(shell內(nèi)部資料)金屬加工液常見問題分析

TROUBLESHOOTINGVIATHEFISHBONEDIAGRAMMETHOD魚骨圖法用于分析金屬加工冷卻液常見問題WhatareFishboneDiagram?何為魚骨圖?TheFishboneDiagramisatoolusedtosystematicallyinvestigatepossiblecausesofproblems.Theonesincludedinthismanualcovers8problemscommoninwater-basedmetalworkingcoolantapplications.作為分析問題的工具,魚骨圖法可以系統(tǒng)地分析問題的成因.本介紹主要就冷卻液使用和維護過程中常見的八種現(xiàn)象運用魚骨圖法加以分析.>Odors異味>Dermatitis皮膚接觸炎癥>Foam泡沫>PoorToolLifeorFinish非正常加工刀具使用壽命或加工工件表面質(zhì)量下降>Rust工件繡蝕>HighCoolantConsumption高冷卻液消耗>UnacceptableResidues工件或刀具表面殘留物>ChangeinpH冷卻液酸堿度變化Whenconfrontedwithoneoftheseproblems,workyourwaythroughtheFishboneDiagramthataddressesit.Youwillidentifythesourceoftheproblembyaskingquestionsandeliminatingpotentialcausesthatdonotapplyinyourparticularcase.對于實際發(fā)生的問題可以參照相對應(yīng)的魚骨圖逐項查找原因.在應(yīng)用現(xiàn)場,通過提問的形式排除法找出問題之所在.HowdoIuseFishboneDiagrams?如何運用魚骨圖?1.Findthediagramthataddressestheproblem.Thenameoftheproblemisprintedatthe“head”ofthefish(rightsideofthepage).

找出于現(xiàn)場問題相對應(yīng)的分析圖.問題標(biāo)注在“魚骨頂部“(圖形右側(cè)).2.Lookatthe“ribs”protrudingfromthespineofthefish.Theseconditionscommonlycontributetotheproblem.Eachriblistsseveralvariablesthatshouldbeinvestigated.

逐項研究由魚主椎骨分離出的斜骨.每一斜骨都可能是造成問題的原因.在每一斜骨上給出的參數(shù)和變量應(yīng)當(dāng)進行詳細的研究.3.Movedownthefishbonefromheadtotail(righttoleft)addressingeachconditioninsequence.Theconditionsarelistedwiththemostcommoncausesshownclosesttothehead.Allvariablesmustbeinvestigatedanddeterminedtobeincontrolorinneedofcorrection.

將可能產(chǎn)生的原因從頭到尾逐相分析.通常容易出現(xiàn)的原因有目的的放在靠近魚頭的位置.所有列出的原因和變量必須加以研究以達到有效控制和對出現(xiàn)問題的及時修正.

繡蝕或斑痕RUSTORSTAINPackaging包裝UnevenCoating冷卻液覆蓋不完全(Dewetting,CloggedNozzles)StorageConditions倉儲狀態(tài)不佳(Humidity,AcidAtmosphere)LowCoatingWeight冷卻液成膜差

pH高酸度Hardness高水硬度Sulfates硫酸鹽含量高Chlorides水中氯離子含量高Contamination水質(zhì)污染補加水MAKE-UPWATER現(xiàn)場應(yīng)用APPLICATIONResidualContamination(i.e.PoorCleaning)表面雜質(zhì)SurfaceChlorides表面氯化物Pre-ExistingRust/Pitting工件原有的繡蝕/銹斑LowConcentration濃度低Contamination外來污染HighMoisture濕度大OxidationDueToExcessHeat高熱氧化HighBacterialGrowth細菌生長冷卻液產(chǎn)品PRODUCT材料問題SUBSTRATEMoistureOnSurface表面水分腐蝕CORROSION屑產(chǎn)生量SoilLoad溫度Temperature清洗劑混入CleanerCarryIn水硬度Hardness氯離子Chlorides外來污染Contamination補加水MAKE-UPWATER工藝過程PROCESS噴嘴堵塞CloggedNozzles接觸時間ContactTime濃度Concentration外來污染Contamination錯用Misapplication防腐蝕添加劑受熱分解LossofInhibitionDueToOverHeating溫度Temperature冷卻液產(chǎn)品PRODUCT設(shè)備EQUIPMENT濕度高HighHumidityLocationInPlant擺放環(huán)境環(huán)境ENVIRONMENTpHpH變化CHANGEINpHImproperTestMethod檢測方法SlugAdditionsofProduct產(chǎn)品成塊狀加入ImproperlyFunctioningPre-mix產(chǎn)品預(yù)混不佳清洗劑或洗滌液混入系統(tǒng)CleanerOrSoap工件帶入CarryInFromParts堿性污染ALKALINECONTAMINATION高濃度HIGHCONCENTRATIONOxidation/HydrolysisAcidCleanerImproperlyFunctioningPre-mix預(yù)混效果差LargeWaterAdditions水加入量過度ImproperTestMethod檢測方法濃度低LOWCONCENTRATION酸性污染ACIDCONTAMINATIONBiologicalGrowthpH值降低DECREASEINpHpH值增加INCREASEINpH異味ODORS食物Food

抹布ShopTowels香煙頭Cigarettes外來污染GROSSCONTAMINATION工件表面雜質(zhì)CoatingComingInOnParts雜油TrampOil細菌(氨味)Bacteria(Ammonia)厭氧菌(硫化氫)AnaerobicBacteria(HydrogenSulfide)霉菌Fungi生物生長BIOLOGICALGROWTH加工過程污染PROCESSCONTAMINATION鄰近系統(tǒng)雜質(zhì)混入OverflowFromNearbySystems口香糖/煙草ChewingTobacco糞便HumanExcrement刀具壽命下降或加工質(zhì)量下降POORTOOLLIFEORPARTFINISH流體溫度高FluidTempTooHigh.冷卻液流動不暢PoorFluidFlow氣泡量大EntrainedAir(Foam)磨料添充WheelLoading刀具積屑Build-upOnTooling雜油量大ExcessiveTramp

Oil清洗性不夠LACKOFDETERGENCY冷卻`不足INSUFFICIENTCOOLING工藝設(shè)計變更DesignChange工件材質(zhì)變化(硬度,孔隙率等)ChangeInAlloy(Hardness,Porosity)LowConcentration濃度低DepletionOf

Lubricant有效潤滑成分分解雜油過多

ExcessiveTramp

Oil潤滑不足INSUFFICIENTLUBRICATION加工工件PART校正不精確PoorAlignmentO.O.S.Tooling刀具TOOLING供應(yīng)商變化NewSupplier濃度太高ConcentrationTooHigh外來雜油多ExcessiveTrampOil清洗成分損失DepletionofDetergentAdditives冷卻液消耗量大HIGHPRODUCTCONSUMPTION選錯產(chǎn)品Misapplication倉儲管理混亂“Borrow”Product

MissingInventory

濃縮液泄漏無記錄和處理UndocumentedOrUncontrolledSpills操作環(huán)境ENVIRONMENT加工工件變硬HarderPartAlloy噴嘴方向不正確MisdirectedNozzles預(yù)混不佳PremixImproperlySet自動加液裝置非正常操作Auto-FeedOut-Of-Control濃度CONCENTRATION工藝過程PROCESS系統(tǒng)泄漏LeakInSystem冷卻系統(tǒng)SYSTEM太高TooHigh泡沫Foam過度溢流和撇油UncontrolledOverflow/Skimming離心分離不正常IncorrectlyFunctioningCentrifuge泄漏Leaks生產(chǎn)量增加IncreaseInProductivity刀具損耗大PoorTooling殘留物超標(biāo)UNACCEPTABLERESIDUES

雜油TrampOil霉菌生長

FungalGrowth工件夾帶雜質(zhì)CoatingComingInOnParts產(chǎn)品消耗量大ExcessiveProductUsed過度蒸發(fā)(溫度高)ExcessiveEvap.(Temp.High)濃度高HighConc.產(chǎn)品PRODUCT污染CONTAMINATION高雜油HighTrampOil乳化劑損失DepletionOfEmulsifier

高水硬度HighHardnessHighT.D.S.水質(zhì)WATERQUALITY清洗性下降LOSSOFDETERGENCY過濾器選型錯誤WrongType過濾系統(tǒng)失靈Broken過濾FILTRATION操作不正常ImproperlyFunctioning液體流入FluidCarryIn上道工序變化ChangeInPriorProcess采用新產(chǎn)品NewFluidInvolved工藝PROCESS泡沫FOAM清洗劑和洗滌液CleanerOrSoap隨工件帶入CoatingComingInOnParts上一工序帶入CarryInFromPreviousProcess外來污染CONTAMINATION切削/進給速度增加IncreasedSpeeds/Feeds泵氣蝕PumpCavitation水硬度低

LowHardness配液不充分SlugProductAdditions產(chǎn)品PRODUCT設(shè)備EQUIPMENT壓力,流量增加ExcessivePressure,Flow,Cascade濃度高HighConcentration過量蒸發(fā)ExcessiveEvaporation泡沫FOAM帶入清洗劑

CleanerCarryIn出現(xiàn)皂類物SoapFormation污染Contamination工藝PROCESS泵氣蝕PumpCavitation低溫LowTemperature金屬屑量SoilLoad產(chǎn)品PRODUCT設(shè)備EQUIPMENT循環(huán)速度RecirculationRate高濃度HighConcentration消泡劑量DefoamerContent噴嘴壓力NozzlePressure選錯產(chǎn)品Misapplication補加水MAKE-UPWATER污染(如工藝水)Contamination(i.e.ProcessWater)軟水LowHardness清洗質(zhì)量不好POORCLEANINGORRESIDUE產(chǎn)生屑量SoilLoad溫度Temperature清洗劑隨工件帶入CleanerCarryIntoRinse工藝PROCESS噴嘴堵塞BlockedNozzles溫度Temperature污染Contamination產(chǎn)品PRODUCT設(shè)備EQUIPMENT清洗介質(zhì)積存于過濾器內(nèi)DetergentStrippingInFilter濃度Concentration屑量SoilLoad超聲氣蝕UltrasonicCavitation浮油OilFloat補加水MAKE-UPWATER水硬度變化Hardness水中懸浮固體SuspendedSolids接觸時間ContactTime噴射形式SprayPattern壓力低LowPressure漂洗不佳

PoorRinsing污染物Contamination生產(chǎn)量增加IncreasedProductionpH干燥不合適ImproperDrying(BlowOff)皮炎DERMATITIS四季變化(干/冷)ChangeInSeason(Dr