CN106675740A - 一种硬脆材料加工用微乳化切削液 - Google Patents
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Abstract
本发明公开了一种硬脆材料加工用微乳化切削液,由以下原料制备制成:精制矿物油、仲烷基磺酸钠、十二烷基二甲基氧化胺、椰油脂肪酸二乙醇酰胺、烷基醇胺、石油磺酸钡、苯并三氮唑、氯化钠、丙三醇、二乙醇胺、消泡剂、壬基酚聚氧乙烯醚磷酸酯、氧化石墨烯、N,N‑二甲基甲酰胺适量、N‑羟基琥珀酰亚胺、1‑乙基‑(3‑二甲基氨基丙基)碳二亚胺盐酸盐、对氨基苯磺酸、十二烷基苯磺酸、过硫酸钾、苯胺适量、去离子水适量;本发明制备的微乳化切削液制备方法简便,润滑性、耐磨、减摩和冷却性良好,可提高加工件的加工精度,且具有很强的防锈和缓蚀性能,使用寿命长,为加工件提供良好的加工精度。
Description
技术领域
本发明涉及微乳化切削液技术领域,尤其涉及一种硬脆材料加工用微乳化切削液。
背景技术
金属切削液是金属加工过程中重要的配套材料,其主要作用是冷却、润滑、清洗和防锈。按照介质状况分为两大类:油基型和水基型切削液,油基型切削液的主要成分通常是矿物油(也有植物油或其他合成材料),并加入油溶性防锈剂、油性剂和含活性元素的极压润滑剂调合而成,相比水基切削液,油基切削液的润滑性能和防锈性能较好,但却具有易产生油雾、易着火等缺点,水基切削液是用大量的水将浓缩液稀释后使用的,因而不具有产生油烟和引发火灾的缺点,水的比热容大,热导率高,汽化热大,是非常优良的冷却剂,切且成本低廉,另外加工后的脱脂清洗也比较简单。微乳液是一种介于乳化液和合成液之间并兼具乳化液润滑性和合成液清晰性的性能优异的切削液,成本较低,是未来加工液的主要发展方向。随着经济的快速发展,各种钢铁和铝合金的加工也飞速发展,目前国内在钢铁和铝合金的润滑方面金属切削液研究较少,主要以进口为主,我国在这方面的的研究工作起步较晚,而且主要集中在材料加工成型上,对切削加工中的润滑和防腐蚀方面的问题重视不够。近年来随着新型加工机械的不断出现,加工条件日趋苛刻,对金属切削液也提出了更高的要求。
付巧莲在《添加剂在微乳液中对铝/钢润滑性能影响的研究》一文中针对铝-钢摩擦副难于润滑的问题,以水性微乳化液为基础液,系统的研究了氯系、磷系、硫系、酯类以及聚醚类五大类润滑添加剂在微乳化液中对钢-钢摩擦副、铝-钢摩擦副的润滑特性。研究发现微乳液的最大无卡咬负荷与添加剂的种类和用量有关,其中对钢-钢摩擦副的润滑效果是多硫化物LZ5340L在水基微乳液中的响应值最好,加入量为5%时最大无卡咬负荷值为1118N,其次是氯化脂肪酸DA8527,硫化甘油三酸酯RC2411也有较好的润滑性能;在微乳化液中对铝-钢的摩擦副润滑结果为,硫系添加剂RC2411对铝-钢的摩擦副润滑效果最好,当其浓度为4%时,铝销的磨损量只有0.1mg,LZ5340L在加入量为4%时,铝销的磨损量也只有0.2mg。通过一系列试验后发现硫系添加剂对钢-钢摩擦副和铝-钢摩擦副具有较好的润滑性能,对其机理进行初步分析认为硫系添加剂能在金属表面形成一层致密的硫化膜,降低剪切应力,起到润滑作用。虽然作者系统的研究了在微乳化液中添加硫系润滑剂能够有效的提高切削液的润滑性能,但是随着加工器件日趋多元化,人们对微乳化切削液的要求越来越高,防锈蚀和使用寿命问题是切削液加工过程中不得不考虑的一个重要因素,因此对微乳化切削液必须进行改性以期获得的切削液能够提高加工效率和工件的表面质量,同时延长刀具和切削液本身的使用寿命,降低加工成本,获得最佳经济效益才是当前的研究热点。
发明内容
本发明目的就是为了弥补已有技术的缺陷,提供一种硬脆材料加工用微乳化切削液。
本发明是通过以下技术方案实现的:
一种硬脆材料加工用微乳化切削液,由以下重量份的原料制备制成:精制矿物油15-20、仲烷基磺酸钠12-15、十二烷基二甲基氧化胺3.5-4.5、椰油脂肪酸二乙醇酰胺7-9、烷基醇胺3.5-4、石油磺酸钡2.4-2.6、苯并三氮唑4-5、氯化钠1.8-2.2、丙三醇0.6-0.7、二乙醇胺3-4、消泡剂0.05-0.1、壬基酚聚氧乙烯醚磷酸酯4-5、氧化石墨烯2-3、N,N-二甲基甲酰胺适量、N-羟基琥珀酰亚胺10.5-11、1-乙基-(3-二甲基氨基丙基)碳二亚胺盐酸盐17-19、对氨基苯磺酸11-12、十二烷基苯磺酸30-35、过硫酸钾10-13、苯胺适量、去离子水适量。
所述一种硬脆材料加工用微乳化切削液,由下列具体步骤制备制成:
(1)将氧化石墨烯在烘箱中105℃下干燥3-5h,取出冷却至室温后加到N,N-二甲基甲酰胺中,超声处理30min得到浓度为2mg/ml的氧化石墨烯分散液,再加入N-羟基琥珀酰亚胺和1-乙基-(3-二甲基氨基丙基)碳二亚胺盐酸盐搅拌反应2-2.5h,然后加入对氨基苯磺酸在室温下连续搅拌反应24h,待反应完成后反复用去离子水洗涤,超声震荡15-30min后干燥备用;
(2)将十二烷基苯磺酸加到去离子水中,电动搅拌直至形成质量浓度为1.5%的十二烷基苯磺酸溶液,再加入苯胺搅拌混合均匀,然后在冰水浴条件下加入步骤(1)制备的产物,磁力搅拌1h得到均一的悬浮液,其中苯胺与步骤(1)制备的产物质量比为2-3:1,将过硫酸钾加到8.35%(v/v)的盐酸溶液中制成浓度为5%的过硫酸钾混合溶液,搅拌均匀后逐滴加到苯胺混合溶液中,在0-5℃下持续反应5-7h,反应结束后静置过夜,抽滤,并用去离子水和甲醇多次洗涤,直至滤液接近无色,将得到的固体物在真空干燥箱中在60℃下干燥12h,研成粉末备用;
(3)在反应容器中加入精制矿物油,搅拌加热至60-65℃时依次加入石油磺酸钡、烷基醇胺、仲烷基磺酸钠、十二烷基二甲基氧化胺、椰油脂肪酸二乙醇酰胺,每加入一种物料搅拌均匀后即可加入下一种物料,而后加入苯并三氮唑,搅拌溶解均匀得油相体系;
(4)在容器中加入去离子水加热到70-80℃,在搅拌下缓慢加入氯化钠和丙三醇充分搅拌溶解,搅拌均匀后加入步骤(2)制备的产物超声分散均匀得水相体系;
(5)在保持60-70℃下将水相体系缓慢加到以200-300r/min转速搅拌的油相体系中,待水相体系滴加结束后控制反应温度为40-50℃,加入消泡剂得到基础浓缩液,向该浓缩液中加入其余剩余物料调成母液,用去离子水将其稀释成浓度为10%的微乳化切削液即可。
本发明的优点是:聚苯胺具有合成原料成本低廉、优异的抗划伤、抗点蚀能力等优点,能够在钢铁和铝合金的表面形成均匀致密的聚苯胺膜,起到良好的防腐防锈的作用,但是其在一般的有机溶剂中溶解性较差,因此需要对其进行掺杂改善其溶解性,聚苯胺具有优异的俘获纳米粒子的寄主能力,可以与一些活泼的无机纳米粒子共同掺杂有效的改善其溶解性及耐蚀能力,氧化石墨烯原料易得,价格低廉,但是其很容易发生团聚,并在聚合物中分散不均匀,并且氧化石墨烯由疏水性的主体和亲水性的含氧活性基团所组成的结构特征,利用缩合法将含有磺酸基团的有机小分子对氧化石墨烯进行共价键接枝改性,增强了氧化石墨烯的水溶性,提高其作为乳化剂的乳化能力,本发明利用十二烷基苯磺酸对聚苯胺进行掺杂,起到接枝增溶的作用,有利于分子链的离域和舒展,降低分子链间的相互作用力,有助于提高聚苯胺乳液的流动性和分散性,并且和氧化石墨烯形成良好的交联网络结构,在水基中具有良好的分散性和稳定性,提高了微乳化切削液的防腐蚀、耐磨、减摩等功能,本发明制备的微乳化切削液制备方法简便,润滑性、耐磨、减摩和冷却性良好,可提高加工件的加工精度,且具有很强的防锈和缓蚀性能,使用寿命长,为加工件提供良好的加工精度。
具体实施方式
一种硬脆材料加工用微乳化切削液,由以下重量份(公斤)的原料制备制成:精制矿物油15、仲烷基磺酸钠12、十二烷基二甲基氧化胺3.5、椰油脂肪酸二乙醇酰胺7、烷基醇胺3.5、石油磺酸钡2.4、苯并三氮唑4、氯化钠1.8、丙三醇0.6、二乙醇胺3、消泡剂0.05、壬基酚聚氧乙烯醚磷酸酯4、氧化石墨烯2、N,N二甲基甲酰胺适量、N羟基琥珀酰亚胺10.5、1乙基(3二甲基氨基丙基)碳二亚胺盐酸盐17、对氨基苯磺酸11、十二烷基苯磺酸30、过硫酸钾10、苯胺适量、去离子水适量。
所述一种硬脆材料加工用微乳化切削液,由下列具体步骤制备制成:
(1)将氧化石墨烯在烘箱中105℃下干燥3h,取出冷却至室温后加到N,N二甲基甲酰胺中,超声处理30min得到浓度为2mg/ml的氧化石墨烯分散液,再加入N羟基琥珀酰亚胺和1乙基(3二甲基氨基丙基)碳二亚胺盐酸盐搅拌反应2h,然后加入对氨基苯磺酸在室温下连续搅拌反应24h,待反应完成后反复用去离子水洗涤,超声震荡15min后干燥备用;
(2)将十二烷基苯磺酸加到去离子水中,电动搅拌直至形成质量浓度为1.5%的十二烷基苯磺酸溶液,再加入苯胺搅拌混合均匀,然后在冰水浴条件下加入步骤(1)制备的产物,磁力搅拌1h得到均一的悬浮液,其中苯胺与步骤(1)制备的产物质量比为2:1,将过硫酸钾加到8.35%(v/v)的盐酸溶液中制成浓度为5%的过硫酸钾混合溶液,搅拌均匀后逐滴加到苯胺混合溶液中,在0℃下持续反应5h,反应结束后静置过夜,抽滤,并用去离子水和甲醇多次洗涤,直至滤液接近无色,将得到的固体物在真空干燥箱中在60℃下干燥12h,研成粉末备用;
(3)在反应容器中加入精制矿物油,搅拌加热至60℃时依次加入石油磺酸钡、烷基醇胺、仲烷基磺酸钠、十二烷基二甲基氧化胺、椰油脂肪酸二乙醇酰胺,每加入一种物料搅拌均匀后即可加入下一种物料,而后加入苯并三氮唑,搅拌溶解均匀得油相体系;
(4)在容器中加入去离子水加热到70℃,在搅拌下缓慢加入氯化钠和丙三醇充分搅拌溶解,搅拌均匀后加入步骤(2)制备的产物超声分散均匀得水相体系;
(5)在保持60℃下将水相体系缓慢加到以200r/min转速搅拌的油相体系中,待水相体系滴加结束后控制反应温度为40℃,加入消泡剂得到基础浓缩液,向该浓缩液中加入其余剩余物料调成母液,用去离子水将其稀释成浓度为10%的微乳化切削液即可。
对实施例制备的微乳化切削液进行性能测试,结果如下:
贮存安定性:无变色、无分层;消泡性(mL•10-1min-1):<2;腐蚀试验(55±2℃,铸铁/h):>48;腐蚀试验(55±2℃,铝/h):>12;防锈性试验(铸铁,h)>48;最大无卡咬负和(N):921;抗磨性(N):>58。
Claims (2)
1.一种硬脆材料加工用微乳化切削液,其特征在于,由以下重量份的原料制备制成:精制矿物油15-20、仲烷基磺酸钠12-15、十二烷基二甲基氧化胺3.5-4.5、椰油脂肪酸二乙醇酰胺7-9、烷基醇胺3.5-4、石油磺酸钡2.4-2.6、苯并三氮唑4-5、氯化钠1.8-2.2、丙三醇0.6-0.7、二乙醇胺3-4、消泡剂0.05-0.1、壬基酚聚氧乙烯醚磷酸酯4-5、氧化石墨烯2-3、N,N-二甲基甲酰胺适量、N-羟基琥珀酰亚胺10.5-11、1-乙基-(3-二甲基氨基丙基)碳二亚胺盐酸盐17-19、对氨基苯磺酸11-12、十二烷基苯磺酸30-35、过硫酸钾10-13、苯胺适量、去离子水适量。
2.根据权利要求1所述一种硬脆材料加工用微乳化切削液,其特征在于,由下列具体步骤制备制成:
(1)将氧化石墨烯在烘箱中105℃下干燥3-5h,取出冷却至室温后加到N,N-二甲基甲酰胺中,超声处理30min得到浓度为2mg/ml的氧化石墨烯分散液,再加入N-羟基琥珀酰亚胺和1-乙基-(3-二甲基氨基丙基)碳二亚胺盐酸盐搅拌反应2-2.5h,然后加入对氨基苯磺酸在室温下连续搅拌反应24h,待反应完成后反复用去离子水洗涤,超声震荡15-30min后干燥备用;
(2)将十二烷基苯磺酸加到去离子水中,电动搅拌直至形成质量浓度为1.5%的十二烷基苯磺酸溶液,再加入苯胺搅拌混合均匀,然后在冰水浴条件下加入步骤(1)制备的产物,磁力搅拌1h得到均一的悬浮液,其中苯胺与步骤(1)制备的产物质量比为2-3:1,将过硫酸钾加到8.35%(v/v)的盐酸溶液中制成浓度为5%的过硫酸钾混合溶液,搅拌均匀后逐滴加到苯胺混合溶液中,在0-5℃下持续反应5-7h,反应结束后静置过夜,抽滤,并用去离子水和甲醇多次洗涤,直至滤液接近无色,将得到的固体物在真空干燥箱中在60℃下干燥12h,研成粉末备用;
(3)在反应容器中加入精制矿物油,搅拌加热至60-65℃时依次加入石油磺酸钡、烷基醇胺、仲烷基磺酸钠、十二烷基二甲基氧化胺、椰油脂肪酸二乙醇酰胺,每加入一种物料搅拌均匀后即可加入下一种物料,而后加入苯并三氮唑,搅拌溶解均匀得油相体系;
(4)在容器中加入去离子水加热到70-80℃,在搅拌下缓慢加入氯化钠和丙三醇充分搅拌溶解,搅拌均匀后加入步骤(2)制备的产物超声分散均匀得水相体系;
(5)在保持60-70℃下将水相体系缓慢加到以200-300r/min转速搅拌的油相体系中,待水相体系滴加结束后控制反应温度为40-50℃,加入消泡剂得到基础浓缩液,向该浓缩液中加入其余剩余物料调成母液,用去离子水将其稀释成浓度为10%的微乳化切削液即可。
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