CN1003793B - 高速强力磨削油及其制备方法 - Google Patents
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Abstract
本发明是一种适用于高速大磨削量磨制工具钢等硬质合金钢工件的高速强力磨削油。其组分为5~10%的添加剂与95~90%的矿物油混合而成。添加剂由C8-C30的混合的脂肪酸及脂肪酸酯、磺化蓖麻油、磷化表面活性剂或硫化表面活性剂、氯化石腊、植物磷酯、二甲基硅油等按一定比例组成。磨削油的开口闪点≥180℃,闭口闪点≥190℃,粘度20~30CST。本发明制造工艺简单,不污染环境,经F-500型高速磨床使用,工件表面无烧伤、无腐蚀、光洁度好。
Description
本发明是一种适用于高速、大磨削量磨制工具钢等硬质合金钢工件的高速强力磨削油。
近年来,一些国家逐渐采用高速强力磨削新工艺代替铸、车、铣、刨等老工艺以大大提高工效和产品质量。但采用高速磨削新工艺必须解决两个技术关键:(1)高强度的砂轮和特殊的机床;(2)高速、大磨削量下磨制工件时的高效冷却液。
据报道,广州机床研究所研制了一种高速磨削冷却液GMY-3。该冷却液组成为16%亚硝酸钠、18%三乙醇胺、4%油酸钠、15%表面活性剂和47%的水。苏联专利(SU1100299A)也公开了一种由亚硝酸钠、硫酸铜、有机胺等组成的金属磨制加工切削液。但亚硝酸盐和有机胺在使用过程中易生成有致癌作用的亚硝酸胺。有机胺、硫酸铜均污染环境,这类水为基质的冷却液,润滑性及防透性差,磨削阻力和对砂轮的磨损也大、稳定性也不好。日本公开特许公报A(昭60.69198)报导了含有机胺及烷基苯基聚氧乙烯醚的磷酸酯及矿物油组成的工具磨削油,用于SKH-9铁合金的磨削而无金属腐蚀及烧伤,但专利尚未提到该磨削油能否用于高速强力磨削,有机胺对环境也有污染。日本公开特许公报A(昭60.141795)报导了一种由C8-C30的磺化石蜡烃、有机钼化物、磷酸酯、锭子油、山梨糖醇单油酸酯、阴离子表面活性剂等组成的硬钢切削油。这种油专用于高速切削,但它的稳定性只有两天。
磨削冷却液一般分油剂型和水质型(包括乳液、合成液及无机盐溶液)。水质型磨削液以水为基质;而油剂型以油为基质。水质型冷却,清洗效果及防火性能好,但润滑性、防锈性和稳定性比油剂型差,对砂轮的磨损及磨削阻力也大。尽管油剂型磨削冷却液的冷却、清洗效果和防火性能不如水质型,但它的润滑性、稳定性、防锈性均比水质型好,特别是在高速磨削中减小磨削阻力、降低砂轮损耗、保持加工面的光洁度、防止加工面变质等方面,油剂型具有独特的优点,特别适用于大磨削量、切深深的高速强力磨削工艺。
本发明研制的高速强力磨削油属于油剂型。在砂轮速度为80米/秒,一次磨削量≥100克/分,一次切深≥5毫米的高速强力磨削中,采用本发明研制的磨削油磨削工件,不损伤工件表面,工件表面不烧伤、不变质、不腐蚀,工件表面光洁度好,对砂轮的磨损小。本发明研制的冷却油生产工艺简单、生产成本低、不腐蚀设备、对人无毒、不污染环境。
本发明的目的是研制一种价廉的适用于高速、大磨削量磨制工具钢等硬质合金钢工件的高速强力磨削油。
本发明的目的是这样实现的:它是由基础油(矿物油)和添加剂按90~95∶10~5的重量比混合而成。本发明的磨削油的组成及重量百分含量如下:
名称含量(重量%)
矿物油 95~90
C8~C30脂肪酸酯和脂肪酸混合物 2.2~4.4
磺化蓖麻油 1.0~2.0
磷化表面活性剂或硫化表面活性剂 1.0~2.0
氯化石蜡 0.5~1.0
植物磷酸 0.3~0.6
二甲基硅油 2~4ppm
脂肪酸酯及脂肪酸混合物属油性添加剂,在金属磨削过程中形成油膜,起润滑和减少摩擦的作用。磺化蓖麻油生成油膜起乳化作用。磷化表面活性剂或硫化表面活性剂及植物磷酯,既有渗透作用又能与金属表面形成化学膜,同时有抗氧化作用。它们和氯化石蜡一样是一种极压添加剂,防止高温高压下金属表面的直接接触,减小摩擦。二甲基硅油主要用作削泡剂。
本发明的高速强力磨削油的制造方法是:
1.以脂肪酯,浓硫酸及脂肪醇重量之和为基准,按重量比,其各组份百分含量之和计为100%。在反应釜内先加入68~69%的脂肪酸,在搅拌下加入2~1%的浓硫酸作催化剂,最后再加30%的脂肪醇,加热到100℃,不断搅拌下反应2小时,同时除去水份及剩余的脂肪醇。停止加热,待反应产物冷却后取出,除去催化剂,便可得到正好适合高速强力磨削油所需比例的C8-C30的脂肪酸酯及脂肪酸混合物。
2.以高速强力磨削油各组分重量之和为基准,按重量比,其各组份百分含量之和计为100%。将C8-C30的脂肪酸酯及脂肪酸混合物与磺化蓖麻油按2.2~4.4%:1.0~2.0%的重量比混合搅拌后,再加1.0~2.0%的磷化表面活性剂或硫化表面活性剂及0.3~0.6%的植物磷酯,继续搅拌缓缓加入0.5~1.0%的氯化石蜡。最后再加2~4ppm的二甲基硅油作消泡剂,经充分搅拌,均匀混匀便可制得磨削油的添加剂,再将95~90%的矿物油(如20#透平油)与上述所得的添加剂混合,最后得到黄色油状高速强力磨削油。
经检测,本高速强力磨削油的开口闪点≥180℃,闭口闪点≥190℃,粘度20~30CST。
该磨削油制造工艺简单、成本低、无腐蚀性,对人无毒害,不污染环境,特别适用于硬质合金钢高速大磨削量加工使用,具有重要的推广应用价值。
本发明研制的高速强力磨削油在成都量具刃具厂引进的美国的NORMAC公司F-500型高速磨床上作了条件试验及实际应用试验。实验结果证明:在该磨床上磨制3~15mm直柄麻花钻头,当砂轮线速度为70~80米/秒,进工件速度为5~8米/分,一次磨削量达100克/分以上;一次磨削深度达5毫米以上时,用本发明研制的高速强力磨削油制造的工件表面不烧伤、不腐蚀、不变质、表面光洁度好,砂轮磨损小。
Claims (12)
1、一种用于工具钢等硬质合金钢的高速强力磨削油,它是由添加剂及矿物油混合而成,其特征是该磨削油的成分及其重量百分比组成为:
矿物油 95~90%
C8~C30脂肪酸酯及脂肪酸混合物 2.2~4.4%
磺化蓖麻油 1.0~2.0%
磷化表面活性剂或硫化表面活性剂 1.0~2.0%
氯化石蜡 0.5~1.0%
植物磷酯 0.3~0.6%
二甲基硅油 2~4ppm
2、根据权利要求1所述的高速强力磨削油,其特征是该磨削油为开口闪点≥180℃、闭口闪点≥190℃、粘度20~30CST的磨削油。
3、一种用于高速大磨削量磨制工具钢等硬质合金钢工件的高速强力磨削油的制造方法,其特征是:
(a)以脂肪酸、浓硫酸及脂肪醇重量之和为基准,按重量比,其各组份百分含量之和计为100%。首先在反应釜内按重量比加入68~69%的脂肪酸,在搅拌下加2~1%的浓硫酸作催化剂,最后再加30%的脂肪醇,加热到100℃,不断搅拌下反应2小时,同时除去水份及剩余的脂肪醇。停止加热、待反应产物冷却后取出,除去催化剂,使可得到正好适合高速强力磨削油所需比例的C8-C30的脂肪酸酯及脂肪酸混合物。
(b)以高速强力磨削油各组分重量之和为基准,按重量比,其各组份百分含量之和计为100%。将(a)步所得的脂肪酸酯与脂肪酸混合物与磺化蓖麻油按2.2~4.4%:1.0~2.0%的重量比混合搅拌后,再加1.0~2.0%的磷化表面活性剂或硫化表面活性剂及0.3~0.6%的植物磷酯,继续搅拌缓缓加入0.5~1.0%的氯化石蜡。再加2~4ppm的二甲基硅油作消泡剂,经充分搅拌,均匀混合便可制得磨削油的添加剂,再将95~90%的矿物油(20#透平油)与上述所得的添加剂混匀,最后得到黄色油状高速强力磨削油。
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