CN105623812A - 醇基中走丝电火花线切割加工液及其制备方法 - Google Patents
醇基中走丝电火花线切割加工液及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种醇基中走丝电火花线切割加工液及其制备方法,所述醇基中走丝电火花线切割加工液包括如下组分:火花放电调节剂、润滑剂、防锈剂、排屑清净剂、去离子水和丙二醇。本发明醇基中走丝电火花线切割加工液具有可超大电流加工、润滑性能好、防锈时间长、排屑清净性好、使用寿命长及综合性价比高的特点。
Description
技术领域
本发明涉及中走丝电火花线切割加工液,特别是涉及醇基中走丝电火花线切割加工液及其制备方法。
背景技术
中走丝电火花线切割机床属于中国独有的自主研发的机床,采用多次往复切割加工技术,第一次采用大电流快速切割,第二次、第三次修光切割时采用限速切割,使机床的切割效率及表面质量有了大幅度的提高。除了机床本身,中走丝电火花线切割加工液的质量直接影响到切割加工的效率速度、工件表面质量、加工精度以及加工过程稳定性。
电火花线切割加工液在我国已经有几十年的历史了,是应用于电火花线切割机床的专用加工液,起到灭弧、冷却、排屑、润滑、防锈等功能。目前,市场上主要有三大类产品:即乳化油型、水基全合成型和微乳化型。乳化油切割加工液问世已有四十多年,其代表性的产品为松香油酸皂乳化加工液,兑水后成乳白色,因含油量比较高,常温下电导率低,不能进行大电流切割,只适合慢走丝电火花切割加工和低厚度切割加工。水基全合成型线切割加工液不含矿物油,清洗、冷却效果都优于油基型加工液,电导率较高,放电间隙较大,可用于加工较高厚度工件。目前市场上的中走丝电火花线切割加工液大多属于这一类型。目前水基全合成加工液使用存在的问题是机床和工件容易生锈。另外,仍然不能进行较大电流的稳定切割加工。目前市场上用于中走丝电火花线切割的微乳化型线切割加工液以乳化膏和乳化皂为主,其融合了乳化油切割加工液和水基全合成加工液的特点,含一定比例的矿物油,加工综合性能良好,但其使用起来不方便,加工精度和稳定性不如水基全合成产品,也不能进行较大电流的稳定切割加工。
随着中走丝电火花线切割机床的发展,在保证加工精度的同时,要求不断提高切割速度,需要适应更大电流(大于15安培)加工的中走丝电火花线切割加工液。目前为止,现有的中走丝电火花线切割加工液在大于15安培电流加工时,容易发生烧结,断丝、短路,从而达不到更高效率的切割加工,因此,为了克服现有技术的不足,研制一种更佳性能的中走丝电火花线切割加工液具有重大的应用价值和现实意义。
发明内容
基于此,有必要针对上述问题,提供一种以去离子水为稀释介质的醇基中走丝电火花线切割加工液及其制备方法,本发明醇基中走丝电火花线切割加工液具有适合超大电流加工、润滑性能好、防锈时间长、排屑清净性好、使用寿命长及综合性价比高的特点。
为实现上述技术目的,具体技术方案如下:
一种醇基中走丝电火花线切割加工液,包括按质量百分比计的如下各组分:
其中,所述火花放电调节剂为山嵛酸酰胺、过硼酸钠、烷基糖苷中的一种或者一种以上连同去离子水和/或丙二醇组成的混合物;所述润滑剂为山嵛酸酰胺和/或五水四硼酸钾连同去离子水和/或丙二醇组成的混合物;所述防锈剂为山嵛酸、月桂基两性咪唑啉、甲基二乙醇胺、甲基苯并三氮唑月桂胺中的一种或一种以上连同去离子水和/或氢氧化钾组成的混合物;所述排屑清净剂为十二烷基二甲基甜菜碱、聚氧乙烯醚磷酸酯、双(2-甲氧基乙基)醚中的一种或一种以上连同去离子水和/或丙二醇组成的混合物。
在其中一些实施例中,所述火花放电调节剂为山嵛酸酰胺、过硼酸钠、烷基糖苷、去离子水和丙二醇的混合物,各组分占所述醇基中走丝电火花线切割加工液总质量的百分比为:
上述火花放电调节剂中的烷基糖苷(APG)可以为烷基糖苷APG1214、烷基糖苷APG0810、烷基糖苷APG0812、烷基糖苷APG1214等。
在其中一些实施例中,所述烷基糖苷为烷基糖苷APG0810。
在其中一些实施例中,所述润滑剂为山嵛酸酰胺、五水四硼酸钾、去离子水和丙二醇的混合物,各组分占所述醇基中走丝电火花线切割加工液总质量的百分比为:
在其中一些实施例中,所述防锈剂为山嵛酸、月桂基两性咪唑啉、甲基二乙醇胺、甲基苯并三氮唑月桂胺、去离子水及氢氧化钾的混合物,各组分占所述醇基中走丝电火花线切割加工液总质量的百分比为:
在其中一些实施例中,所述排屑清净剂为十二烷基二甲基甜菜碱、聚氧乙烯醚磷酸酯、双(2-甲氧基乙基)醚、去离子水和丙二醇的混合物,各组分占所述醇基中走丝电火花线切割加工液总质量的百分比为:
在其中一些实施例中,所述醇基中走丝电火花线切割加工液包括按质量百分比计如下的各组分:
火花放电调节剂:
润滑剂:
防锈剂:
排屑清净剂:
本发明还公开了一种上述醇基中走丝电火花线切割加工液的制备方法,包括如下具体步骤:
A)按上述配方称量或量取所述火花放电调节剂、防锈剂、润滑剂、排屑清净剂和丙二醇;
B)将所述防锈剂与丙二醇混合,搅拌,直至成为透明均匀液体;
C)向步骤B所得透明均匀液体中加入所述火花放电调节剂、润滑剂和排屑清净剂,搅拌均匀,冷却静置,过滤后即得所述醇基中走丝电火花线切割加工液。
在其中一些实施例中,所述步骤B中的搅拌时间为49~51min。
在其中一些实施例中,所述步骤B中的所述防锈剂与所述丙二醇混合后加热至40℃。
本发明采用山嵛酸酰胺、烷基糖苷等材料来作为火花放电调节剂,取代传统的松香类、油酸皂,既满足更大电流(大于15安培)加工,又不容易腐败变质;烷基糖苷(APG)无毒,对皮肤刺激小、安全、清洗力显著;同时具有抗静电功能,在硬水中使用仍效果显著。山嵛酸无毒,已成为很多行业的不可取代的长碳脂肪酸,被专家称为二十一世纪的化工原料;咪唑啉及其衍生物,兼具防锈性和清洗性能;丙二醇作为基础材料,能够在超大电流加工下达到良好的排屑清净性能,并且具有一定的润滑性能。
本发明所采用的山嵛酸酰胺、过硼酸钠、烷基糖苷和丙二醇的火花放电调节剂组合,配制的线切割加工液能够控制超大电流下的火花放电,灭弧效果好,线切割加工液组分在瞬间高温下不烧结;本发明利用新型的排屑清净剂体系配制的线切割加工液,能够极大地降低线切割加工液的表面张力,能够将切割间隙中的微粒和蚀除物质迅速排屑清净,从而保持顺利稳定放电加工;新型防锈剂体系的采用使得配制的线切割加工液具有更好的防锈效果;特殊润滑剂体系的采用使得配制的线切割加工液具有更好的润滑效果,加工的工件表面精度更高;采用新型材料配制的线切割加工液对细菌和霉菌抵抗能力更强,不易腐败变质,使用寿命更长;此外,本发明的线切割加工液还具有环保的特点。
因此,总的来说,本发明的中走丝线切割加工液具有以下有益效果:
1、具有适宜的火花放电调节和灭弧性能,满足超大电流(大于15安培)加工
2、具有极佳的清洗性与排屑性,冷却性能优异
3、具有良好的润滑性与防锈性,工件表面精度高
4、环境友好,优异的抑菌效果,使用寿命长及性价比高。
具体实施方式
以下将结合具体实施例对本发明做进一步描述和说明,但下述实施例并不限制本发明的保护范围。
本发明实施例中所用原料均为市售普通原料,其中:山嵛酸酰胺和山嵛酸购自四川天宇油脂化学有限公司。
实施例1
一种醇基中走丝电火花线切割加工液,各组分的质量百分比如下:
火花放电调节剂:
润滑剂:
防锈剂:
排屑清净剂:
本实施例醇基中走丝电火花线切割加工液的制备方法如下:
A)按配方称量或量取火花放电调节剂、防锈剂、润滑剂、排屑清净剂和丙二醇;
B)将防锈剂与丙二醇混合,搅拌50min,直至成为透明均匀液体;
C)向步骤B所得透明均匀液体中加入步骤A所称量的火花放电调节剂、润滑剂和排屑清净剂,搅拌均匀,冷却静置,过滤后即得所述醇基中走丝电火花线切割加工液;其中步骤B,所述防锈剂与所述丙二醇混合后加热至40℃。
实施例2
一种醇基中走丝电火花线切割加工液,由下述质量百分比的各组分组成:
火花放电调节剂:
润滑剂:
防锈剂:
排屑清净剂:
本实施例醇基中走丝电火花线切割加工液的制备方法同实施例1。
实施例3
一种醇基中走丝电火花线切割加工液,由下述质量百分比的各组分组成:
火花放电调节剂:
润滑剂:
防锈剂:
排屑清净剂:
本实施例醇基中走丝电火花线切割加工液的制备方法同实施例1。
实施例4
一种醇基中走丝电火花线切割加工液,由下述质量百分比的各组分组成:
火花放电调节剂:
润滑剂:
防锈剂:
排屑清净剂:
本实施例醇基中走丝电火花线切割加工液的制备方法同实施例1。
实施例5
一种醇基中走丝电火花线切割加工液,由下述质量百分比的各组分组成:
火花放电调节剂:
润滑剂:
防锈剂:
排屑清净剂:
本实施例醇基中走丝电火花线切割加工液的制备方法同实施例1。
实施例6
一种醇基中走丝电火花线切割加工液,由下述质量百分比的各组分组成:
火花放电调节剂:
润滑剂:
防锈剂:
排屑清净剂:
本实施例醇基中走丝电火花线切割加工液的制备方法同实施例1。
实施例7
一种醇基中走丝电火花线切割加工液,由下述质量百分比的各组分组成:
火花放电调节剂:
润滑剂:
防锈剂:
排屑清净剂:
本实施例醇基中走丝电火花线切割加工液的制备方法同实施例1。
将上述实施例1~7所得醇基中走丝电火花线切割加工液(以下称为原液)分别进行检测,均达到以下检测结果:
以上所述实施例的各技术特征可以进行任意的组合,为使描述简洁,未对上述实施例中的各个技术特征所有可能的组合都进行描述,然而,只要这些技术特征的组合不存在矛盾,都应当认为是本说明书记载的范围。
以上所述实施例仅表达了本发明的几种实施方式,其描述较为具体和详细,但并不能因此而理解为对发明专利范围的限制。应当指出的是,对于本领域的普通技术人员来说,在不脱离本发明构思的前提下,还可以做出若干变形和改进,这些都属于本发明的保护范围。因此,本发明专利的保护范围应以所附权利要求为准。
Claims (10)
1.一种醇基中走丝电火花线切割加工液,其特征在于,包括按质量百分比计的如下各组分:
其中,所述火花放电调节剂为山嵛酸酰胺、过硼酸钠、烷基糖苷中的一种或者一种以上连同去离子水和/或丙二醇组成的混合物;所述润滑剂为山嵛酸酰胺和/或五水四硼酸钾连同去离子水和/或丙二醇组成的混合物;所述防锈剂为山嵛酸、月桂基两性咪唑啉、甲基二乙醇胺、甲基苯并三氮唑月桂胺中的一种或一种以上连同去离子水和/或氢氧化钾组成的混合物;所述排屑清净剂为十二烷基二甲基甜菜碱、聚氧乙烯醚磷酸酯、双(2-甲氧基乙基)醚中的一种或一种以上连同去离子水和/或丙二醇组成的混合物。
2.根据权利要求1所述的醇基中走丝电火花线切割加工液,其特征在于,所述火花放电调节剂为山嵛酸酰胺、过硼酸钠、烷基糖苷、去离子水和丙二醇的混合物,各组分占所述醇基中走丝电火花线切割加工液总质量的百分比为:
3.根据权利要求2所述的醇基中走丝电火花线切割加工液,其特征在于,所述烷基糖苷为烷基糖苷APG0810。
4.根据权利要求1所述的醇基中走丝电火花线切割加工液,其特征在于,所述润滑剂为山嵛酸酰胺、五水四硼酸钾、去离子水和丙二醇的混合物,各组分占所述醇基中走丝电火花线切割加工液总质量的百分比为:
5.根据权利要求1所述的醇基中走丝电火花线切割加工液,其特征在于,所述防锈剂为山嵛酸、月桂基两性咪唑啉、甲基二乙醇胺、甲基苯并三氮唑月桂胺、去离子水及氢氧化钾的混合物,各组分占所述醇基中走丝电火花线切割加工液总质量的百分比为:
6.根据权利要求1所述的醇基中走丝电火花线切割加工液,其特征在于,所述排屑清净剂为十二烷基二甲基甜菜碱、聚氧乙烯醚磷酸酯、双(2-甲氧基乙基)醚、去离子水和丙二醇的混合物,各组分占所述醇基中走丝电火花线切割加工液总质量的百分比为:
7.根据权利要求1所述的醇基中走丝电火花线切割加工液,其特征在于,包括按质量百分比计如下的各组分:
火花放电调节剂:
润滑剂:
防锈剂:
排屑清净剂:
8.一种权利要求1~7任一项所述的醇基中走丝电火花线切割加工液的制备方法,其特征在于,包括如下具体步骤:
A)按权利要求1~7任一项所述的配方称量或量取所述火花放电调节剂、防锈剂、润滑剂、排屑清净剂和丙二醇;
B)将所述防锈剂与丙二醇混合,搅拌,直至成为透明均匀液体;
C)向步骤B所得透明均匀液体中加入所述火花放电调节剂、润滑剂和排屑清净剂,搅拌均匀,冷却静置,过滤后即得所述醇基中走丝电火花线切割加工液。
9.根据权利要求8所述的醇基中走丝电火花线切割加工液的制备方法,其特征在于,所述步骤B中的搅拌时间为49~51min。
10.根据权利要求8所述的醇基中走丝电火花线切割加工液的制备方法,其特征在于,所述步骤B中的所述防锈剂与所述丙二醇混合后加热至40℃。
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