule of Defect Generation and Defect DetectionSource: Deutsche Gesellschaft für Qualität
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Course of Life CycleGeneration of
75 % of Defects
Detection of
80 % of Defects
Mate
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���� Organization + Documentation
���� Manufacturing + Control Resources
���� Personnel + Training
How to realize a Quality Management System
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A Quality Management system should be regarded
as a tool for a
never ending improvement
of the
Metal / Powder Injection Molding Process
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Strategy
GuidanceAnalysisCustomer
Satisfaction
The Nature of a Quality Management System
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Control
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Definition of Quality
Description of the Product and the Process
Process Analysis FMEA, 6 Sigma …
Prototype Production
Revised Product and
Quality ManagementHandbook
Process Instructions
Working Instructions
Inspection of the Quality Management Systemby means of
Development of a Quality Management System for the MIM/PIM Process
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Revised Product andProcess Description � Internal Audits
� External Accredited Certification Authority e.g. in accordance to EN ISO 9001 - 2000
� Customers
Start Production
Results fromQualityControl
Activities
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Weighting Factors
Potential consequence Potential DefectPotential Cause
of the DefectPreventive
Action
Testing Procedures
In-correct dimension
Wrong feedstockcomposition
Defective scale
Preventive calibration
Density measurement of feedstock
In-correct dimension
Wrong sintering Furnace setting
Training of operator
Comparison of furnace setting with process documentation
Checklist (working instruction)
7 4 3 84
FMEA-Form according to Deutsche Gesellschaft für Qualität
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Weighting Factors
Risk Priority Number
RPZ = B x A x E
instruction)
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A - Probability of occurrence of a defect
���� 1 unlikely, ���� 2 to 3 very low���� 4 to 6 low���� 7 to 8 medium
B – Impact, that means the effect on the customer
���� 1 hardly observable���� 2 to 3 inconsiderable or less disturbance���� 4 to 6 low disturbance���� 7 to 8 high impact, e.g. stop of production���� 9 to 10 very high impact, e.g. risk for human beings
Weighting Factors
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���� 7 to 8 medium���� 9 to 10 high
E – Probability of detection before shipment to the customer
���� 1 high���� 2 to 5 medium���� 6 to 8 low���� 9 very low���� 10 unlikely
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Medium Priority
Highpriority
Lowpriority
Very high priority
The Risk Priority Number is calculated by multiplying the Weighting Factors
RPZ = B x A x E
From the RPZ the priorities of actions are given by the following schema:
The interpretation of the Risk Priority Number
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125 500
Risk Priority Number
1 1000
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Maesure
men
t
20
30
40
50
60
Upper Control Limit (Mean plus 2σσσσ)
Mean
Upper Specification (Mean plus 3σσσσ)
Internal Spezification
External Specification(tolerance band according to technical drawing)
Design of a Quality Control Card
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Sample No.
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115
0
10
Lower Specification (Mean minus 3σσσσ)
Lower Control Limit (Mean minus 2σσσσ)
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Improvement of Process Capability by means of Statistical Process Control(SPC)
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Archer 1
Archer 2
Archer 3
Archer 3
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Dust Humidity
Temperature
Problems
Human Beings
Education
Private
Job-Related
Material
Mechanical Properties
DimensionsScattering
Surface
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Environment
Temperature
Machine
Cleaning
Tooling
MaintenanceMethods
ProcessOrganization
Workflow
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Machine / Process Capability
Approval for Serial Production
Long Term Validation of Machine / Process Capability
Focus on
���� Human Beings���� Machine���� Material���� Methods���� Environment
To beSubjected to a
Process of Permanent Improvement
Machine Capability
De
ve
lop
me
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an
dTe
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Pro
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Se
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Process Evaluation and Validation
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Machine Capability
Process oriented,but, min. 50 measurements
���� Result: Cm and Cmk
Process Capability
Adequate long period of time under normal conditions of serial production to secure that all quality affecting circumstances can become effective.Recommendation: min 125 single parts in 3 to 5 control samplesbetter is 20 Production days
Result: Cp and Cpk
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Pre-Alloyed PowderPowder Composition
Binder or Components of
Binder
RecycledFeedstock
(Gating Material)
Metering Out
PropertiesProduction Data
Working Instructions���� Handling���� Storing Conditions
Working Instructions
Mixing and Homogenization
Working Instructions
Documentation related to Feedstock Preparation
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Granulation Working Instructions
Feedstock Characterization
PropertiesProduction Data
Working Instructions
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1. Introduction
2. What is possible
3. Principle Defects
4. How to realize improvements with respect to technicalcharacteristics and economy?
Content
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5. Design of a Quality Management system
6. Closing remarks
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� The Basics of the MIM / PIM process are well understood
� There are many different process routes available with respect to���� raw material selection���� binder selection and binder composition���� feedstock production���� de-binding processes���� sintering processes
� In the mean time a lot of measurement technologies have been developed to control the raw materials and feedstock characteristics in principle
� also the basics of the two-phase-flow-mechanics are available
� the electronically controlled injection molding machines allow highly sophisticated control of
Closing Remarks
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� the electronically controlled injection molding machines allow highly sophisticated control of the molding process
� there are also highly sophisticated furnace systems available to control the de-binding and sintering processes
� But nevertheless, very small scattering in the very complex system of a huge number of independent parameters have in special situations dramatic effects on the result of the entire MIM / PIM process and are causing big problems with respect to the quality of the product.
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� the interdependences between the single, at the first glance independent process parameter are not very clear and cannot be descript precisely enough to make MIM / PIM a fully automated process.
� MIM / PIM still needs highly experienced operators to make the process successful.
� A well designed Statistical Process Control system combined with an excellent Quality Management system is necessary to produce
multi-functional, complex shaped structural parts of high performance materials
Consequences
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multi-functional, complex shaped structural parts of high performance materials
in high quantities in an economic way
utilizing the
Metal / Powder Injection Molding Process
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CO2 De-binding
Final de-binding and sintering in one Furnace
1.175 €
Pre-de-binding in air Final de-binding and sintering in one Furnace
1.250 €
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Economic Comparison of Different Processes - ideal Conditions and comparable Capacities (especially quality issues are not regarded)
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Pre-de-binding in air Final de-binding on N2 Sintering in Vacuum
1.550 €
Process Time [h]
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