NAVISTAR TMS 9523-2006 Development and Quality Control Procedures for SMC - FRP Parts.pdf

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1、INTERNATIONAL TRUCK AND ENGINE CORPORATION TMS (TRUCK MATERIAL SPECIFICATION) NUMBER: TMS-9523 TITLE: Development and Quality Control Procedures for SMC FRP Parts REVISION: D WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering DATE ISSUED: August 2006 PRINTED COPIES OF THIS D

2、OCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and

3、 to determine the applicability of regulatory limits prior to use. Change Notice: Added Sections 2.1 and 8.0; revised Sections 3.0 and 6.1. Reference: File 30-14A Keywords: SMC, FRP, plastic panels, SMC plastic, plastic parts. 1.0 APPLICATIONThis specification is applied to aid in controlling proced

4、ures used to develop critical parts molded from SMC reinforced plastics specified as per International CEMS D-22. Parts, such as tilt hoods, cowl panels, and heater cases, are typical applications. The objective of this specification is to control material flow, and the physical and mechanical prope

5、rties developed in the prototype parts and insure reproducibility between the prototype, qualification, and production SMC/FRP parts. 2.0 SCOPE This specification covers the production process data, test analysis data, and sample parts that the molder is required to submit. Requirements for Quality

6、Control of production parts are also covered. 2.1 Restricted Chemical SubstancesEffective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the CEMS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest i

7、ssue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 INTERNATIONAL CEMS D-22 International IQR Quality Standard INTERNATIONAL TMS-9012 CFR Title 29, Part 1910 INTERNATI

8、ONAL CEMS DT-14 INTERNATIONAL CEMS B-50 4.0 GENERAL REQUIREMENTSBefore production approval is granted, all parts shall be functionally tested by the TDTC Technical Development Group. The molder shall supply parts for such tests based on materials and manufacturing processes that can be routinely use

9、d on a production basis. The minimum process and test data to be supplied with test/prototype parts is indicated below. 4.1 SMC Material A complete description of the SMC material(s) used in the part shall be provided. This shall include the molders compound number; the type and percentage by weight

10、 of the resin, glass, and filler; and the viscosity of the system. Tolerances or process control limits for these factors shall be included. This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical St

11、andards. Suppliers are required to assume all patent liability. 2006 International Truck and Engine Corporation AUGUST 2006 Page 1 of 4 2NUMBER: TITLE: Development and Quality Control Procedures REVISION: TMS-9523 for SMC-FRP PartsD This document is restricted and may not be sent outside Internation

12、al Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2006 International Truck and Engine Corporation 4.1.1 SMC Material Properties Physical property data for the SMC material(s) (flat panel data) w

13、ill be submitted. Specific details of properties to be reported will be agreed upon between TDTC Materials Engineering and the supplier. 4.2 Charge Pattern A drawing of the charge pattern showing the number of plies, the charge weight, and the dimensions of the charge, will be provided. 4.3 Molding

14、Conditions A description of the molding conditions will be provided This shall include the mold temperatures (core and cavity), press closure speed, cycle time (time mold is closed) and tonnage exerted on the mold during closing. 4.4 Glass PatternPhotographs of a burn-off or an X-ray of the entire p

15、art clearly showing glass pattern will be provided. Identification of severe flow or knit line conditions shall be shown. 4.5 Molded Part PropertiesPhysical properties of the molded part as per Navistar Spec. D-22, at locations indicated on the part drawing will be provided. 4.6 Functional TestingFu

16、nctional testing will be performed by TDTC Technical Development Group. If the functional tests show deficiencies in the molded parts, the molder will be asked to alter or modify the material and/or production process. If material and/or process changes are made, the molder shall resubmit new parts

17、for retesting and provide new process/test data as required by Section 4 of this specification. 4.7 Class A Exterior SurfacesParts considered to be Class A, produced with IMC as per TMS 9012, shall have a surface reading of 100 maximum on the Loria scale as per CEMS DT-14. Examples of such parts are

18、 hood skins, fender extensions and sunshades. The readings shall be taken from a flat section of the part, away from edges, ribs, bosses etc. on an unpainted surface. Material may be qualified for this criterion from flat panels. This testing will be in accordance with International CEMS Test Method

19、 DT-14. Results of this qualification will be included in the Pre-Production Part Approval package submission to TDTC Materials Engineering. 4.7.1 Initial Submissions The Loria test method (DT-14) is intended for initial submissions only, e.g. new material qualifications or PPAP packages. This quali

20、fication standard is not meant to be an ongoing test requirement. Once certified, the material shall be considered approved for surface. Any changes to the material formulation or manufacturing process would require another Loria submission. 4.7.1.1 Molding Tool/DiesOn initial submissions for part q

21、ualification, data on the molding tool surface finish will be provided with the Loria test results. 4.8 Pre-Production Part ApprovalPre-production approval of all parts referencing this specification is required prior to acceptance of PPAP or production parts. Approval of the parts shall be in writi

22、ng from TDTC Materials Engineering to the supplier, to International Purchasing and Supplier Development, and to the International assembly plants involved. AUGUST 2006 Page 2 of 4 3NUMBER: TITLE: Development and Quality Control Procedures REVISION: TMS-9523 for SMC-FRP PartsD This document is restr

23、icted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2006 International Truck and Engine Corporation 4.8.1 Additional Material/Process Information The s

24、upplier shall submit additional information, as necessary, to satisfy the objective of this specification. Information provided by the vendor to International per this specification shall be considered confidential. Distribution shall be restricted to appropriate TDTC Materials Engineering, Purchasi

25、ng, and International Quality Control personnel. 5.0 QUALITY After approval of the molders material and process, all parts must be produced exactly as described by the above procedure. No changes will be allowed without written approval of the Truck Development and Technology Center (TDTC). Field fa

26、ilures caused by unapproved changes in m rials or process shall be the sole responsibility of the molder. ate6.0 SOURCE APPROVAL AND QUALITY CONTROL6.1 Supplier RequirementsAll suppliers to International Truck and Engine are required to be registered to ISO 9001 Quality System Requirements. Internat

27、ional will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificate

28、s to their International Corporate Buyer upon request. 6.2 ApprovalParts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples which were approved by the purchaser. No changes in formulation or processing practices are permitted

29、without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify Materials Engineering at TDTC and International Purchasing and Supplier Development of the proposed change(s). Test data

30、indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 6.3 Process ControlThe supplier shall either perform and repo

31、rt results of tests on specific lots of parts produced or provide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier, Materials Engineering and/or the quality control manager of the

32、 using International plant may determine testing and reporting requirements on specific products. 7.0 DESIGNATION ON DRAWINGS This specification is applied to parts by the addition of a material note as follows: “Material and Process as per TMS 9523” AUGUST 2006 Page 3 of 4 4NUMBER: TITLE: Developme

33、nt and Quality Control Procedures REVISION: TMS-9523 for SMC-FRP PartsD This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2006

34、International Truck and Engine Corporation 8.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Suppliers may obtain copies of this specification by contacting: Materials Engineering and Technology Dept. Truck Development and Technology Center 2911 Meyer Road Fort Wayne, IN 46803 E-mail:MaterialsEngineeringNav-I Global Engineering Documents 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/AUGUST 2006 Page 4 of 4