PFMEA of Die casting Process--Help needed?

T

tk5013

#1
Hi all,

I am doing my project in PFMEA of Aluminium Die casting process.

Details:

Process-Aluminium- High pressure-Cold Chamber Die casting

Process flow:​

1) Raw material melting
2) Metal Pouring
3)Injection
4)Solidification
5)Casting Extraction
6)Die coat Spray
7)Runner Breakage
8)Trimming
9)Fettling
10)Inspection

From the last six month data ,we collected the various type of defects

Defects in the order of occurrence (High to low)

Blowholes
Poorflow
Casting Damage
White rust
Trimming Damage
Insert Blowholes
Bubbles
Airholes
Leakage(oil)
Unwash
Gate area Deep Broken

The doubts i have in mind are

i) Is Defect a Failure Mode
ii) If yes, Which defects mentioned above are failure modes to be considered for Process FMEA
iii) After identifying failure mode, how to identify the effect and cause
iv) i have little knowledge about casting process. pls specify the Potential effect and causes for the above defects
v)How can i assign severity for above defects
vi)can i use the past data to decide the severity level and occurrence


Pls explain me in detail


Thanks in advance

Karuna
 
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Marc

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#2
Can anyone help with this one? My Thanks in advance!
 
B

Bill Mitchell

#3
I personally cannot help but luckly I have a great team of Technical Experts. I will forward this to them and get some feedback for you. We have a a large background in PFMEA's so I am sure we can help.
 
B

Bill Mitchell

#4
Hi all,

I am doing my project in PFMEA of Aluminium Die casting process.

Details:

Process-Aluminium- High pressure-Cold Chamber Die casting

Process flow:​

1) Raw material melting
2) Metal Pouring
3)Injection
4)Solidification
5)Casting Extraction
6)Die coat Spray
7)Runner Breakage
8)Trimming
9)Fettling
10)Inspection

From the last six month data ,we collected the various type of defects

Defects in the order of occurrence (High to low)

Blowholes
Poorflow
Casting Damage
White rust
Trimming Damage
Insert Blowholes
Bubbles
Airholes
Leakage(oil)
Unwash
Gate area Deep Broken

The doubts i have in mind are

i) Is Defect a Failure Mode
ii) If yes, Which defects mentioned above are failure modes to be considered for Process FMEA
iii) After identifying failure mode, how to identify the effect and cause
iv) i have little knowledge about casting process. pls specify the Potential effect and causes for the above defects
v)How can i assign severity for above defects
vi)can i use the past data to decide the severity level and occurrence


Pls explain me in detail


Thanks in advance

Karuna
Hi:

I received a quick response from our technical person. Just so you are aware this individual has a backgroud in COre Tools and PFMEA. He has provide training and consulting to all big automotive companies.

Per his feed back: No this is not and effective PFMEA The process flow is not detailed enough to determine failure nodes. For example Injection has 4 to 8 steps in the process. These need to be included to review potential risk and failure.

In comparison t a plasitc mold injection process a PFMEA generally includes up to 60 steps.

Defects are not Failure modes and relate more to how they affect the customer.

This is a brief response and I hope it helps. Generally what you are asking is a 2 day class and would be impossible to relay on a blog.
 
B

Bill Mitchell

#5
My technical person just sent this over. He has added some feedback into the original post.

Hi all,

I am doing my project in PFMEA of Aluminium Die casting process.

Details:

Process-Aluminium- High pressure-Cold Chamber Die casting


Process flow:
Process flow is not detailed enough. Each process step must be defined and the specific requirements of the step then determined. Once the requirement is determined, the failure mode is the negative of the requirement. For example:

Step Requirement Potential Failure Mode
Pour melted material Pour at a rate of XX per minute Material not poured at a rate of XX per minute



1) Raw material melting
2) Metal Pouring
3)Injection
4)Solidification
5)Casting Extraction
6)Die coat Spray
7)Runner Breakage
8)Trimming
9)Fettling
10)Inspection


From the last six month data ,we collected the various type of defects

Defects in the order of occurrence (High to low)

Blowholes
Poorflow
Casting Damage
White rust
Trimming Damage
Insert Blowholes
Bubbles
Airholes
Leakage(oil)
Unwash
Gate area Deep Broken

The doubts i have in mind are

i) Is Defect a Failure Mode – No defects relate more to the effect. A failure mode is related to the process
ii) If yes, Which defects mentioned above are failure modes to be considered for Process FMEA
iii) After identifying failure mode, how to identify the effect and cause – The effect is what the customer would experience assuming the failure mode occurred. Causes can be determined using many different tools, cause and effect analysis being a key tool.
iv) i have little knowledge about casting process. pls specify the Potential effect and causes for the above defects – Response beyond the scope of this email. We can do this as part a an FMEA coaching / consulting project.
v)How can i assign severity for above defects – based on how the effect impacts the customer
vi)can i use the past data to decide the severity level and occurrence – It can be helpful with effects but it has more of a relationship with occurrence depending on the type of data.
 
T

tk5013

#6
Hi all,

Thanks for your reply.I'm really grateful to you all.

I got the process steps from the control plan

Raw material Testing

Ingot / Runner mixing

Pre heating of Dies

Plunger limit switch position.

Pressure setting

Operation cycle setting

Oil temp

Die temp

Dycote mixing

Spraying

Molten metal Cleaning

PDC Process inspection

Runner breaking

Fettling

Visual inspection

Vacuum Impregnation

Casting Identification

Final inspection

Packing & Dispatch



Hope its perfect.

Can anyone list some potential failure modes for the above process and its effects.

Thanks in advance
Karuna
 
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