CN106479632A - 润滑油组合物及其用途 - Google Patents
润滑油组合物及其用途 Download PDFInfo
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Abstract
本发明涉及一种润滑油组合物及其用途,主要解决现有技术的冷镦成型油在部分冷镦工艺与设备润滑统一供油的冷镦设备中使用时,容易生成大量的泡沫,并随着设备油路的循环系统分散到工艺部位和传动齿轮部位,造成润滑油膜不均匀而容易破裂,传动齿轮磨损及工件表面不规整,降低模具使用寿命的问题。本发明通过采用以重量份数计包含以下组份:a)100基础油;b)0.1~5.0份极压抗磨剂;c)0.01~0.5份金属减活剂;d)1.0~15.0份油性剂;e)1.0~15.0清净分散剂的技术方案较好的解决了该问题,可用于部分冷镦工艺与设备润滑统一供油的冷镦机润滑系统。
Description
技术领域
本发明涉及一种润滑油组合物及其用途。
背景技术
冷镦工艺是金属加工工艺中的重要工艺过程之一,对于大批量生产的汽车紧固件、摩托车、自行车、家电上的异形的自动化生产是必不可少的制造方法。由于冷镦油在使用过程中不可避免的会混进一些杂质,直接影响油品抗泡沫性能。这些外来污染物可以是灰尘、加工金属碎屑,但主要是加工工艺中使用的前处理固体润滑剂原料(如皂化粉和拉拔粉)。当原材料表面这层固体润滑剂(皂化粉和拉拔粉)随着生产被带入油品并随着生产量的增加而积聚。一般冷镦油在使用过程中,由于受到震荡、搅拌等操作条件的影响,不可避免的会有空气混入油箱中,使油品极易产生气泡。而这些皂化粉、拉拔粉在使用过程中,由于受到震荡、搅拌等作用,会随着油路在整个润滑系统循环分散,一方面使油品放气性变差,增强润滑油泡沫的稳定性,使产生的泡沫不易破裂消失;同时会与油品中酸性添加剂、因油品氧化产生的酸性物质或外来酸性污染物进行反应,这些反应产物会降低油品的使用性能,致使油品放气性变差,增强润滑油泡沫的稳定性,使产生的泡沫不易破裂消失。一般成品油中均含有5-10ppm的抗泡剂,当抗泡剂分散不好或存放稳定性差,抗泡剂消耗和油箱进水均会造成油箱泡沫的产生;当冷镦油油位高度不够,在运行时更易带入大量的空气会增大冷镦油泡沫的产生,最终导致新泡沫产生快,泡沫来不及消除而积累甚至溢出油箱。大量积聚的泡沫会随着油路循环系统被输送到设备的各个润滑点,包括工艺部位和传动齿轮部位,造成因泡沫的掺入导致的润滑油膜不均匀而破裂,形成润滑界面的干摩擦,由此造成传动齿轮磨损及工件表面不规整,降低模具使用寿命。
目前常用的冷镦成型油经过常规的抗泡性能分析实验测试,新油本身具有较好的泡沫性能,可以满足指标要求。但在实际使用工况中依然会出现较严重的泡沫现象。为了满足冷镦工艺对油品抗泡性能性能特殊的要求,部分冷镦油中较大量使用了具有优良抗泡性能的含硅或硅与非硅复合的抗泡剂,但含硅的抗泡剂在油品中的溶解度较低,较大量使用会使油品的外观出现浑浊。也有部分采用现场补加的方式进行对该问题的解决,但这无疑增加了现场的管理的成本和操作的不便,而现场的泡沫情况依然不稳定。因此,上述常用冷镦油不能满足部分工艺和设备润滑统一、容易产生较大量泡沫的特殊的冷镦机。
通过国内外专利及文献查询,发现一常用的冷镦油技术,例如专利CN 104403738A涉及到一种普通常用的冷镦油组合物,不适合与本发明所描述的冷镦工艺与齿轮润滑统一用油的冷镦设备。同时其体系中使用较大量的含硅抗泡剂(2.3%),一方面成本较高,另一方面对油品的外观会带来不利的影响。
发明内容
本发明所要解决的技术问题之一是主要解决现有技术的冷镦成型油在部分冷镦工艺与设备润滑统一供油的冷镦设备中使用时,容易生成大量的泡沫,并随着设备油路的循环系统分散到工艺部位和传动齿轮部位,造成润滑油膜不均匀而容易破裂,传动齿轮磨损及工件表面不规整,降低模具使用寿命的问题,提供一种新的冷镦润滑两用的润滑油组合物。本发明所要解决的技术问题之二是提供一种所述润滑油组合物的用途。该组合物具有较高的抗泡沫性能,可适用于部分冷镦工艺与设备润滑统一供油、容易产生较大量泡沫的特殊的冷镦机。
为解决上述技术问题之一,本发明采用的技术方案如下:一种润滑油组合物,以重量份数计包含以下组份:
a)100基础油;
b)0.1~5.0份极压抗磨剂;
c)0.01~0.5份金属减活剂;
d)1.0~15.0份油性剂;
e)1.0~15.0清净分散剂;
所述基础油选自加氢矿物基础油或聚α烯烃中的至少一种;
所述极压抗磨剂为硫化烯烃与硫代磷酸复酯胺盐的混合物;
所述金属减活剂为噻二唑衍生物;
所述油性剂为硫化植物油与脂肪酸酯的混合物;
所述清净分散剂为磺酸盐、烷基酚盐、烷基水杨酸盐、丁二酰亚安、聚异丁烯衍生物中的至少一种。
上述技术方案中,优选地,以重量份数计,极压抗磨剂的用量为0.5~3.0份,金属减活剂的用量为0.02~0.3份,油性剂的用量为6.0~12.0份,清净分散剂的用量为6.0~12.0份。
上述技术方案中,优选地,所述清净分散剂为超碱值合成磺酸钙和高碱值合成磺酸钙的混合物;其中,超碱值合成磺酸钙的TBN为400,高碱值合成磺酸钙的TBN为300;混合物中,超碱值合成磺酸钙与高碱值合成磺酸钙的重量比为1∶(0.1~1.0),优选为1∶(0.5~1.0)。
上述技术方案中,优选地,所述基础油选自加氢矿物基础油,黏度指数大于90。
上述技术方案中,优选地,极压抗磨剂混合物中,硫化烯烃与选硫代磷酸复酯胺盐的重量比为1∶(0.1~0.6)。
上述技术方案中,优选地,油性剂混合物中,硫化植物油与脂肪酸酯的重量比为1∶(0.2~0.4)。
上述技术方案中,优选地,所述组合物中还包括选自抗泡剂或抗氧剂中的至少一种;以重量份数计,抗泡剂的用量为0.01~0.2份,抗氧剂的用量为0.05~1.2份;其中,所述抗泡剂选自甲基硅油、乙基硅油、丙烯酸酯与醚共聚物中的至少一种;所述抗氧剂选自烷基化二苯胺、N-苯基-α-萘胺或酚类抗氧剂中的至少一种。
本发明的冷镦油组合物的制备方法为:将所需量的清净分散剂、金属减活剂、抗氧剂、油性剂、抗泡剂在50~80℃温度下加入基础油中,搅拌0.5~2小时,使其全部溶解;将温度控制在45~65℃下将极压抗磨剂加入到上述混合物中即可得到本发明的组合物。
为解决上述技术问题之二,本发明采用的技术方案如下:所述的冷镦油组合物用于部分工艺和设备润滑统一、容易产生较大量泡沫的特殊的冷镦机。其中所述冷镦油组合物的组份、重量份数以及优选范围与解决技术问题之一所采取的技术方案中的相同。
本发明采用以下各种试验方法来对所述冷镦油组合物的性能进行评定,其中有润滑油泡沫特性测定法(GB/T12579或ASTM D892),润滑剂承载能力测定法(四球法)_综合磨损指数ZMZ(GB/T3142),润滑剂承载能力测定法(四球法)(最大无卡咬负荷PB)(GB/T3142),润滑剂承载能力测定法(四球法)(烧结负荷PD)(GB/T3142),石油产品铜片腐蚀试验法(GB/T5906或ASTM D130)。
本发明采用了对清净分散剂与基础油和抗泡剂进行适当的配伍性筛选。所述清净分散剂为磺酸盐、烷基酚盐、烷基水杨酸盐、丁二酰亚安、聚异丁烯衍生物中至少一种的混合物;混合物中,主要成分为不同碱值的合成磺酸钙盐;所述抗泡剂选自甲基硅油、乙基硅油、丙烯酸酯与醚共聚物或上述的混合物中的至少一种;所述基础油选自加氢矿物基础油,黏度指数大于90。充分利用了各组份的协同作用,使得组合物能够具有优良的抗泡沫性能(润滑油泡沫特性测定法测试油品受到污染后依然满足指标要求),同时保持着优良的极压抗磨性能(采用润滑剂承载能力测定法(四球法)(综合磨损指数ZMZ)测试不小于631N,采用润滑剂承载能力测定法(四球法)(最大无卡咬负荷PB)测试的最大无卡咬负荷不小于1000N,采用润滑剂承载能力测定法(四球法)(烧结负荷PD)(GB/T3142)测试的烧结负荷不小于6080N,)和优良的抗腐蚀性(铜片腐蚀)(采用石油产品铜片腐蚀试验法(GB/T5906或ASTM D130)测试的结果不大于1)。
下面通过实施例对本发明作进一步的阐述。
具体实施方式
【实施例1~6】
按照表1中的重量份数,分别称取所需量的清净分散剂、金属减活剂、抗氧剂、油性剂、防锈剂和抗泡剂加入至基础油(68黏度等级)中,在70℃下加热搅拌至完全均匀,然后降低温度至60℃下加入极压抗磨剂,搅拌至完全均匀得到所述冷镦润滑两用的冷镦油组合物。组合物中各组份的种类及用量,具体见表1。
其中T101为低碱值磺酸钙;T105为中碱值合成磺酸钙;T106B为高碱值合成磺酸钙;T106A为超碱值合成磺酸钙;T152为双丁二酰亚胺;T154为聚异丁烯衍生物;Rc2540为硫化烯烃;T307为硫代磷酸复酯胺盐;T404为硫化棉籽油;T501为2,6-二叔丁基对甲酚;Irganox L135为混合型屏蔽分;Irganox L57为烷基化二苯胺;T561为2,5-二巯基-1,3,4-噻二唑衍生物;T922为含硅和非硅抗泡剂的复合物;Px3841为丙烯酸酯与醚的共聚物。
【实施例7】
对【实施例1~6】中的组合物的抗泡性能、极压抗磨性能(综合磨损指数、最大无卡咬符合、烧结负荷)、抗腐蚀性(铜片腐蚀)进行测试,试验结果见表2。
抗泡性能是冷镦油重要的性能之一。对【实施例1~6】中各组合物的泡沫特性进行了测试。油样的泡沫特性值越小,说明冷镦油抗泡性能越好。【实施例1~6】中各组合物的抗泡性能均不大于50ml,说明各组合物可以满足一般冷镦工艺的要求。比较而言,各组合物抗泡性能优劣依次为:【实施例6】≈【实施例5】>【实施例4】≈【实施例3】>【实施例2】≈【实施例1】。
此外,对【实施例5】、【实施例6】中各组合物进行了极压抗磨性能(综合磨损指数,烧结负荷,最大无卡咬负荷)、抗腐蚀性(铜片腐蚀)试验,结果显示各组合物的极压抗磨性、抗腐蚀性(铜片腐蚀)均未受影响,均能满足冷镦润滑的特殊要求。
【比较例1~4】
按照表1中【比较例1~4】的重量份数,分别称取所需量的清净分散剂、金属减活剂、抗氧剂、油性剂、防锈剂和抗泡剂加入至基础油(68黏度等级)中,在70℃下加热搅拌至完全均匀,然后降低温度至60℃下加入极压抗磨剂,搅拌至完全均匀得到【比较例1~4】所述冷镦油组合物。【比较例1~4】组合物中各组份的种类及用量,具体见表1。
【比较例5~14】
按照表3中【比较例5~14】重量份数,将现场混入的拉拔粉和皂化粉按1∶2的比例混合后向【实施例1~6】、【比较例1~4】中加入0.3%的量在室温下进行搅拌,搅拌速度为1500r/min,搅拌3分钟,然后再将温度升至80℃,搅拌速度为1500r/min,搅拌3分钟。由此获得【比较例5~14】所述受污染的冷镦油组合物。【比较例5~14】组合物中各组份的种类及用量,具体见表3。
【比较例15~17】
按照表3中【比较例15~17】重量份数,将现场混入的拉拔粉和皂化粉按1∶2的比例混合后向【实施例6】中分别加入0.5%、0.8%、1.0%的量在室温下进行搅拌,搅拌速度为1500r/min,搅拌3分钟,然后再将温度升至80℃,搅拌速度为1500r/min,搅拌3分钟。由此获得【比较例15~17】所述受污染的冷镦油组合物。【比较例15~17】组合物中各组份的种类及用量,具体见表3。
【比较例18】
对【比较例1~4】中各组合物的泡沫特性进行了测试,测试结果见表2;对【比较例5~17】中各组合物的泡沫特性进行了测试,测试结果见表3
对【比较例1~4】中各组合物的泡沫特性进行了测试。【比较例1~4】中各组合物的抗泡性能均不大于50ml,说明各组合物可以满足一般冷镦工艺的要求。比较而言,【比较例1~4】与【实施例1~6】整体抗泡性能优劣次序为:【实施例1~6】>【比较例1~4】。
对【比较例5~14】中各组合物的泡沫特性进行了测试。【比较例5~10】中各组合物的抗泡性能均不大于50ml,说明【实施例1~6】中各组合物受到工艺中使用的拉拔粉和皂化粉污染后依然可以满足冷镦工艺的要求。比较而言,【比较例11~14】中各组合物的抗泡性能均大于50ml,说明【比较例1~4】中各组合物受到工艺中使用的拉拔粉和皂化粉污染后,抗泡性能失效,不再满足冷镦工艺的要求。
对【比较例15~17】中各组合物的泡沫特性进行了测试。【比较例15~17】中各组合物的抗泡性能均不大于50ml,说明【实施例6】的冷镦油组合物受到工艺中使用的拉拔粉和皂化粉污染,并随着生产量的增加污染物积聚后依然可以满足冷镦工艺的要求。
综合上述对【实施例1~6】、【比较例1~4】、【比较例5~14】和【比较例15~17】中各组合物的泡沫特性的测试结果,说明了本发明组合物具有优良的抗泡沫性能(【实施例1~6】中各组合物进行测试,结果均满足冷镦工艺的特殊要求)和抗泡稳定性(采用润滑油泡沫特性测定法对【比较例5~10】和【比较例15~17】中各组合物进行测试,结果油品在受到污染后依然满足冷镦工艺的特殊要求);同时,对【实施例5】、【实施例6】中各组合物进行了极压抗磨性能(综合磨损指数,烧结负荷,最大无卡咬负荷)、抗腐蚀性(铜片腐蚀)试验,结果显示各组合物的极压抗磨性、抗腐蚀性(铜片腐蚀)均未受影响,均能满足冷镦润滑的特殊要求。【实施例5】比【实施例6】具有较好的经济性。
Claims (9)
1.一种润滑油组合物,以重量份数计包含以下组份:
a)100基础油;
b)0.1~5.0份极压抗磨剂;
c)0.01~0.5份金属减活剂;
d)1.0~15.0份油性剂;
e)1.0~15.0清净分散剂;
所述基础油选自加氢矿物基础油或聚α烯烃中的至少一种;
所述极压抗磨剂为硫化烯烃与硫代磷酸复酯胺盐的混合物;
所述金属减活剂为噻二唑衍生物;
所述油性剂为硫化植物油与脂肪酸酯的混合物;
所述清净分散剂为磺酸盐、烷基酚盐、烷基水杨酸盐、丁二酰亚安、聚异丁烯衍生物中的至少一种。
2.根据权利要求1所述的润滑油组合物,其特征在于以重量份数计,极压抗磨剂的用量为0.5~3.0份,金属减活剂的用量为0.02~0.3份,油性剂的用量为6.0~12.0份,清净分散剂的用量为6.0~12.0份。
3.根据权利要求1所述的润滑油组合物,其特征在于所述清净分散剂为超碱值合成磺酸钙和高碱值合成磺酸钙的混合物;其中,超碱值合成磺酸钙的TBN为400,高碱值合成磺酸钙的TBN为300;混合物中,超碱值合成磺酸钙与高碱值合成磺酸钙的重量比为1:(0.1~1.0)。
4.根据权利要求3所述的润滑油组合物,其特征在于超碱值合成磺酸钙与高碱值合成磺酸钙的重量比为1:(0.5~1.0)。
5.根据权利要求1所述的润滑油组合物,其特征在于所述基础油选自加氢矿物基础油,黏度指数大于90。
6.根据权利要求1所述的润滑油组合物,其特征在于极压抗磨剂混合物中,硫化烯烃与选硫代磷酸复酯胺盐的重量比为1:(0.1~0.6)。
7.根据权利要求1所述的润滑油组合物,其特征在于油性剂混合物中,硫化植物油与脂肪酸酯的重量比为1:(0.2~0.4)。
8.根据权利要求1所述的润滑油组合物,其特征在于所述组合物中还包括选自抗泡剂或抗氧剂中的至少一种;以重量份数计,抗泡剂的用量为0.01~0.2份,抗氧剂的用量为0.05~1.2份;其中,所述抗泡剂选自甲基硅油、乙基硅油、丙烯酸酯与醚共聚物中的至少一种;所述抗氧剂选自烷基化二苯胺、N-苯基-α-萘胺或酚类抗氧剂中的至少一种。
9.权利要求1~8任一所述的润滑油组合物用于冷镦工艺与设备润滑统一供油的冷镦机的润滑。
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