CN108929764B - 一种半合成不锈钢切削液及其制备方法 - Google Patents

一种半合成不锈钢切削液及其制备方法 Download PDF

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CN108929764B
CN108929764B CN201810988234.XA CN201810988234A CN108929764B CN 108929764 B CN108929764 B CN 108929764B CN 201810988234 A CN201810988234 A CN 201810988234A CN 108929764 B CN108929764 B CN 108929764B
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extreme pressure
stainless steel
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董恩莲
林敏娟
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GUANGDONG WINDSCAPE ENVIRONMENTAL PROTECTION TECHNOLOGY CO LTD
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Abstract

本发明提出了一种半合成不锈钢切削液，其由以下重量分数的原料制成：10‑30份基础油、3‑8份活性硫极压剂、5‑10份非活性硫极压剂、4‑8份磷酸酯极压剂、8‑15份聚合脂肪酸酯、3‑5份低碱值磺酸钙防锈剂、8‑15份乳化剂、0.5‑3份异构醇耦合剂、5‑15份pH值稳定剂、0.5‑3份异噻唑啉酮类杀菌剂、0.1‑2份有机硅消泡剂、15‑30份蒸馏水。本发明的有益效果是：本发明的半合成不锈钢切削液，具有优良的润滑、极压、冷却性能，可有效解决不锈钢加工过程中出现的刀具寿命短、加工工件表面质量不良的问题，且不含甲醛释放型杀菌剂、氯化石蜡，对人体健康安全。

Description

一种半合成不锈钢切削液及其制备方法
技术领域
本发明涉及一种半合成不锈钢切削液及其制备方法。
背景技术
不锈钢具有抗拉强度高、延伸率高、耐蚀性强、耐磨性好、耐热性好、化学相容性好等诸多优点，已被广泛地应用于航空航天、仪器仪表、生活日用品等各个领域。不锈钢在切削加工过程中，易出现切削温度高、刀具寿命短和加工工件表面质量低等现象。针对不锈钢切削的特点，其切削液必须具有优良的润滑极压、冷却性能。
不锈钢切削液可分为切削油、乳化油、半合成、全合成四种类型。切削油冷却性差，在生产过程中易产生切削油冒烟及油雾现象，对操作人员健康产生危害，并有着火风险。乳化液中基础油含量大使得其冷却性一般，且较易腐败发臭。全合成切削液润滑性差，易造成刀具寿命短、工件表面质量低的问题。半合成切削液是由基础油、极压剂、润滑剂、防锈剂、表面活性剂等组成，基础油含量远低于乳化油，因此其兼顾了切削油、乳化油、全合成切削液的优点，具有优良的润滑极压、冷却性能。水基切削液由于其使用特性，适合微生物的繁殖生长，目前市面上的不锈钢切削液大多采用甲醛释放型杀菌剂延长使用寿命。其次为控制成本，有些不锈钢切削液生产厂家会采用氯化石蜡来提高产品的润滑极压性能，甲醛释放型杀菌剂释放的甲醛具有致癌性，氯化石蜡中的短链氯化石蜡为欧盟REACH法规中的SVHC(高关注度物质)，均会给操作人员带来健康风险。
发明内容
本发明的目的在于提出一种半合成不锈钢切削液，具有优良的润滑极压、冷却性能，有效解决不锈钢加工过程中出现的刀具寿命短、加工工件表面质量不良的问题，且不含甲醛释放型杀菌剂、氯化石蜡，对人体健康安全。
为实现上述目的，本发明提供的技术方案是，一种半合成不锈钢切削液，包括以下重量份数的组分：
10-30份基础油、3-8份活性硫极压剂、5-10份非活性硫极压剂、4-8份磷酸酯极压剂、8-15份聚合脂肪酸酯、3-5份低碱值磺酸钙防锈剂、8-15份乳化剂、0.5-3份异构醇类耦合剂、5-15份pH值稳定剂、0.5-3份异噻唑啉酮类杀菌剂、0.1-2份有机硅消泡剂、以及15-30份蒸馏水。
作为本发明进一步的方案：上述的半合成不锈钢切削液，包括以下重量份数的组分：15-25份基础油、4-7份活性硫极压剂、6-10份非活性硫极压剂、4-6份磷酸酯极压剂、10-14份聚合脂肪酸酯、3-4份低碱值磺酸钙防锈剂、10-15份乳化剂、0.5-2份异构醇耦合剂、8-14份pH值稳定剂、0.5-2.5份异噻唑啉酮类杀菌剂、0.1-1份有机硅消泡剂、20-30份蒸馏水。
作为本发明进一步的方案：所述基础油选自石蜡基基础油、环烷基基础油、聚α烯烃、植物油、合成酯类油。
作为本发明进一步的方案：所述活性硫极压剂选自硫化烯烃、硫化烯烃棉籽油、硫化脂肪酸酯中的至少一种。
作为本发明进一步的方案：所述非活性硫极压剂选自硫化甘油三酯、硫化脂肪酸、硫化猪油中的至少一种。
作为本发明进一步的方案：所述聚合脂肪酸酯为碳原子数为8～20脂肪酸与多元醇酯化形成的分子量在1000-10000的聚合体。
作为本发明进一步的方案：所述低碱值磺酸钙防锈剂选自总碱值为15～60mgKOH/g的石油磺酸钙、总碱值为15～60mgKOH/g的合成烷基苯磺酸钙中的至少一种。
作为本发明进一步的方案：所述磷酸酯极压剂选自磷酸三甲酚酯、亚磷酸二正丁酯、三辛基亚磷酸酯、碳原子数为8～20的烷基膦酸酯、脂肪醇聚氧乙烯醚磷酸酯中的至少一种；
其中，所述的碳原子数为8～20的烷基膦酸酯选自异构十三醇膦酸酯、十二烷基膦酸酯、正辛基膦酸酯、异辛基膦酸酯、正癸基膦酸酯、十六烷基膦酸酯、十八烷基膦酸酯、十八烯基膦酸酯中的至少一种。
作为本发明进一步的方案：所述pH值稳定剂pH值稳定剂选自烷基醇胺中的至少一种，具体选自一乙醇胺、一异丙醇胺、三乙醇胺、三异丙醇胺、甲基二乙醇胺、2-氨基-2-甲基-1-丙醇、正丁基二乙醇胺、异丁基二乙醇胺、二甘醇胺中的至少一种。
作为本发明进一步的方案：所述乳化剂选自脂肪醇聚氧乙烯醚、脂肪酸聚氧乙烯酯、脂肪酸烷基醇酰胺、碳原子数为8～20的脂肪酸、烷基磺酸钠、烷基苯磺酸钠中的至少一种；
其中，所述的碳原子数为8-20的脂肪酸选自正癸酸、月桂酸、椰油酸、硬脂酸、异硬脂酸、油酸、蓖麻油脂肪酸、氢化蓖麻油脂肪酸中的至少一种。
作为本发明进一步的方案：所述异构醇耦合剂为含有至少一个支链的碳原子数为8～20的一元醇中的至少一种。
作为本发明进一步的方案：所述异构醇耦合剂选自异构十三醇、异辛醇、异壬醇、异癸醇、异构二十醇、异构十六醇、异构十八醇中的至少一种。
作为本发明进一步的方案：所述有机硅消泡剂选自甲基硅油、乙基硅油、乳化硅油、聚醚改性有机硅消泡剂中的至少一种。
本发明还提出了上述半合成不锈钢切削液的制备方法，包括以下步骤：
(1)称取蒸馏水放入搅拌反应釜中，依次加入pH值稳定剂、异噻唑啉酮类杀菌剂、乳化剂，搅拌0.5～1h至混合均匀形成透明溶液；
(2)向步骤(1)所得透明溶液中依次加入基础油、异构醇耦合剂、活性硫极压剂、非活性硫极压剂、磷酸酯极压剂、聚合脂肪酸酯、低碱值磺酸钙防锈剂、有机硅消泡剂，搅拌1～2h至混合均匀形成半透明液体，即得。
本发明使用基础油和聚合脂肪酸酯作为不锈钢切削的低温阶段的润滑主体，基础油与聚合脂肪酸酯的极性分子吸附在刀具与不锈钢表面，形成具有一定强度的润滑层，阻止刀具与工件的直接接触，从而实现润滑减磨的作用。
本发明采用活性硫极压剂、非活性硫极压剂与磷酸酯极压剂的复配来解决不锈钢切削的中温至高温阶段的润滑要求。随着不锈钢加工的继续进行，加工区域的温度升高(300～400℃)，导致润滑层破裂，边界润滑失效，此时极压剂与工件表面发生化学反应产生化学膜，阻止刀具与工件直接的接触。不同类型的极压剂具有不同的发挥极压润滑效果的温度范围，磷酸酯类极压剂的作用温度在300～700℃，活性硫极压剂为600～900℃，非活性硫极压剂为800℃以上；因此通过这三种极压剂的合理复配，在中温至高温的广泛温度范围内，切削液均能稳定地发挥极压润滑性能，从而达到良好的加工表面质量并减少刀具磨损、延长刀具寿命。
本发明的有益效果是：本发明的半合成不锈钢切削液，通过聚合脂肪酸酯、磷酸酯极压剂、非活性硫极压剂与活性硫极压剂的科学搭配，具有优良的润滑极压性能与冷却性能，可有效解决不锈钢加工过程中出现的刀具寿命短、加工工件表面质量不良的问题，且不含甲醛释放型杀菌剂与氯化石蜡，对人体健康安全。
具体实施方式
为让本领域的技术人员更加清晰直观的了解本发明，下面将对本发明作进一步的说明。
实施例1
一种半合成不锈钢切削液，按质量百分比计的原料组成如下：
25份环烷基基础油、3份硫化烯烃、10份硫化猪油、4份三辛基亚磷酸酯、8份聚合脂肪酸酯(分子量1000)、3份总碱值为15～60mgKOH/g的石油磺酸钙、5份脂肪醇聚氧乙烯醚、6份脂肪酸烷基醇酰胺、3份异辛醇、15份三乙醇胺、1份异噻唑啉酮杀菌剂、1份乳化硅油、20份蒸馏水。
上述半合成不锈钢切削液的制备方法，包括以下步骤：
(1)称取蒸馏水放入搅拌反应釜中，依次加入pH值稳定剂、异噻唑啉酮类杀菌剂、乳化剂，搅拌0.5～1h至混合均匀形成透明溶液；
(2)向步骤(1)所得透明溶液中依次加入基础油、异构醇耦合剂、活性硫极压剂、非活性硫极压剂、磷酸酯极压剂、聚合脂肪酸酯、低碱值磺酸钙防锈剂、有机硅消泡剂，搅拌1～2h至混合均匀形成半透明液体，即得。
实施例2
一种半合成不锈钢切削液，按质量百分比计的原料组成如下：
20份石蜡基基础油、8份硫化烯烃棉籽油、6份硫化脂肪酸、5份异构十三醇醚磷酸酯剂、15份聚合脂肪酸酯(分子量7500)、4份总碱值为15～60mgKOH/g的合成烷基苯磺酸钙、5份烷基磺酸钠、10份脂肪酸聚氧乙烯酯、1.5份异构十六醇、10份二甘醇胺、2.5份异噻唑啉酮类杀菌剂、0.5份甲基硅油、20.5份蒸馏水。
上述半合成不锈钢切削液的制备方法同实施例1。
实施例3
15份聚α烯烃、5份硫化脂肪酸酯、8份硫化脂肪酸、8份十二烷基膦酸酯、10份聚合脂肪酸酯(分子量3200)、3份总碱值为15～60mgKOH/g的石油磺酸钙、2份总碱值为15～60mgKOH/g的合成烷基苯磺酸钙、5份脂肪醇聚氧乙烯醚、8份脂肪酸聚氧乙烯酯、0.5份异构二十醇、8份2-氨基-2-甲基-1-丙醇、3份异噻唑啉酮类杀菌剂、2份乙基硅油、15份蒸馏水。
上述半合成不锈钢切削液的制备方法同实施例1。
实施例4
10份植物油、7份硫化烯烃棉籽油、5份硫化猪油、5份亚磷酸二正丁酯、10份聚合脂肪酸酯(分子量5000)、3.5份总碱值为15～60mgKOH/g的石油磺酸钙、4份烷基磺酸钠、6份脂肪酸烷基醇酰胺、2.5份异构十三醇、5份异丁基二乙醇胺、2.5份异噻唑啉酮类杀菌剂、1份聚醚改性有机硅消泡剂、25份蒸馏水。
上述半合成不锈钢切削液的制备方法同实施例1。
实施例5
30份合成酯类油、4份硫化烯烃、10份硫化甘油三酯、5份磷酸三甲酚酯、10份聚合脂肪酸酯(分子量10000)、3份总碱值为15～60mgKOH/g的合成烷基苯磺酸钙、4份烷基苯磺酸钠、4份脂肪酸聚氧乙烯酯、2份异构十八醇、14份甲基二乙醇胺、0.5份异噻唑啉酮类杀菌剂、1.5份甲基硅油、30份蒸馏水。
上述半合成不锈钢切削液的制备方法同实施例1。
对比例1
30份合成酯类油、14份硫化烯烃、5份磷酸三甲酚酯、10份聚合脂肪酸酯(分子量10000)、3份总碱值为15～60mgKOH/g的合成烷基苯磺酸钙、4份烷基苯磺酸钠、4份脂肪酸聚氧乙烯酯、2份异构十八醇、14份甲基二乙醇胺、0.5份异噻唑啉酮类杀菌剂、1.5份甲基硅油、30份蒸馏水。
上述半合成不锈钢切削液的制备方法同实施例1。
对比例2
30份合成酯类油、4份硫化烯烃、10份硫化甘油三酯、5份磷酸三甲酚酯、10份氯化石蜡、3份总碱值为15～60mgKOH/g的合成烷基苯磺酸钙、4份烷基苯磺酸钠、4份脂肪酸聚氧乙烯酯、2份异构十八醇、14份甲基二乙醇胺、0.5份异噻唑啉酮类杀菌剂、1.5份甲基硅油、30份蒸馏水。
上述半合成不锈钢切削液的制备方法同实施例1。
试验例1
将实施例5、对比例1、对比例2三种半合成不锈钢切削液与市场上某款不锈钢切削油分别进行烧结负荷PD的润滑性能表征测试，并在CNC机床上进行不锈钢钻孔加工，记录单个钻头可加工孔个数，以此考察刀具寿命。PD测试参照GB/T 3142-1982进行，数值越大表明理论润滑性能越好。不锈钢钻孔加工的参数为：不锈钢工件材质为316不锈钢，钻头材质为钨钢钻头，直径4.0mm，钻孔深度为10.0mm，转速1800rpm，进给量F＝150mm/min。
实施例5、对比例1和对比例2测试PD和钻孔加工均使用10％稀释液，不锈钢切削油则为原液。测试结果如下表：
Figure BDA0001780191280000061
由上表可以看出，本发明的半合成不锈钢切削油具有与不锈钢切削油相当的刀具寿命，且本发明的PD和刀具寿命与含氯化石蜡的对比例2相当，显著高于缺乏非活性硫极压剂的对比例1。
以上所述仅为本发明的较佳实施例，并非以此限制本发明的实施范围，本领域技术人员应该明了，对本发明的任何改进，对本发明产品各原料的等效替换及辅助成分的添加、具体方式的选择等，均落在本发明的保护范围和公开范围之内。

Claims (8)

1.一种半合成不锈钢切削液，其特征在于，包括以下重量份数的组分：
10-30份基础油、3-8份活性硫极压剂、5-10份非活性硫极压剂、4-8份磷酸酯极压剂、8-15份聚合脂肪酸酯、3-5份低碱值磺酸钙防锈剂、8-15份乳化剂、0.5-3份异构醇耦合剂、5-15份pH值稳定剂、0.5-3份异噻唑啉酮类杀菌剂、0.1-2份有机硅消泡剂、以及15-30份蒸馏水；
所述基础油选自石蜡基基础油、环烷基基础油、聚α烯烃、植物油、合成酯类油中的至少一种；
所述活性硫极压剂选自硫化烯烃、硫化烯烃棉籽油、硫化脂肪酸酯中的至少一种；
所述非活性硫极压剂选自硫化甘油三酯、硫化脂肪酸、硫化猪油中的至少一种；
所述磷酸酯极压剂选自磷酸三甲酚酯、亚磷酸二正丁酯、三辛基亚磷酸酯、碳原子数为8-20的烷基膦酸酯、脂肪醇聚氧乙烯醚磷酸酯中的至少一种；
所述低碱值磺酸钙防锈剂选自总碱值为15-60mg KOH/g的石油磺酸钙、总碱值为15-60mg KOH/g的合成烷基苯磺酸钙中的至少一种；
所述聚合脂肪酸酯为碳原子数为8-20脂肪酸与多元醇酯化形成的分子量在1000-10000的聚合体；
所述乳化剂选自脂肪醇聚氧乙烯醚、脂肪酸聚氧乙烯酯、脂肪酸烷基醇酰胺、碳原子数为8-20的脂肪酸、烷基磺酸钠、烷基苯磺酸钠中的至少一种；
所述异构醇耦合剂选自含有至少一个支链的碳原子数为8-20的一元醇中的至少一种；
所述pH值稳定剂选自烷基醇胺中的至少一种。
2.根据权利要求1所述的半合成不锈钢切削液，其特征在于，包括以下重量份数的组分：15-25份基础油、4-7份活性硫极压剂、6-10份非活性硫极压剂、4-6份磷酸酯极压剂、10-14份聚合脂肪酸酯、3-4份低碱值磺酸钙防锈剂、10-15份乳化剂、0.5-2份异构醇耦合剂、8-14份pH值稳定剂、0.5-2.5份异噻唑啉酮类杀菌剂、0.1-1份有机硅消泡剂、20-30份蒸馏水。
3.根据权利要求1或2所述的半合成不锈钢切削液，其特征在于，所述pH值稳定剂选自一乙醇胺、一异丙醇胺、三乙醇胺、三异丙醇胺、甲基二乙醇胺、2-氨基-2-甲基-1-丙醇、正丁基二乙醇胺、异丁基二乙醇胺、二甘醇胺中的至少一种。
4.根据权利要求1或2所述的半合成不锈钢切削液，其特征在于，所述有机硅消泡剂选自甲基硅油、乙基硅油、乳化硅油、聚醚改性有机硅消泡剂中的至少一种。
5.根据权利要求1或2所述的半合成不锈钢切削液，其特征在于，所述碳原子数为8-20的烷基膦酸酯选自十二烷基膦酸酯，正辛基膦酸酯、异辛基膦酸酯、正癸基膦酸酯、十六烷基膦酸酯、十八烷基膦酸酯中的至少一种。
6.根据权利要求1或2所述的半合成不锈钢切削液，其特征在于，所述碳原子数为8-20的脂肪酸选自正癸酸、月桂酸、椰油酸、硬脂酸、异硬脂酸、油酸、蓖麻油脂肪酸、氢化蓖麻油脂肪酸中的至少一种。
7.根据权利要求1或2所述的半合成不锈钢切削液，其特征在于，所述异构醇耦合剂选自异构十三醇、异辛醇、异壬醇、异癸醇、异构二十醇、异构十六醇、异构十八醇中的至少一种。
8.根据权利要求1或2所述的半合成不锈钢切削液的制备方法，其特征在于，包括如下步骤：
(1)称取蒸馏水放入搅拌反应釜中，依次加入pH值稳定剂、异噻唑啉酮类杀菌剂、乳化剂，搅拌0.5-1h至混合均匀形成透明溶液；
(2)向步骤(1)所得透明溶液中依次加入基础油、异构醇耦合剂、活性硫极压剂、非活性硫极压剂、磷酸酯极压剂、聚合脂肪酸酯、低碱值磺酸钙防锈剂、有机硅消泡剂，搅拌1-2h至混合均匀形成半透明液体，即得。
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