In order to improve the processing efficiency, workpiece accuracy and surface quality, extend the service life of the tool or mold, and obtain the best economic benefits, in addition to selecting the appropriate material or geometric parameters of the tool or mold according to the processing conditions, select the appropriate process parameters and In addition to the amount of processing, the correct selection of metal processing media also plays a very important role.
Metal processing media include water-soluble cutting fluids, oily cutting fluids, cleaning agents, etc., which account for only about 2% to 3% of the manufacturing cost, but can affect other 80% cost components, such as tool life and abrasive costs. , yield, downtime, etc. Therefore, the rational selection of metal processing media has a great impact on manufacturing costs.
The correct choice of metal processing media is the basis, on the basis of which it is necessary to optimize product use according to the site environment.
The following are some aspects that should be considered when selecting a metal processing medium.
Adapt to local conditions
Metal processing media should not be used for simple copying, because the same products are used in different environments and the effects are completely different. Specifically, it is necessary to consider a variety of factors. This includes equipment conditions, water quality conditions (for water soluble products), processing techniques, processed materials, and local environmental and health requirements. For example, local water quality has a significant impact on the stability of water-soluble products, including stability, anti-foaming and service life; there is also the condition of the filter unit of the equipment and the oil leakage of the equipment, such as some old-fashioned lathes due to their own lubricating oil tanks. Small, coupled with the lubrication system, the oil is difficult to return to the crude oil tank after pumping out, so that the small fuel tank will be sucked up shortly after driving, and a large amount of oil will run into the large fuel tank of cutting oil. In order to maintain balance, many machine tool users will cut and lubricate the two sizes of fuel tanks, causing the oil tanks to be heavily contaminated with cutting oil, resulting in serious machine wear and rapid decline in accuracy.
General purpose processing media should be used when magnetic filtering devices are available. Stainless steel has high toughness and poor thermal conductivity. It is easy to produce sticky knife during cutting. It has high requirements for permeability and cooling of water-soluble cutting. The processing factors, such as whether it has extreme pressure performance requirements, if it is light load processing, Non-extreme pressure type media can be used. Conversely, extreme pressure type media must be used, otherwise the tool life will be greatly reduced. Typical examples, such as the MAPLE hinge process, usually require higher concentration, how to balance and light load processing requirements, and are also a major part of saving use.
Emissions of processing media are also an important factor in cost considerations, and products that require low processing costs and are easily compliant. Due to the many factors involved, the selection of suitable processing media will be a very professional job. Many professionals have accumulated considerable application experience, but for special types of processing and supplier special products still need field application. Test to verify the suitability of the product.
Reasonable use of cutting fluid
Improve material cutting performance: reduce cutting force and friction to inhibit the growth of chip and scale, reduce workpiece surface roughness, improve machining dimensional accuracy; reduce cutting temperature and extend tool durability.
Improve the operation performance: cool the workpiece, make it easy to load and unload, wash away the chips, avoid filter or pipe blockage; reduce smoke, splash, foaming, no special odor, make the working environment meet the health and safety regulations, will not cause the machine tool And the workpiece is rusted, does not damage the machine tool paint; it is not easy to deteriorate, easy to manage, easy to handle the waste liquid; does not cause skin allergy, harmless to the human body.
Economic benefits and cost considerations: including the cost of purchasing cutting fluid, supplementary expenses, management costs, and improving efficiency and saving costs.
Consider labor safety and health regulations, fire protection laws, and sewage discharge regulations.
Choose a professional supplier
Since metalworking media are specialized chemicals, the choice of a professional supplier is critical. Professional suppliers usually have the following basic conditions: rich practical experience; full range of products, can provide a full range of production processing media, water-soluble products, oily products, cleaning agents, greases, etc.; professional quality, on-site service Timely and professional; share cutting-edge technology with customers; provide comprehensive and reasonable solutions for customers.
Sound tracking and evaluation mechanism
Since metal processing media usually belong to auxiliary materials in manufacturing materials, it is easy to be neglected. However, in practice, a perfect use record and evaluation system is a key reference data for rational selection of processing media. The data should include the use of processing media for additive records, consumable replacement records (such as tools, abrasive dressing frequency), and records of environmental health issues.
Chemical outsourcing management
The outsourcing management of related chemicals (including metal processing media) has been applied abroad for many years. At present, there are many application examples in some large domestic wholly-owned and joint venture manufacturing enterprises. This management model has proven to be one of the effective ways of cost control.
Manufacturing companies can focus on building their core competencies, and the management of production auxiliary materials is handed over to professional suppliers. The contractor will provide customers with full management from “cradle to grave†according to their own R&D, manufacturing and management experience, dispatching on-site personnel, providing corresponding maintenance equipment, analyzing and processing data using professional software technology, and reviewing project management performance with customers on a regular basis. .
Because the model quantifies the metrics by contract, it can enable manufacturing companies to prioritize cost budget targets and achieve deeper levels of cooperation between contractors and manufacturing companies. Given the professionalism and complexity of outsourcing management, the contractor's credit and management experience is relatively high, and there are currently few suppliers that can provide similar solutions in China.
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