CN111534359B - 一种基于elid磨削的砂轮在位电火花精密修形用加工液 - Google Patents

一种基于elid磨削的砂轮在位电火花精密修形用加工液 Download PDF

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CN111534359B
CN111534359B CN202010346583.9A CN202010346583A CN111534359B CN 111534359 B CN111534359 B CN 111534359B CN 202010346583 A CN202010346583 A CN 202010346583A CN 111534359 B CN111534359 B CN 111534359B
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关佳亮
郭奎崇
尚海洋
徐真真
王建杰
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Beijing University of Technology
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Abstract

本发明公开了一种基于ELID磨削的砂轮在位精密电火花修形用加工液，属于电火花精密加工领域。加工液的组成成分为：三元聚羧酸、三乙醇胺、石油磺酸钠、辛基酚聚氧乙烯醚、聚乙二醇、松香、聚乙二醇、聚乙烯醇、均三嗪、聚醚酯、山梨醇酐月桂酸酯、高碳醇、正辛酸、巯基苯并噻唑、去离子水。该加工液在符合电火花加工所要求的电导率较低，能够进行放电蚀除的同时，还具有杂质少对ELID专用磨削液电解修锐功能无影响特点。解决了传统加工液在进行ELID磨削在位电火花精密电火花修形时参入ELID专用磨削液后使磨削液的电导率降低、影响电解修锐功能，提高了加工效率和精度。同时该加工液以去离子水为基础液，其中的添加剂成分所占比例较少，对环境无污染。

Description

一种基于ELID磨削的砂轮在位电火花精密修形用加工液
技术领域
本发明涉及的技术领域为金属基超硬磨料砂轮的精密加工。具体涉及为一种基于ELID磨削的砂轮在位电火花精密修形用加工液，解决金属结合剂超硬磨料砂轮精密修形难题，提高磨削加工精度和质量。
促进硬脆材料的应用和发展
背景技术
ELID磨削技术在具有砂轮形状精度保持性高，能够进行在线修锐特点的同时，也存在着所用金属结合剂超硬磨料砂轮修形难的难题。电火花加工技术能够对金属难加工材料进行复杂形面的精密加工，可实现砂轮的进行精密修形。然而针对在位电火花修形、在线电解修锐(ELID磨削)精密加工方法而言，传统的电火花加工液(煤油、含芳烃的矿物油)在对砂轮进行修形时，会渗入到ELID磨削液中，使磨削液对砂轮的在线电解修锐功能降低。采用去离子水为介质的加工液虽然可以克服煤油的缺点，但却存在着电导率不稳定，放电效率低，放电火花大小难以控制的缺点。本发明针对上述电火花加工介质应用于在位电火花修形时存在的问题，开发一种基于ELID磨削的砂轮在位电火花精密修形用加工液。
发明内容
针对ELID磨削金属基超硬磨料砂轮在位电火花精密修形中传统电火花加工液煤油存在污染ELID磨削液，使砂轮的电解修锐功能降低和以去离子水为介质的电导率不稳定的难题，本发明提供了一种基于ELID磨削的砂轮在位电火花精密修形用加工液，既能够满足作为放电介质达产生火花放电到蚀除金属的目的，又能够减小放电间隙和稳定放电火花能量使蚀除量微小均匀。同时该加工液具有良好的冷却、排屑、防锈、润滑、清洗等作用，可以提高电火花加工精度和效率，使电火花更加均匀，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，不会影响ELID磨削液的电导率，且添加剂成分所占比例少，对环境无污染。
一种基于ELID磨削的砂轮在位电火花精密修形用加工液，其特征在于：三元聚羧酸、三乙醇胺、石油磺酸钠、辛基酚聚氧乙烯醚、松香、聚乙二醇、聚乙烯醇、均三嗪、聚醚酯、山梨醇酐月桂酸酯、高碳醇、正辛酸、巯基苯并噻唑、去离子水。各组分质量百分含量为：0.76％～1.03％的三元聚羧酸、1.3％～2.1％的三乙醇胺、1.1％～1.7％的石油磺酸钠、0.67％～1％的辛基酚聚氧乙烯醚、2.1％～2.8％的聚乙二醇、1％～1.3％的松香、1.1％～1.5％的聚乙烯醇、1.2％～2.1％的均三嗪、2％～2.6％的聚醚酯、1.1％～1.6％的山梨醇酐月桂酸酯、0.3％～0.5％的高碳醇、1％～1.4％的正辛酸、1.3％～1.8％的巯基苯并噻唑、78.77％～85.07％的去离子水。
该加工液在使用时，需与去离子水以1:20的比例稀释。
一种基于ELID磨削的砂轮在位电火花精密修形用加工液，其特征在于，制备具体步骤如下：
S1将三元聚羧酸和三乙醇胺以1:1～1.2的比例混合配制，均匀搅拌8-10min，混合温度为30℃～35℃，制作防锈剂复配剂；
S2将S1配制的复配剂与聚醚酯、高碳醇、山梨醇酐月桂酸酯、去离子水充分混合，匀速搅拌35～40min，混合温度为30℃～40℃；
S3将石油磺酸钠、辛基酚聚氧乙烯醚、松香、聚乙二醇、聚乙烯醇、正辛酸、三乙醇胺添加到S2配制的备用溶液中，升温至45℃～50℃进行混合，均匀搅拌35～40min，冷却至25℃～30℃备用；
S4将均三嗪、巯基苯并噻唑添加到S3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。
S5将S4配制的加工液与去离子水以1:20的比例稀释后方可应用于电火花加工中。
所述三元聚羧酸、三乙醇胺防锈剂，可以抑制湿气及其它化学成份对机床床身和工具电极造成腐蚀，两者协同使用可以提高防锈性能，使机床保持良好电火花加工性能；
所述聚醚酯为润滑剂，对加工表面进行润滑、清洗，提高工件已加工表面质量和精度，保护加工电极表面，同时能够降低开发液的电导率，并具有防锈功能。
所述高碳醇为消泡剂，抑制电火花加工过程中泡沫产生或消除已产生的泡沫，防止因气泡的存在对被加工工件的表面质量产生影响，同时防止加工液因漫溢而损失，保持该加工液的稳定性；
所述山梨醇酐月桂酸酯为乳化剂，能降低分散相与分散介质间的界面张力，防止分散相液滴的相互聚结形成分层、析油、相变，使加工液形成均匀稳定的分散体系；
所述石油磺酸钠、辛基酚聚氧乙烯醚为表面活性复配剂，可以控制加工液具有适当的表面张力，使加工液具有良好的乳化、分散、浸润、洗涤、防腐和增容性能，两种成分协同使用配制而成的复配剂可以增强乳化性能，从而减少乳化剂的用量，提高加工液的稳定性；
所述聚乙二醇、松香为爆炸剂，增强加工液在火花放电时的爆炸力，提高电火花加工过程中的电蚀除能力和排屑效率。
所述聚乙二醇、聚乙烯醇为分散剂，促使加工液中的各种添加剂在加工液中能够均匀溶解，加工过程中保持放电火花的稳定，蚀除量均匀；
所述正辛酸、三乙醇胺为PH调节剂，平衡加工液的PH值，使加工液达到合适的酸碱度；
所述均三嗪为杀菌剂，能有效地控制或杀死加工液中的病原微生物，兼具防腐蚀的作用；
所述巯基苯并噻唑为缓蚀剂，对机床床身、电极和工件起到防腐蚀的作用；
所述去离子水，在电火花加工过程中作为放电介质的同时起到冷却和冲洗的作用。
本发明所涉及的一种基于ELID磨削的砂轮在位电火花精密修形用加工液与传统电火花加工液不同，主要的优点在于：
1)该加工液具有优良的清洗、润滑、防锈、排屑等功用；
2)一种基于ELID磨削的砂轮在位电火花精密修形用加工液在符合电火花加工所要求的电导率较低，能够进行放电蚀除的同时，还具有杂质少对ELID专用磨削液电解修锐功能无影响特点；
3)开发液在电火花加工过程中的物理和化学作用下，能够使电火花爆炸产生能量的大小和均匀性可控；
4)开发液电导率可以根据精密加工精度要求，通过调整加工液中润滑剂、分散剂和爆炸剂等添加剂成分的比例关系使开发液的电导率保持在1x10-11us/cm～1.5us/cm之间。加工间隙可以减小到一微米左右，放电火花也可以调整得更加致密、连续、微小，实现电火花加工的微米级去除，获得更高加工的精度和表面质量。
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
一种基于ELID磨削的砂轮在位电火花精密修形用加工液，各组分质量百分含量为：0.78％的三元聚羧酸、1.4％的三乙醇胺、1.3％的石油磺酸钠、0.72％的辛基酚聚氧乙烯醚、2.3％的聚乙二醇、1％的松香、1.2％的聚乙烯醇、1.3％的均三嗪、2.2％的聚醚酯、1.3％的山梨醇酐月桂酸酯、0.3％的高碳醇、1.1％的正辛酸、1.5％的巯基苯并噻唑、83.6％的去离子水。
S1将0.78％三元聚羧酸和0.83％三乙醇胺以1:1的比例混合配制，均匀搅拌8min，混合温度为35℃，制作防锈剂复配剂；
S2将S1配制的复配剂与2.2％聚醚酯、0.3％高碳醇、0.78％山梨醇酐月桂酸酯、83.6％去离子水充分混合，匀速搅拌35min，混合温度为35℃；
S3将1.3％石油磺酸钠、0.72％辛基酚聚氧乙烯醚、2.3％聚乙二醇、1％松香、1.2％聚乙烯醇、1.1％正辛酸、0.57％三乙醇胺添加到S2配制的备用溶液中，升温至45℃进行混合，均匀搅拌36min，冷却至25℃备用；
S4将1.3％均三嗪、1.5％巯基苯并噻唑添加到S3配制的备用溶液中，均匀搅拌20min，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1:20的比例稀释后方可应用于电火花加工中。
实施例2
一种基于ELID磨削的砂轮在位电火花精密修形用加工液，各组分质量百分含量为：1％的三元聚羧酸、1.9％的三乙醇胺、1.6％的石油磺酸钠、0.83％的辛基酚聚氧乙烯醚、2.3％的聚乙二醇、1.3％的松香、1.3％的聚乙烯醇、1.2％的均三嗪、2.5％的聚醚酯、1.5％的山梨醇酐月桂酸酯、0.3％的高碳醇、1.1％的正辛酸、1.5％的巯基苯并噻唑、81.67％的去离子水。
S1将1％三元聚羧酸和1.2％三乙醇胺以1:1.2的比例混合配制，均匀搅拌10min，混合温度为33℃，制作防锈剂复配剂；
S2将S1配制的复配剂与2.5％聚醚酯、0.3高碳醇、1.5％山梨醇酐月桂酸酯、81.67％去离子水充分混合，匀速搅拌40min，混合温度为40℃；
S3将1.6％石油磺酸钠、0.83％辛基酚聚氧乙烯醚、2.3％聚乙二醇、1.3％松香、1.3％聚乙烯醇、1.1％正辛酸、0.7％三乙醇胺添加到S2配制的备用溶液中，升温至50℃进行混合，均匀搅拌40min，冷却至30℃备用；
S4将1.2％均三嗪、1.5％巯基苯并噻唑添加到S3配制的备用溶液中，均匀搅拌22min，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1:20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 (1)

1.一种基于ELID磨削的砂轮电火花在位精密修形用加工液，其特征在于：三元聚羧酸、三乙醇胺、石油磺酸钠、辛基酚聚氧乙烯醚、聚乙二醇、松香、聚乙烯醇、均三嗪、聚醚酯、山梨醇酐月桂酸酯、高碳醇、正辛酸、巯基苯并噻唑和去离子水；各组分质量百分含量为：0.76％～1.03％的三元聚羧酸、1.3％～2.1％的三乙醇胺、1.1％～1.7％的石油磺酸钠、0.67％～1％的辛基酚聚氧乙烯醚、2.1％～2.8％的聚乙二醇、1％～1.3％的松香、1.1％～1.5％的聚乙烯醇、1.2％～2.1％的均三嗪、2％～2.6％的聚醚酯、1.1％～1.6％的山梨醇酐月桂酸酯、0.3％～0.5％的高碳醇、1％～1.4％的正辛酸、1.3％～1.8％的巯基苯并噻唑、78.77％～85.07％的去离子水；
该加工液在使用时，需与去离子水以1:20的比例稀释；
制备具体步骤如下：
S1将三元聚羧酸和三乙醇胺以1:1~1.2的比例混合配制，均匀搅拌8-10min，混合温度为30℃~35℃，制作防锈剂复配剂；
S2将S1配制的复配剂与聚醚酯、高碳醇、山梨醇酐月桂酸酯、去离子水充分混合，匀速搅拌35～40min，混合温度为30℃~40℃；
S3将石油磺酸钠、辛基酚聚氧乙烯醚、聚乙二醇、松香、聚乙二醇、聚乙烯醇、正辛酸、三乙醇胺添加到S2配制的备用溶液中，升温至45℃~50℃进行混合，均匀搅拌35～40min，冷却至25℃~30℃备用；
S4将均三嗪、巯基苯并噻唑添加到S3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；
S5将S4配制的加工液与去离子水以1:20的比例稀释后应用于电火花加工中；
所述聚醚酯为润滑剂；
所述聚乙二醇、聚乙烯醇为分散剂；
所述聚乙二醇、松香为爆炸剂；
所述润滑剂、分散剂和爆炸剂按比例配制成形后，在电火花加工过程中的物理和化学作用下，能够使电火花爆炸产生能量的程度和均匀性可控。
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