CN106350189A - 一种具有超高润滑性能的黑色金属专用合成切削液及其制备方法 - Google Patents

一种具有超高润滑性能的黑色金属专用合成切削液及其制备方法 Download PDF

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CN106350189A
CN106350189A CN201610621908.3A CN201610621908A CN106350189A CN 106350189 A CN106350189 A CN 106350189A CN 201610621908 A CN201610621908 A CN 201610621908A CN 106350189 A CN106350189 A CN 106350189A
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cutting fluid
superelevation
ferrous metal
greasy property
synthetic cutting
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潘云飞
张洪灿
聂晓霖
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Nanjing Kerun New Material Technology Co Ltd
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Abstract

本发明涉及一种具有超高润滑性能的黑色金属专用合成切削液及其制备方法，属于金属加工用切削液技术领域。该切削液由有机醇胺、防锈剂、极压润滑剂、边界润滑剂、软水剂、金属减活剂、耦合剂、杀菌剂、消泡剂、水组成。本发明将多种极压润滑剂和边界润滑剂有机组合，确保切削液在不同的加工温度及压力条件下，均有有效成分浸润并发挥润滑效果，加之不同润滑剂之间存在协同增效作用，使得该切削液具有超强的润滑性能。实践证明，本切削液可用于铸铁、碳钢、合金钢、不锈钢乃至硬质合金等材质工件的磨削、铣削、车削、攻丝、钻孔、珩磨等加工，很多场合可直接替代含油切削液使用，且更加绿色环保、使用寿命长。

Description

一种具有超高润滑性能的黑色金属专用合成切削液及其制备 方法
技术领域
本发明涉及一种不含油的、黑色金属专用的、具有超高润滑性能的水基切削液，具体地说是具有超高润滑性能的黑色金属专用合成切削液及其制备方法，属于金属加工用切削液技术领域。
背景技术
在金属加工领域，切削液因具有润滑、防锈、冷却、清洗等功能而被广泛使用。水基切削液按照原液含油量的多少可分为乳化液、半合成切削液、合成切削液三类，其中前两类含油产品因具有更好的润滑性及工艺适应性，目前在市场上受到更多使用者的青睐；但其在稳定性、冷却性方面相对较差，使用周期不长。近年来，合成切削液逐渐成为切削液技术发展的主流，因其在稳定性、冷却性、清洗性、抗菌性、工件可见性方面等方面有着得天独厚的优势，故越来越引起人们的关注，使用场合也越来越多。
当代机械加工产业向着高效、高载荷、高精度方向发展，加工工件种类及结构越来越复杂化，环保意识越来越深入人心，这些都对切削液综合性能提出了更高的要求，例如润滑及防锈能力强、气味低、不易腐败、绿色环保、对皮肤和呼吸道无刺激，等等。目前市面上的合成切削液种类繁多，鱼龙混杂，但罕有同时满足上述各项性能的全能产品。有的切削液润滑性能一般，仅能满足磨削、轻载荷车铣等加工难度和精度要求低的工艺，适用面较窄；有的切削液选用亚硝酸盐作为防锈剂，虽然防锈能力强、成本低廉，但对人体有很强的毒性和致癌性；有的切削液使用三嗪、三丹油、氯酚等作为杀菌防霉剂，对人体刺激性强，易造成皮肤过敏的情况；有的切削液不注重自身的消泡性能，产品过多依赖消泡剂，很难适用于高浓度、高压及过滤体系发达的场合。
在上述合成切削液的各项性能指标中，最为核心的为润滑性能，它是制约市面上多数合成切削液大规模使用的主要原因。润滑性能的好坏直接影响加工精度及刀具寿命，而后者正是切削液使用者最关心的两大因素。合成切削液由于完全不含油，加工时也就缺少了天然的油膜润滑层；同时在配方设计时，许多油溶性润滑剂无法兼容于体系，这些对于研发工程师而言，都是极大的挑战。为达到与含油切削液相当的润滑性能，我们对大量原料进行筛选、配伍调试、模拟表征以及实践验证，尤其注重极压润滑剂和边界润滑剂的协同作用，最终获得理想的产品，可以满足多种加工工艺的润滑需求。
发明内容
本发明解决的技术问题是：提出一种解决合成切削液润滑性能相对不足，对加工工艺适应性窄的缺点的方案，提供了一种具有超高润滑性能的黑色金属专用合成切削液及其制备方法，可用于铸铁、碳钢、合金钢、不锈钢乃至硬质合金等材质工件的磨削、铣削、车削、攻丝、钻孔、珩磨等加工，很多场合可直接替代含油切削液使用，且更加绿色环保、使用寿命长。
为了解决上述技术问题，本发明提出的技术方案是：一种具有超高润滑性能的黑色金属专用合成切削液，组份按重量百分比组成如下：
优选的，所述极压润滑剂为硫化脂肪酸酯、硫化改性菜籽油、磷酸酯、氯化脂肪酸中的一种或多种。
优选的，所述边界润滑剂为聚氧乙烯聚氧丙烯醚、自乳化酯、聚乙二醇400、甘油中的一种或多种。
优选的，所述有机醇胺为单乙醇胺、二乙醇胺、三乙醇胺、异丙醇胺、异丁醇胺、二甘醇胺中的一种或多种。
优选的，所述防锈剂为有机二元酸、有机三元酸、硼酸酯、硼砂中的一种或几种；所述软水剂为EDTA四钠；所述金属减活剂为苯并三氮唑、甲基苯并三氮唑、2-巯基苯并噻唑中的一种；所述耦合剂为新癸酸。
优选的，所述杀菌剂为吗啉类衍生物、恶唑啉类衍生物、异噻唑啉酮及其衍生物、碘代丙炔基氨基甲酸丁酯、2-丁基-1,2-苯并异噻唑啉-3-酮中的一种或多种。
优选的，所述消泡剂为乳化硅油、甲基硅油、二甲基硅油中的一种。
优选的，所述水为自来水、去离子水中的一种。
本发明提出的另一技术方案是：一种具有超高润滑性能的黑色金属专用合成切削液的制备方法，包括以下步骤：按照配比，边搅拌边加入有机醇胺、极压润滑剂、耦合剂，加热至50～60℃，持续搅拌30分钟后关闭加热；逐步加入水、软水剂、防锈剂、边界润滑剂、金属减活剂、杀菌剂，搅拌至溶液呈透明状态；加入消泡剂，搅拌20分钟后获得成品。
本发明的有益效果：
本发明的切削液采用多种极压润滑剂和边界润滑剂的有机组合，确保其在不同的加工温度及压力段，均有有效成分浸润并发挥润滑效果，加之不同润滑剂之间存在协同增效作用，使得该切削液具有超强的润滑性能，可用于黑色金属的磨削、铣削、车削、攻丝、钻孔、珩磨等加工；
本发明具有优良的防锈性能，适用于各类黑色金属，满足工序间存放要求；
本发明气味低，所有组分绿色环保，对人体无刺激，罕有过敏现象发生；
本发明稀释液呈无色或浅色透明状，工件可见性极佳，且抗杂油乳化，沉降性好、消泡性好；
本发明稀释液碱储备充足，加工环境适应性和抗菌能力强，使用寿命长，无需频繁换槽，维护成本低。
具体实施方式
实施例1
边搅拌边加入单乙醇胺5％、三乙醇胺12％、硫化改性菜籽油1％、新癸酸2％，加热至50～60℃，持续搅拌30分钟后关闭加热；逐步加入自来水59.6％、EDTA四钠1％、有机三元酸3％、硼酸酯5％、聚氧乙烯聚氧丙烯醚5％、甘油4％、苯并三氮唑0.2％、吗啉类衍生物2％，搅拌至溶液呈透明状态；加入乳化硅油0.2％，搅拌20分钟后获得成品。
本实施例制得的具有超高润滑性能的黑色金属专用合成切削液，具有优良的防锈性、清洗性及沉降性，适用于普通黑色金属的切磨加工，尤其适用于轴承套圈的粗、精磨加工。稀释液浓度2-4％适用于一般磨削加工，稀释液浓度3-6％适用于车削、铣削加工。该切削液相比于市面上常见合成切削液，在较低的使用浓度下即可达到所需的润滑和防锈效果，同等工艺下消耗量可比后者减少30～50％；该切削液相比于含油切削液，工件可见性极佳，易清洗，磨屑易沉降和过滤去除，使用体验好。
实施例2
边搅拌边加入单乙醇胺5％、三乙醇胺15％、磷酸酯2％、氯化脂肪酸3％、新癸酸4％，加热至50～60℃，持续搅拌30分钟后关闭加热；逐步加入自来水49.4％、EDTA四钠1％、有机三元酸3％、硼酸酯5％、自乳化酯5％、甘油5％、苯并三氮唑0.2％、吗啉类衍生物2％，碘代丙炔基氨基甲酸丁酯0.2％，搅拌至溶液呈透明状态；加入乳化硅油0.2％，搅拌20分钟后获得成品。
本实施例制得的具有超高润滑性能的黑色金属专用合成切削液，具有极高的工艺适应性，对于不同的加工温度及压力均能很好地适应，因此适用于黑色金属工件的磨削、铣削、车削、攻丝、钻孔、珩磨等各种加工，使用浓度为5-10％。由大量实践获知，相比于市面上常见合成切削液，使用该切削液的刀具寿命可提高50％以上。等浓度下该切削液的润滑性能与市面上常规的含油切削液相当，甚至稍好于后者，但使用寿命常是后者的两倍以上，因此可大幅降低使用者的成本。
实施例3
边搅拌边加入异丁醇胺5％、二甘醇胺10％、磷酸酯2％、氯化脂肪酸3％、新癸酸4％，加热至50～60℃，持续搅拌30分钟后关闭加热；逐步加入自来水56.4％、EDTA四钠1％、有机二元酸3％、有机三元酸3％、自乳化酯5％、甘油5％、苯并三氮唑0.2％、吗啉类衍生物2％，碘代丙炔基氨基甲酸丁酯0.2％，搅拌至溶液呈透明状态；加入乳化硅油0.2％，搅拌20分钟后获得成品。
本实施例制得的具有超高润滑性能的黑色金属专用合成切削液，主要适用于硬质合金材质的切磨加工，使用浓度为3-6％。该切削液相比于市面上常见合成切削液，在较低的使用浓度下即可达到所需的润滑效果，同等工艺下消耗量可比后者减少30～50％；另外，该切削液对钴析出有非常好的抑制作用，长期使用不变色：对于使用六个月以上的槽液，经ICP-AES分析，钴离子含量低于5ppm。该切削液加工精度高，工件加工后可获得极佳的表面光洁度。
上述三个实施例所制合成切削液与市面上某合成切削液以及某乳化型切削液的攻丝扭矩测试值对比如下：(测试采用德国进口Microtap攻丝扭矩机，测试条件及参数为1.7225模具钢测试块，M4盲孔，转速800rpm，攻丝深度8mm，测试浓度为5％，扭矩值越小说明润滑性能越好)
本发明不局限于上述实施例所述的具体技术方案，凡采用等同替换形成的技术方案均为本发明要求的保护范围。

Claims (9)

1.一种具有超高润滑性能的黑色金属专用合成切削液，其特征在于组份按重量百分比组成如下：
2.根据权利要求1所述的具有超高润滑性能的黑色金属专用合成切削液，其特征在于：所述极压润滑剂为硫化脂肪酸酯、硫化改性菜籽油、磷酸酯、氯化脂肪酸中的一种或多种。
3.根据权利要求1所述的具有超高润滑性能的黑色金属专用合成切削液，其特征在于：所述边界润滑剂为聚氧乙烯聚氧丙烯醚、自乳化酯、聚乙二醇400、甘油中的一种或多种。
4.根据权利要求1所述的具有超高润滑性能的黑色金属专用合成切削液，其特征在于：所述有机醇胺为单乙醇胺、二乙醇胺、三乙醇胺、异丙醇胺、异丁醇胺、二甘醇胺中的一种或多种。
5.根据权利要求1所述的具有超高润滑性能的黑色金属专用合成切削液，其特征在于：所述防锈剂为有机二元酸、有机三元酸、硼酸酯、硼砂中的一种或多种；所述软水剂为EDTA四钠；所述金属减活剂为苯并三氮唑、甲基苯并三氮唑、2-巯基苯并噻唑中的一种；所述耦合剂为新癸酸。
6.根据权利要求1所述的具有超高润滑性能的黑色金属专用合成切削液，其特征在于：所述杀菌剂为吗啉类衍生物、恶唑啉类衍生物、异噻唑啉酮及其衍生物、碘代丙炔基氨基甲酸丁酯、2-丁基-1,2-苯并异噻唑啉-3-酮中的一种或多种。
7.根据权利要求1所述的具有超高润滑性能的黑色金属专用合成切削液，其特征在于：所述消泡剂为乳化硅油、甲基硅油、二甲基硅油中的一种。
8.根据权利要求1所述的具有超高润滑性能的黑色金属专用合成切削液，其特征在于：所述水为自来水、去离子水中的一种。
9.根据权利要求1所述的具有超高润滑性能的黑色金属专用合成切削液的制备方法，其特征在于包括以下步骤：按照配比，边搅拌边加入有机醇胺、极压润滑剂、耦合剂，加热至50～60℃，持续搅拌30分钟后关闭加热；逐步加入水、软水剂、防锈剂、边界润滑剂、金属减活剂、杀菌剂，搅拌至溶液呈透明状态；加入消泡剂，搅拌20分钟后获得成品。
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