CN110125495A - 一种提高电火花加工效率的加工液及其制备方法 - Google Patents

一种提高电火花加工效率的加工液及其制备方法 Download PDF

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CN110125495A
CN110125495A CN201910391148.5A CN201910391148A CN110125495A CN 110125495 A CN110125495 A CN 110125495A CN 201910391148 A CN201910391148 A CN 201910391148A CN 110125495 A CN110125495 A CN 110125495A
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关智
刘本东
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Hefei Minglong Electronic Technology Co ltd
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Abstract

本发明公开了一种提高电火花加工效率的加工液及其制备方法,属于电火花精密加工领域。该加工液的组成成分为:石油磺酸钠、壬基酚聚氧乙烯醚、三乙醇胺、二环己胺、聚乙二醇、蔗糖、二聚棉籽油酸、OP‑10(聚氧乙烯烷基酚醚‑10)、聚乙烯醇、聚硅氧烷、正辛酸、聚苯胺、异噻唑啉酮、去离子水。该加工液除了具有冷却、排屑、防锈、润滑、清洗等作用,还可以增强电火花加工的效率,减小放电间隙,使放电更加均匀,保证电火花加工工件的加工速度、表面加工质量和加工精度,同时该加工液为水溶性电火花加工液,不含矿物油和有害物质,对环境无污染。

Description

一种提高电火花加工效率的加工液及其制备方法
技术领域
本发明涉及的技术领域为电火花精密加工,广泛应用于模具制造业和砂轮修型领域,推动了模具行业的技术进步。该工作液为电火花加工的重要组成部分之一,作为放电介质与工具电极和工件构成电火花加工系统,在电火花加工过程中还起着冷却、润滑、排屑、增强放电性能等作用,对提高电火花加工整个环节的效率起着重要作用。
背景技术
电火花加工具有能加工难切削材料和复杂形状工件、加工时无切削力、不产生毛刺和刀痕沟纹等缺陷、工具电极材料无须比工件材料硬等优良的特性,广泛应用于模具制造业和砂轮修型领域。在电火花加工中,通常工作液选用煤油、变压器油、含芳烃的矿物油,但这些介质存在挥发快、闪电低、放电间隙大、加工效率低、易发生火灾、对人体有伤害,不环保等缺陷。本发明是针对以上电火花加工液存在的问题而开发的一种提高电火花加工效率的加工液。
发明内容
针对以上电火花加工液存在的问题,本发明提供了一种提高电火花加工效率的工作液,该加工液具有良好的冷却、排屑、防锈、润滑、清洗等作用,可以增强电火花加工的效率,减小放电间隙,使放电更加均匀,保证电火花加工工件的加工速度、表面加工质量和加工精度,不含矿物油和有害物质,对环境无污染。
一种提高电火花加工效率的加工液,其特征在于:包括石油磺酸钠、壬基酚聚氧乙烯醚、三乙醇胺、二环己胺、聚乙二醇、蔗糖、二聚棉籽油酸、OP-10(聚氧乙烯烷基酚醚-10)、聚丙二醇、聚乙烯醇、聚硅氧烷、正辛酸、聚苯胺、异噻唑啉酮、去离子水。各组分质量百分含量为:3%~4.5%的石油磺酸钠、3%~4.5%的壬基酚聚氧乙烯醚、5%~8%的三乙醇胺、4%~6%的二环己胺、2%~3%的聚乙二醇、2%~3%的蔗糖、5%~7%的二聚棉籽油酸、4%~5.5%的OP-10(聚氧乙烯烷基酚醚)、3%~5%的聚丙二醇、3%~5%的聚乙烯醇、0.6%~0.8%的聚硅氧烷、2%~5%的正辛酸、0.8%~1%的聚苯胺、0.8%~1.2%的异噻唑啉酮、41.5%~59.9%的去离子水。
该加工液在使用时,需与去离子水以1:30的比例稀释。
所述一种提高电火花加工效率的加工液及其制备方法,其特征在于,制备具体步骤如下,
S1将石油磺酸钠和壬基酚聚氧乙烯醚以1:1~1.5的比例混合配制,混合温度为30℃~50℃,制作表面活性剂复配剂;
S2将S1配制的复配剂与二聚棉籽油酸、去离子水充分混合,匀速搅拌35~45min,混合温度为25℃~40℃;
S3将三乙醇胺、二环己胺、聚乙二醇、蔗糖、二聚棉籽油酸、OP-10(聚氧乙烯烷基酚醚-10)、聚丙二醇、聚乙烯醇、聚硅氧烷、聚苯胺添加到S2配制的备用溶液中,升温至45℃~55℃进行混合,均匀搅拌,冷却至30℃~35℃备用;
S4将正辛酸、异噻唑啉酮添加到S3配制的备用溶液中,搅拌均匀,冷却至室温得到该电火花加工加工液。
S5将S4配制的加工液与去离子水以1:30的比例稀释后方可应用于电火花加工中。
所述石油磺酸钠、壬基酚聚氧乙烯醚为表面活性剂,可以降低加工液的表面张力,使加工液具有良好的乳化、分散、浸润和增容性能,两种成分协同使用配制而成的复配剂可以增强乳化效率,从而减少乳化剂的用量,增强加工液的稳定性;
所述三乙醇胺、二环己胺为防锈剂,延迟或限制机床、工具电极及被加工件的锈蚀时间和程度,保持良好电火花加工性能;
所述聚苯胺为防腐添加剂,能够有效阻止空气、水、盐分发挥作用,从而遏止金属生锈和腐蚀,延长磨削液使用时间;
所述聚乙二醇、蔗糖为爆炸剂,增加电火花加工的加工效率,有利于放电加工过程中爆炸能量的增加和排屑,是提高电火花加工效率的重要成分;
所述二聚棉籽油酸为润滑剂,润滑、冷却和密封在加工过程中摩擦部分的物质,延长电极的使用寿命,提高电火花加工工件表面质量和精度;
所述OP-10(聚氧乙烯烷基酚醚-10)为乳化剂,改善乳化稳定性和扩大乳化范围,使该加工液防止或减少分层、析油、相变;
所述聚硅氧烷为消泡剂,抑制电火花加工过程中泡沫产生或消除已产生的泡沫,保持该加工液的稳定性;
所述聚丙二醇、聚乙烯醇为分散剂,促使颗粒均匀分布在加工液中,保持加工液稳定性,同时跟其他成分协同作用,具有防锈性、润滑性和表面活性剂的作用;
所述异噻唑啉酮为杀菌剂,抑制和杀灭加工液及电火花加工过程中的细菌和真菌,同时起到防腐蚀的作用;
所述所述正辛酸、三乙醇胺为PH调节剂,调节和平衡加工液的PH值,使加工液达到最佳的酸碱度;
所述去离子水,在电火花过程中起到冷却、润滑和冲洗作用,防止电火花加工过程中出现热化学磨损现象。
本发明所涉及的一种提高电火花加工效率的加工液与传统电火花加工液不同,主要的优点在于:
1)该加工液具有良好的冷却、排屑、防锈、润滑、清洗等作用,可以有效地抑制加工过程中泡沫的产生;
2)可以增强电火花加工的效率,减小放电间隙,使放电更加均匀,保证电火花加工工件的加工速度、表面加工质量和加工精度;
3)不含矿物油和有害物质,对环境无污染,排污处理容易;
具体实施方式
下面将通过具体的实施例对本发明的配制方式进行清楚、完整地描述,所列举的实施例仅是本发明的一部分实施例,而不是全部的实施例。
实施例1
一种提高电火花加工效率的加工液,各组分质量百分含量为:3%的石油磺酸钠、3%的壬基酚聚氧乙烯醚、6%的三乙醇胺、4%的二环己胺、2.5%的聚乙二醇、2.5%的蔗糖、5%的二聚棉籽油酸、5.5%的OP-10(聚氧乙烯烷基酚醚)、3%的聚丙二醇、3%的聚乙烯醇、0.6%的聚硅氧烷、2%的正辛酸、0.8%的聚苯胺、1%的异噻唑啉酮、58.1%的去离子水配制而成。
一种提高电火花加工效率的加工液的制备方法,具体步骤如下:
S1将3%的石油磺酸钠和3%的壬基酚聚氧乙烯醚以1:1的比例混合配制,均匀搅拌10~15min,混合温度为35℃~50℃,配制表面活性剂复配剂;
S2将S1配制的复配剂与5%的二聚棉籽油酸、58.1%的去离子水充分混合,匀速搅拌35~45min,混合温度为30℃~45℃;
S3将6%的三乙醇胺、4%的二环己胺、2.5%的聚乙二醇、2.5%的蔗糖、5%的二聚棉籽油酸、5.5%的OP-10(聚氧乙烯烷基酚醚-10)、3%的聚丙二醇、3%的聚乙烯醇、0.6%的聚硅氧烷、0.8%的聚苯胺添加到S2配制的备用溶液中,升温至50℃~55℃进行混合,均匀搅拌25~35min,自然冷却至30℃~35℃备用;
S4将2%的正辛酸、1%的异噻唑啉酮添加到S3配制的备用溶液中,搅拌均匀,冷却至室温得到该电火花加工加工液。
S5将S4配制的加工液与去离子水以1:30的比例稀释后方可应用于电火花加工中。
实施例2
一种提高电火花加工效率的加工液,各组分质量百分含量为:3%的石油磺酸钠、3.6%的壬基酚聚氧乙烯醚、7%的三乙醇胺、6%的二环己胺、3%的聚乙二醇、3%的蔗糖、6%的二聚棉籽油酸、4%的OP-10(聚氧乙烯烷基酚醚)、4.5%的聚丙二醇、4.5%的聚乙烯醇、0.7%的聚硅氧烷、2%的正辛酸、0.9%的聚苯胺、1.1%的异噻唑啉酮、50.7%的去离子水。
一种提高电火花加工效率的加工液的制备方法,具体步骤如下:
S1将3%的石油磺酸钠和3.6%的壬基酚聚氧乙烯醚以1:1.2的比例混合配制,均匀搅拌10~20min,混合温度为30℃~40℃,配制表面活性剂复配剂;
S2将6%的二聚棉籽油酸、7%的三乙醇胺、6%的二环己胺、3%的聚乙二醇、3%的蔗糖、6%的二聚棉籽油酸、4%的OP-10(聚氧乙烯烷基酚醚-10)、4.5%的聚丙二醇、4.5%的聚乙烯醇、0.7%的聚硅氧烷、0.9%的聚苯胺、58.1%的去离子水添加到S1配制的表面活性剂复配剂中,升温至45℃~55℃进行混合,均匀搅拌30~40min,自然冷却至30℃~40℃备用;
S3将2%的正辛酸、1.1%的异噻唑啉酮添加到S2配制的备用溶液中,均匀搅拌20~25min,冷却至室温得到该电火花加工加工液。
S4将S3配制的加工液与去离子水以1:30的比例稀释后方可应用于电火花加工中。
以上所述仅是本发明的较佳实施例,并非是对本发明其它形式的限制,任何熟悉本专业的技术人员可能利用上述技术内容作为基础加以改变或改进,这些未脱离本发明配制方式的改进,也均应保护为本发明的实施例,仍属于本发明权利要求的保护范围。

Claims (10)

1.一种提高电火花加工效率的加工液,其特征在于:包括石油磺酸钠、壬基酚聚氧乙烯醚、三乙醇胺、二环己胺、聚乙二醇、蔗糖、二聚棉籽油酸、OP-10(聚氧乙烯烷基酚醚-10)、聚丙二醇、聚乙烯醇、聚硅氧烷、正辛酸、聚苯胺、异噻唑啉酮、去离子水;
各组分质量百分含量为:3%~4.5%的石油磺酸钠、3%~4.5%的壬基酚聚氧乙烯醚、5%~8%的三乙醇胺、4%~6%的二环己胺、2%~3%的聚乙二醇、2%~3%的蔗糖、5%~7%的二聚棉籽油酸、4%~5.5%的OP-10(聚氧乙烯烷基酚醚)、3%~5%的聚丙二醇、3%~5%的聚乙烯醇、0.6%~0.8%的聚硅氧烷、2%~5%的正辛酸、0.8%~1%的聚苯胺、0.8%~1.2%的异噻唑啉酮、41.5%~59.9%的去离子水;
该加工液在使用时,需与去离子水以1:30的比例稀释。
2.一种提高电火花加工效率的加工液制备方法,其特征在于,制备具体步骤如下,
S1将石油磺酸钠和壬基酚聚氧乙烯醚以1:1~1.5的比例混合配制,混合温度为30℃~50℃,制作表面活性剂复配剂;
S2将S1配制的复配剂与二聚棉籽油酸、去离子水充分混合,匀速搅拌35~45min,混合温度为25℃~40℃;
S3将三乙醇胺、二环己胺、聚乙二醇、蔗糖、二聚棉籽油酸、OP-10(聚氧乙烯烷基酚醚-10)、聚丙二醇、聚乙烯醇、聚硅氧烷、聚苯胺添加到S2配制的备用溶液中,升温至45℃~55℃进行混合,均匀搅拌,冷却至30℃~35℃备用;
S4将正辛酸、异噻唑啉酮添加到S3配制的备用溶液中,搅拌均匀,冷却至室温得到该电火花加工加工液;
S5将S4配制的加工液与去离子水以1:30的比例稀释后方可应用于电火花加工中。
3.根据权利要求2所述所述的一种提高电火花加工效率的加工液制备方法,其特征在于,所述石油磺酸钠、壬基酚聚氧乙烯醚为表面活性剂,可以降低加工液的表面张力,使加工液具有良好的乳化、分散、浸润和增容性能,两种成分协同使用配制而成的复配剂可以增强乳化效率,从而减少乳化剂的用量,增强加工液的稳定性。
4.根据权利要求2所述所述的一种提高电火花加工效率的加工液制备方法,其特征在于,所述三乙醇胺、二环己胺为防锈剂,延迟或限制机床、电极及被加工件的锈蚀时间和程度。
5.根据权利要求2所述的一种提高电火花加工效率的加工液制备方法,其特征在于,所述聚苯胺为防腐添加剂,能够有效阻止空气、水、盐分发挥作用,从而遏止金属生锈和腐蚀。
6.根据权利要求2所述的一种提高电火花加工效率的加工液制备方法,其特征在于,所述聚乙二醇、蔗糖为爆炸剂,增加电火花加工的加工效率,有利于放电加工过程中爆炸能量的增加和排屑。
7.根据权利要求2所述的一种提高电火花加工效率的加工液制备方法,其特征在于,所述二聚棉籽油酸为润滑剂,润滑、冷却和密封在加工过程中摩擦部分的物质。
8.根据权利要求2所述的一种提高电火花加工效率的加工液制备方法,其特征在于,所述OP-10(聚氧乙烯烷基酚醚-10)为乳化剂。
9.根据权利要求2所述的一种提高电火花加工效率的加工液制备方法,其特征在于,所述聚硅氧烷为消泡剂,抑制电火花加工过程中泡沫产生或消除已产生的泡沫。
10.根据权利要求2所述的一种提高电火花加工效率的加工液制备方法,其特征在于,所述聚丙二醇、聚乙烯醇为分散剂,促使颗粒均匀分布在加工液中,保持加工液稳定性;
所述异噻唑啉酮为杀菌剂,抑制和杀灭加工液及电火花加工过程中的细菌和真菌,同时起到防腐蚀的作用;
所述正辛酸、三乙醇胺为PH调节剂,调节和平衡加工液的PH值,使加工液达到最佳的酸碱度;
所述去离子水,在电火花过程中起到冷却、润滑和冲洗作用,防止电火花加工过程中出现热化学磨损现象。
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