三大汽车公司冲压工艺分析报告

AKSteelCorporationBethlehemSteelCorporationDaimlerChryslerCorporationDofascoInc.FordMotorCompanyGeneralMotorsCorporationIspat/InlandInc.LTVSteelCompanyNationalSteelCorporationRougeSteelCompanyStelcoInc.U.S.SteelGroup,aUnitofUSXCorporationWCISteel,Inc.WeirtonSteelCorporationAuto/SteelPartnershipThispublicationwaspreparedby:BodySystemsAnalysisProjectTeamTheAuto/SteelPartnershipProgram2000TownCenter,Suite320Southfield,Michigan48075-1123248.356.8511fax:AnAnalysisofStampingProcessCapabilityandImplicationsforDesign,DieTryoutandProcessControlAuto/SteelPartnershipProgramBodySystemsAnalysisProjectTeam2000TownCenter-Suite320Southfield,MI48075-11232000Auto/SteelPartnershipAKSteelCorporationBethlehemSteelCorporationDaimlerChryslerCorporationDofascoInc.FordMotorCompanyGeneralMotorsCorporationIspatInlandInc.LTVSteelCompanyNationalSteelCorporationRougeSteelCompanyStelcoInc.U.S.SteelGroup,aUnitofUSXCorporationWCISteel,Inc.WeirtonSteelCorporationThispublicationisforgeneralinformationonly.Thematerialcontainedhereinshouldnotbeusedwithoutfirstsecuringcompetentadvicewithrespecttoitssuitabilityforanygivenapplication.ThispublicationisnotintendedasarepresentationorwarrantyonthepartofTheAuto/SteelPartnership–oranyotherpersonnamedherein–thattheinformationissuitableforanygeneralorparticularuse,orfreefrominfringementofanypatentorpatents.Anyonemakinguseoftheinformationassumesallliabilityarisingfromsuchuse.ThispublicationisintendedforusebyAuto/SteelPartnershipmembersonly.Formoreinformationoradditionalcopiesofthispublication,pleasecontacttheAuto/SteelPartnership,2000TownCenter,Suite320,Southfield,MI48075-1123orphone:248-945-7777,fax:[phone],website::Part-to-Part,Run-to-Run,andBegin-EndofRun...................................253.2.5SteelPropertiesandPressSetupControlandStampingVariation..273.2.6EffectofMeanShiftsonStatisticalProcessControlTechniques....294.0ToleranceConsiderations.............................................344.1Tolerances....................................................344.2CpandCpk(PpandPpk).........................................344.3RecommendedTolerancesforSheetMetal............................354.4PartTolerancesandFunctionalBuild................................365.0ConclusionsandSummary............................................37AppendixA-PartSketchesbyCompany..........................................39iiiivListofFiguresFigure1.BodySideComponentsChosenforCompanyC...........................4Figure2.ComponentsofVariation.............................................7Figure3.PotentialSourcesofStampingVariation..................................8Figure4.TotalVariationPartitionedintoComponents...............................9Figure5.BodySideOuterforCompanyA:12MeasurementLocations.................12Figure6.HistogramofMeanValuesacross5PartsforCompanyC....................15Figure7.MeanConformance:Rigidvs.Non-RigidPanels...........................15Figure8.MeanConformance:Two-PieceBodySidePanelvs.One-Piece...............16Figure9.CorrelationofMeanatPartApprovalvs.Production.........................19Figure10.EffectofStampingMeanShiftonBodySideAssembly......................20Figure11.AverageVariation(StandardDeviation)byTypeofPart......................23Figure12.Part-to-PartVariation:HomeLineTryoutApprovalvs.Production,byDimension...24Figure13.ComponentsofVariationforBodySidePanelatCompanyCandC