CN108929765B - 一种水基不锈钢切削液的制备及应用 - Google Patents
一种水基不锈钢切削液的制备及应用 Download PDFInfo
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Abstract
本发明公开了一种水基不锈钢切削液。其主体成分及用量包括：妥尔油二乙醇酰胺辛烯基琥珀酸单酯，油酸三乙醇胺酯，硼酸三乙醇胺酯，聚醚L61，Surfyonl DF‑110D，三乙醇胺，去离子水。本发明水基不锈钢切削液，润滑性冷却性能好，工作液循环时全程低泡，切削粉末沉降速度快，操作人员不过敏，工作液防锈性能优良。本发明保证了切削液的润滑性能和清洗性能的长期稳定。
Description
技术领域
本发明涉及一种水基金属加工润滑防锈技术领域，特别涉及一种水基不锈钢切削液的制备及其使用方法。
背景技术
不锈钢具有高强度、高耐磨性和低膨胀系数等优点而被广泛地应用于机械、石油化工、电子仪表、国防等工业部门。在物理性能方面其导热点较低，由于这些性能，使其切削加工具有以下特点,即切削力大，切削温度高，粘刀现象严重，加工硬化趋势强。由于以上的切削特性，不锈钢在切削过程中表现出切削功率消耗大，切削温度高，出现刀具寿命短和加工工件表面质量低等现象。
不锈钢材料的导热系数低，而且高温硬化现象严重，切削过程中产生的切削热不能及时的排除，使工件表面和刀具表面的温度升高，由于其高温硬度高、合金中含有许多高熔点、高激活能的组元、原子结构比较稳定等特点，从而使干切削过程中产生较大的切削力。用于不锈钢的切削液可分为非水溶性和水溶性两大类。就冷却性来看，油溶性切削液的冷却效率是很低的。对于不锈钢切削，由于它自身具有导热点低的特点，所以油性切削液不易进行有效的冷却。
在实际操作中往往会由于加工余量大、产生热量多未能及时散热而使切削油冒烟，从而影响加工。水溶性切削液能迅速传散切削时产生的热量从而达到理想的冷却效果。水溶性切削液又分为乳化液和合成液两种，合成液虽然在冷却性能方面是最优的，但其润滑性却较差，在加工中较难形成理想的润滑膜、容易产生刀具面与工件之间的直接接触而形成所谓的干摩擦，使刀与屑之间接触长度变长，剪切角变小，从而增加切削难度。所以它很难满足在切削时以边界润滑为主的不锈钢切削加工的要求。乳化油的润滑性和冷却性介于油剂和合成液之间，但普通乳化油由于含油量大使得冷却性一般、较易腐败发臭，故难以满足不锈钢加工的特殊加工要求。
因此，需要一种用于不锈钢加工过程中的切削液，其润滑性能、抗腐蚀性能和清洗性能能够长期匹配，解决不锈钢加工过程中润滑问题；解决刀具磨损问题；解决废液排放的环保问题。
发明内容
本发明的目的在于克服现有不锈钢切削油和水基切削液的诸多弊端，提供一种全新的不锈钢水基切削液。
为了实现上述目的，本发明采用如下技术方案：
一种水基不锈钢切削液。其主体成分及用量包括：妥尔油二乙醇酰胺辛烯基琥珀酸单酯5-15份，油酸三乙醇胺酯1-3份，硼酸三乙醇胺酯5-15份，聚醚L61 2-5份，SurfyonlDF-110D 0.1-1份，三乙醇胺2-5份，去离子水60-90份。
进一步优选为妥尔油二乙醇酰胺辛烯基琥珀酸单酯10份，油酸三乙醇胺酯2份，硼酸三乙醇胺酯10份，聚醚L61 5份，Surfyonl DF-110D 0.5份，三乙醇胺5份，去离子水67.5份。
所述的妥尔油二乙醇酰胺辛烯基琥珀酸单酯易溶于水，产品润滑性好，极低浓度就具有很好的润滑效果，同时可以增溶其他非水基润滑剂。产品百分之五的水溶液对铝合金、铸铁等金属有很好的缓蚀效果，常温浸泡168h，所有金属无异常。
所述的妥尔油二乙醇酰胺辛烯基琥珀酸单酯的制备方法如下：所述的妥尔油二乙醇酰胺辛烯基琥珀酸单酯制备方法如下：妥尔油加入到反应釜中，然后搅拌升温至90-110℃，加入二乙醇胺，升温至120-140℃反应3-6h，接着降温至80-100℃，加入辛烯基琥珀酸酐继续反应1-3小时，降至室温放料得到妥尔油二乙醇酰胺辛烯基琥珀酸单酯。
所述的妥尔油、二乙醇胺、辛烯基琥珀酸酐的质量比为3：0.8-1.2：1.5-2.5。进一步优选为称取3份精制妥尔油加入到反应釜中，然后搅拌升温至100℃，缓慢加入1份二乙醇胺，升温至130℃反应5h，接着降温至90℃，加入2份辛烯基琥珀酸酐继续反应2小时，降至室温放料得到妥尔油二乙醇酰胺辛烯基琥珀酸单酯。
所述的油酸三乙醇胺酯，具有优异的润滑效果，但是因其是油溶性物质，导致在水基切削液体系几乎没用应用。本发明技术人员发现，当把油酸三乙醇胺酯加入到自制的妥尔油二乙醇酰胺辛烯基琥珀酸单酯中，能够充分乳化使其溶于水而不析油，大大加强了体系的润滑性。同时因油溶性本质具有极低的起泡性，能够部分消除妥尔油二乙醇酰胺辛烯基琥珀酸单酯产生的微泡。所述的油酸三乙醇胺酯推荐厂家为上海千为油脂科技有限公司生产。
所述的硼酸三乙醇胺酯，具有优异的极压抗磨效果，切削后工件或机台表面留有不发粘的保护膜长时间的防止工件和机台生锈。
所述的聚醚L61为丙二醇嵌段聚醚，在切削过程中能形成粘附性强、承载能力大的稳定润滑膜，具有很强的抗剪切能力，在摩擦面上不会因分子被剪断而导致粘度下降，弥补了油酸三乙醇胺酯在切削过程中分子健断裂，润滑效果降低的缺陷。同时在切削过程中能够部分消除妥尔油二乙醇酰胺辛烯基琥珀酸单酯产生的微量泡沫。
Surfynol DF-110D属于炔二醇类消泡剂。在水基体系中具有消泡性和脱气性，但没有许多传统的泡沫控制剂在切削循环过程中或被乳化、或被切削工件带走、或体系分层等副作用而导致消泡效果急剧下降的不足。可消除微泡、具有长期的泡沫控制性、能够无缺陷地控制泡沫。在本发明中，本发明技术人员惊奇的发现，该原料在不改变体系的润滑性的基础下，能够降低体系的粘度，能够加快不锈钢切削粉末的沉降，使体系产生的切削粉末快速沉降分离。
本发明所述的组合物，作为工作液在恶劣的强制循环供液中，在循环过程中不另外添加任何消泡剂的情况下，全程低泡。本领域人员知晓，切削液使用的时候常常会由于起泡导致废液增加、车间环境变得恶劣、生产效率低下，严重的话会不锈钢加工品质。不发明不添加杀菌剂，不会引起操作人员因接触杀菌剂而过敏。
所述的水基不锈钢切削液的制备方法，其特征在于，包括如下步骤：
(1)妥尔油二乙醇酰胺辛烯基琥珀酸单酯，油酸三乙醇胺酯，硼酸三乙醇胺酯，聚醚L61，Surfyonl DF-110D，三乙醇胺加入到混料罐，充分搅拌得到黄色透明粘稠液；
(2)将去离子水加入到步骤(1)中，充分搅拌得到水基不锈钢切削液。
本发明为一种水基不锈钢切削液，与现有市售切削油和同类水基切削液相比具有如下显著优点：
1.杜绝了切削油不添加杀菌剂变质发臭，添加了杀菌剂使操作人员皮肤过敏的的风险。
2.没有烧伤，切削速度快，切削粉末沉降速度快。
3.有效提高刀具和磨头的使用寿命，降低了生产成本。
具体实施方式
实施例1
该不锈钢切削液包括按质量百分比计的组分如下：
妥尔油二乙醇酰胺辛烯基琥珀酸单酯10份，油酸三乙醇胺酯2份，硼酸三乙醇胺酯10份，聚醚L61 5份，Surfyonl DF-110D 0.5份，三乙醇胺5份，去离子水67.5份。
妥尔油二乙醇酰胺辛烯基琥珀酸单酯制备方法如下：称取3份精制妥尔油加入到反应釜中，然后搅拌升温至100℃，缓慢加入1份二乙醇胺，升温至130℃反应5h，接着降温至90℃，加入2份辛烯基琥珀酸酐继续反应2小时，降至室温放料得到妥尔油二乙醇酰胺辛烯基琥珀酸单酯。
实施例2
该不锈钢切削液包括按质量百分比计的组分如下：
妥尔油二乙醇酰胺辛烯基琥珀酸单酯5份，油酸三乙醇胺酯3份，硼酸三乙醇胺酯15份，聚醚L61 5份，Surfyonl DF-110D 0.1份，三乙醇胺5份，去离子水66.9份。
妥尔油二乙醇酰胺辛烯基琥珀酸单酯制备方法同实施例1。妥尔油、二乙醇胺、辛烯基琥珀酸酐的质量比为3：0.8：2.5。
实施例3
该不锈钢切削液包括按质量百分比计的组分如下：
妥尔油二乙醇酰胺辛烯基琥珀酸单酯15份，油酸三乙醇胺酯1份，硼酸三乙醇胺酯5份，聚醚L61 2份，Surfyonl DF-110D 1份，三乙醇胺2份，去离子水74份。
妥尔油二乙醇酰胺辛烯基琥珀酸单酯制备方法同实施例1。妥尔油、二乙醇胺、辛烯基琥珀酸酐的质量比为3：1.2：1.5。
上述实施例的制备方法：
(1)妥尔油二乙醇酰胺辛烯基琥珀酸单酯，油酸三乙醇胺酯，硼酸三乙醇胺酯，聚醚L61，Surfyonl DF-110D，三乙醇胺加入到混料罐，充分搅拌得到黄色透明粘稠液；
(2)将去离子水加入到步骤(1)中，充分搅拌得到水基不锈钢切削液。
上述实施例的使用方法：
按以下质量比例配置：去离子水：本发明切削液＝95％：5％。将切削液和去离子水混合并使搅拌器在100rpm的转速下搅拌5分钟，得到悬浮稳定的工作液供切削设备使用。
为了验证本发明的切削液性能，现选取实施例1进行性能评价
通过和国标对比，本发明产品优于国标水平。
最后说明的是，以上实施例仅用以说明本发明的技术方案而非限制，尽管参照较佳实施例对本发明进行了详细说明，本领域的普通技术人员应当理解，可以对本发明的技术方案进行修改或者等同替换，而不脱离本发明技术方案的宗旨和范围，其均应涵盖在本发明的权利要求范围当中。
Claims (4)
1.一种水基不锈钢切削液，其主体成分及用量包括：妥尔油二乙醇酰胺辛烯基琥珀酸单酯5-15份，油酸三乙醇胺酯1-3份，硼酸三乙醇胺酯5-15份，聚醚L61 2-5份，SurfyonlDF-110D 0.1-1份，三乙醇胺2-5份，去离子水60-90份，所述的妥尔油二乙醇酰胺辛烯基琥珀酸单酯制备方法如下：妥尔油加入到反应釜中，然后搅拌升温至90-110℃，加入二乙醇胺，升温至 120-140℃反应 3-6h，接着降温至80-100℃，加入辛烯基琥珀酸酐继续反应1-3小时，降至室温放料得到妥尔油二乙醇酰胺辛烯基琥珀酸单酯。
2.根据权利要求1所述的水基不锈钢切削液，其特征在于，妥尔油二乙醇酰胺辛烯基琥珀酸单酯10份，油酸三乙醇胺酯2份，硼酸三乙醇胺酯10份，聚醚L61 5份，Surfyonl DF-110D 0.5份，三乙醇胺5份，去离子水67.5份。
3.根据权利要求1所述的水基不锈钢切削液，其特征在于，妥尔油、二乙醇胺、辛烯基琥珀酸酐的质量比为3：0.8-1.2：1.5-2.5。
4.一种如权利要求1所述的水基不锈钢切削液的制备方法，其特征在于：
（1）妥尔油二乙醇酰胺辛烯基琥珀酸单酯，油酸三乙醇胺酯，硼酸三乙醇胺酯，聚醚L61，Surfyonl DF-110D，三乙醇胺加入到混料罐，充分搅拌得到黄色透明粘稠液；
（2）将去离子水加入到步骤（1）中，充分搅拌得到水基不锈钢切削液。
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