金属加工液常见问题分析.pdf

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1、TROUBLESHOOTINGVIATHEFISHBONEDIAGRAMMETHOD鱼骨图法用于分析金属加工冷却液常见问题WhatareFishboneDiagram?何为鱼骨图?TheFishboneDiagramisatoolusedtosystematicallyinvestigatepossiblecausesofproblems.Theonesincludedinthismanualcovers8problemscommoninwater-basedmetalworkingcoolant

2、applications.作为分析问题的工具,鱼骨图法可以系统地分析问题的成因.本介绍主要就冷却液使用和维护过程中常见的八种现象运用鱼骨图法加以分析.>Odors异味>Dermatitis皮肤接触炎症>Foam泡沫>PoorToolLifeorFinish非正常加工刀具使用寿命或加工工件表面质量下降>Rust工件绣蚀>HighCoolantConsumption高冷却液消耗>UnacceptableResidues工件或刀具表面残留物>ChangeinpH冷却液酸碱度变化Whenconfronte

3、dwithoneoftheseproblems,workyourwaythroughtheFishboneDiagramthataddressesit.Youwillidentifythesourceoftheproblembyaskingquestionsandeliminatingpotentialcausesthatdonotapplyinyourparticularcase.对于实际发生的问题可以参照相对应的鱼骨图逐项查找原因.在应用现场,通过提问的形式排除法找出问题之所在.HowdoIu

4、seFishboneDiagrams?如何运用鱼骨图?1.Findthediagramthataddressestheproblem.Thenameoftheproblemisprintedatthe“head”ofthefish(rightsideofthepage).找出于现场问题相对应的分析图.问题标注在“鱼骨顶部“(图形右侧).2.Lookatthe“ribs”protrudingfromthespineofthefish.Theseconditionscommonlycontribute

5、totheproblem.Eachriblistsseveralvariablesthatshouldbeinvestigated.逐项研究由鱼主椎骨分离出的斜骨.每一斜骨都可能是造成问题的原因.在每一斜骨上给出的参数和变量应当进行详细的研究.3.Movedownthefishbonefromheadtotail(righttoleft)addressingeachconditioninsequence.Theconditionsarelistedwiththemostcommoncausessh

6、ownclosesttothehead.Allvariablesmustbeinvestigatedanddeterminedtobeincontrolorinneedofcorrection.将可能产生的原因从头到尾逐相分析.通常容易出现的原因有目的的放在靠近鱼头的位置.所有列出的原因和变量必须加以研究以达到有效控制和对出现问题的及时修正.材料问题SUBSTRATE冷却液产品PRODUCTLowConcentrationPre-ExistingRust/Pitting浓度低工件原有的绣蚀/锈斑C

7、ontamination外来污染SurfaceChloridesHighMoisture表面氯化物湿度大ResidualContaminationOxidationDueTo(i.e.PoorCleaning)表面杂质ExcessHeat高热氧化绣蚀或斑痕RUSTORMoistureOnSurfaceHighBacterialGrowthSTAIN表面水分细菌生长pHPackaging高酸度包装Hardness高水硬度UnevenCoating冷却液覆盖不完全(Dewetting,CloggedN

8、ozzles)Sulfates硫酸盐含量高StorageConditions仓储状态不佳Chlorides(Humidity,AcidAtmosphere)水中氯离子含量高ContaminationLowCoatingWeight水质污染冷却液成膜差补加水MAKE-UPWATER现场应用APPLICATION冷却液产品环境设备PRODUCTENVIRONMENTEQUIPMENT浓度Concentration外来污染Contamination接触时间错用Misapplication