最佳化清洗製程對軸承清潔度之研究開發

本研究利用田口實驗最佳化設計法來探討清洗製程對軸承清潔度之影響。研究選擇4種清洗液種類：煤油(A1)、煤油+10%甲醇(A2)、煤油+10%丙酮(A3)、精煉煤油(A4)；2種超音波洗滌時間120秒(B1)、60秒(B2)及2種軸承尺寸：小為內環(C1)，大為外環(C2)等清洗製程之3個控制因子，配合田口法L8直交表進行清洗製程參數設計，並進行軸承清潔度之量測與金屬碎屑分析。採用田口法的望小特性來計算其S/N比與品質數據，利用變異分析，探討控制因子對軸承表面殘留顆粒數尺寸的影響。結果發現，控制因子對軸承表面總殘留物(金屬及非金屬)顆粒數尺寸15~150µm的最佳化清洗製程參數組合為A2B1C1(煤油+10%甲醇、120秒、內環)，軸承表面殘留金屬顆粒數尺寸100~150µm之成份為製工具磨耗產生的碎屑，15~100µm之成份為軸承本身的碎屑；殘留非金屬顆粒之成份為空氣中的棉絮、環境中的懸浮物及濾紙背景物。對軸承表面殘留物金屬顆粒數尺寸15~150µm的最佳化清洗製程參數組合雖然也為A2B1C1(煤油+10%甲醇、120秒、內環)，但清洗液對15~150µm的金屬顆粒數SN比之影響最顯著，其貢獻度高達53.2%；洗滌時間之影響次之，其貢獻度亦有43.1%；軸承尺寸的影響則不明顯。對軸承表面殘留物金屬顆粒數尺寸50~150µm的最佳化清洗製程參數組合為A2B1C2(煤油+10%甲醇、120秒、外環)，清洗液對50~150µm的金屬顆粒數SN比之影響最顯著，其貢獻度高達71.7%；軸承尺寸和洗滌時間的影響則不明顯。軸承表面殘留物金屬顆粒數尺寸50~150µm的數據、SN比及其品質損失。對比於外環，內環的SN比較高，其品質損失為外環的62%。對比於現有製程，可發現最佳化的條件的SN比較高，而最佳化條件之品質損失僅為現有製程的18%。綜合以上的分析比較，本研究田口實驗最佳化所得到之A2(煤油+10%甲醇)清洗液及B1(120秒)洗滌時間之清洗製程確實可應用在產業之實際製程上。

關鍵字

田口法；清洗液；超音波洗滌；軸承清潔度

並列摘要

This study uses the Taguchi experiment optimization design method to explore the impact of the cleaning process on bearing cleanliness. The study selected 4 types of cleaning fluids: kerosene (A1), kerosene + 10% methanol (A2), kerosene + 10% acetone (A3), refined kerosene (A4); 2 kinds of ultrasonic cleaning time 120 seconds (B1), 60 Second (B2) and 2 kinds of bearing sizes: small is the inner ring (C1), outer is the outer ring (C2) and other three control factors of the cleaning process, in conjunction with the Taguchi method L8 orthogonal table for cleaning process parameter design, and bearing cleanliness measurement and metal debris analysis. Using the small characteristic of the Taguchi method to calculate its S/N ratio and quality data, and using variation analysis to explore the influence of the control factor on the number of particles remaining on the bearing surface. It was found that the optimal cleaning process parameter combination of the control factor for the total number of particles (metal and non-metallic) on the bearing surface 15~150µm is A2B1C1 (kerosene + 10% methanol, 120 seconds, inner ring), and the bearing surface remained The number of metal particles with a size of 100~150µm is the debris generated by tool wear, and the 15~100µm is the debris of the bearing itself; the remaining non-metallic particles are the cotton wool in the air, the suspended matter in the environment and the filter paper background Thing. The optimal cleaning process parameter combination for the number of residual metal particles on the bearing surface is 15~150µm, although it is also A2B1C1 (kerosene + 10% methanol, 120 seconds, inner ring), but the cleaning fluid has a SN of 15~150µm metal particles. Compared with the most significant effect, its contribution rate is as high as 53.2%; the impact of washing time is second, its contribution rate is also 43.1%; the effect of bearing size is not obvious. The optimal cleaning process parameter combination for the number of residual metal particles on the bearing surface 50~150µm is A2B1C2 (kerosene + 10% methanol, 120 seconds, outer ring), and the effect of the cleaning solution on the SN ratio of 50~150µm metal particles The most significant, its contribution is as high as 71.7%; the influence of bearing size and washing time is not obvious. The number of residual metal particles on the bearing surface is 50~150µm, the SN ratio and the quality loss. Compared with the outer ring, the SN of the inner ring is relatively high, and its quality loss is 62% of the outer ring. Compared with the existing process, it can be found that the optimized condition has a higher SN, and the quality loss of the optimized condition is only 18% of the existing process. Based on the above analysis and comparison, the cleaning process of A2 (kerosene + 10% methanol) cleaning solution and B1 (120 seconds) cleaning time obtained by the optimization of the Taguchi experiment in this study can indeed be applied to the actual process of the industry.