CN113528219A - 一种环保型水溶性金属加工切削液 - Google Patents
一种环保型水溶性金属加工切削液 Download PDFInfo
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- CGMKPKRNUNDACU-UHFFFAOYSA-N carbamimidoyl(dodecyl)azanium;chloride Chemical compound Cl.CCCCCCCCCCCCN=C(N)N CGMKPKRNUNDACU-UHFFFAOYSA-N 0.000 claims abstract description 27
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Abstract
本发明属于切削液领域,具体涉及一种环保型水溶性金属加工切削液,本方案提供一种环保型水溶性金属加工切削液,包括:20.0%~40.0%的自乳化合成脂、20.0%~30.0%的二元羧酸、25.0%~35.0的pH值调节剂、5.0%~25.0软化水、0.5%~8.0%十二烷基胍盐酸盐、5.0%~14.0%醇醚羧酸。十二烷基胍盐酸盐可以灭杀TGB、SRB和FB三种菌,有效抑制切削液中细菌滋生,提高了切削液的抗菌性,同时提高切削液的稳定性,醇醚羧酸在酸碱环境下具有优良的抗电解质稳定性,可以提高切削液的抗硬化能力。本方案通过添加十二烷基胍盐酸盐有效抑制了切削液中细菌滋生,同时保持了切削液中物质稳定,提高了切削液的稳定性。
Description
技术领域
本发明属于切削液领域,具体涉及一种环保型水溶性金属加工切削液。
背景技术
切削液(cutting fluid,coolant)是一种用在金属切削、磨加工过程中,用来冷却和润滑刀具和加工件的工业用液体,切削液由多种超强功能助剂经科学复合配合而成,同时具备良好的冷却性能、润滑性能、防锈性能、除油清洗功能、防腐功能、易稀释特点。克服了传统皂基乳化液夏天易臭、冬天难稀释、防锈效果差的毛病,对车床漆也无不良影响,适用于黑色金属的切削及磨加工,属当前最领先的磨削产品。
申请号为CN201410548551.1文件了一种用于切削加工的全合成润滑防锈组合物,组合物按质量百分比包括以下组分:30.0%~40.0%的自乳化合成酯、25.0%~35.0%的二元羧酸、25.0%~35.0%的pH值调节剂、10.0%~20.0%的软化水;具有优良的润滑性、防锈性、冷却性和清洗性,能有效减少金属加工过程的摩擦力,降低摩擦热,并保证加工工件的光洁度,在自来水中加入本发明的组合物10.0%~20.0%,即能配制出外观透明,性能稳定的全合成切削液浓缩液。此浓缩液用自来水稀释成5.0%浓度的切削液工作液,可直接用于铸铁和钢材的切削、磨削加工,能满足加工的润滑性能和防锈性能要求,上述方案中切削液在加工设备使用时间比较短,频率比较低时,切削液不能充分与空气接触,切削液中生长的菌为缺氧菌,容易使切削液内细菌滋生繁殖,造成切削液浪费失效,需要进一步提高切削液的抗菌性能。
发明内容
本方案提供一种提高抗菌性的环保型水溶性金属加工切削液。
为了达到上述目的,本方案提供一种环保型水溶性金属加工切削液,包括:20.0%~40.0%的自乳化合成脂、20.0%~30.0%的二元羧酸、25.0%~35.0的pH值调节剂、5.0%~25.0软化水、0.5%~8.0%十二烷基胍盐酸盐、5.0%~14.0%醇醚羧酸。
本方案原理:十二烷基胍盐酸盐可以灭杀TGB、SRB和FB三种菌,有效抑制切削液中细菌滋生,提高了切削液的抗菌性,同时提高切削液的稳定性,醇醚羧酸可以克服阴离子表面活性剂抗硬水性差和非离子表面活性剂钙皂分散能力的缺点,醇醚羧酸不会剧烈发泡,在酸碱环境下具有优良的抗电解质稳定性,可以提高切削液的抗硬化能力。
本方案有益效果:本方案通过添加十二烷基胍盐酸盐有效抑制了切削液中细菌滋生;同时保持了切削液中物质稳定,提高了切削液的稳定性;对环境无污染,绿色环保;有效抑制细菌滋生减少对加工设备的腐蚀,提高加工设备使用寿命;不会剧烈发泡,起到更好的降温和冲洗效果,减少切削液的散失,降低成本;方便快速回收切削液。
进一步,26.0%自乳化合成脂、25.0%二元羧酸、25.0%的pH值调节剂、10.0%软化水、4.0%十二烷基胍盐酸盐、10.0%醇醚羧酸。
进一步,一种环保型水溶性金属加工切削液制备方法包括以下步骤:
步骤1:按照比例配置自乳化合成脂、二元羧酸、pH值调节剂、软化水、十二烷基胍盐酸盐与醇醚羧酸;步骤2:将自乳化合成脂添加到反应釜中,并加热至60℃~75℃;步骤3:将二元羧酸、十二烷基胍盐酸盐与醇醚羧酸均匀混合后添加到反应釜中;步骤4:将pH值调节剂和软化水添加到反应釜中,在5℃~10℃温度下搅拌均匀20~50min,即可制得切削液。
进一步,所述步骤1中乳化合成脂、二元羧酸与pH值调节剂质量比为1.04:1:1。
进一步,所述步骤1中软化水含有0.1%-0.3%的三聚磷酸钠或者二乙胺四醋酸铵,使水质变软,提高切削液的抗硬化能力。
进一步,所述步骤4中采用电磁搅拌的方式对反应釜中混合液均匀搅拌。可以使物质尽可能充分混合,使物质分布均匀。
进一步,所述步骤4采用电动控制的带有螺旋桨式搅拌头的机械搅拌方式进行反应釜中混合液均匀搅拌,搅拌头转速为150~250rmp/min。可以使物质尽可能充分混合,使物质分布均匀。
进一步,所述步骤4中配合使用超声波的方式进行混合液振荡,超声波对混合液进行分散,使物质充分混合。
本方案通过添加十二烷基胍盐酸盐和醇醚羧酸,有效抑制切削液中细菌滋生,提高了切削液的抗菌性,同时提高切削液的稳定性,醇醚羧酸可以克服阴离子表面活性剂抗硬水性差和非离子表面活性剂钙皂分散能力的缺点,醇醚羧酸不会剧烈发泡,在酸碱环境下具有优良的抗电解质稳定性,可以提高切削液的抗硬化能力。
附图说明
图1为本发明实施例3添加十二烷基胍盐酸盐切削液SRB菌15天生长变化曲线。
图2为本发明实施例4的一种环保型水溶性金属加工切削液使用装置的结构示意图。
图3为本发明实施例4的一种环保型水溶性金属加工切削液使用装置的逻辑框图。
具体实施方式
下面通过具体实施方式进一步详细的说明:
附图说明:机床1、设备2、喷头3、管道4、抽液泵5、切削液箱6、搅拌轴7、螺旋叶片8、摄像头9、振动传感器10、电机11。
实施例1:
本实施例提供一种环保型水溶性金属加工切削液,包括:20.0%~40.0%的自乳化合成脂(本实施例中自乳化合成脂质量分数为26.0%)、20.0%~30.0%的二元羧酸(本实施例中二元羧酸质量分数为25.0%)、25.0%~35.0的pH值调节剂(本实施例中pH值调节剂质量分数为25.0%)、5.0%~25.0%的软化水(本实施例中软化水质量分数为10.0%)、0.5%~5%十二烷基胍盐酸盐(本实施例中十二烷基胍盐酸盐质量分数为2.0%)、3.0%~10.0%醇醚羧酸(本实施例中醇醚羧酸质量分数为12.0%)。
上述环保型水溶性金属加工切削液制备方法包括以下步骤:
步骤1:按照质量分数比例配置自乳化合成脂、二元羧酸、pH值调节剂、软化水、十二烷基胍盐酸盐与醇醚羧酸;软化水含有0.1%-0.3%的三聚磷酸钠或者二乙胺四醋酸铵,使水质变软,提高切削液的抗硬化能力;本实施例中二元羧酸为长链二元羧酸和短链二元羧酸混合。
步骤2:将自乳化合成脂添加到反应釜中,并加热至60℃~75℃;
步骤3:将二元羧酸、十二烷基胍盐酸盐与醇醚羧酸均匀混合后添加到反应釜中;
步骤4:将pH值调节剂和软化水添加到反应釜中,在5℃~10℃温度下搅拌均匀20~50min,即可制得切削液。采用电磁搅拌的方式对反应釜中混合液均匀搅拌。可以使物质尽可能充分混合,使物质分布均匀。采用电动控制的带有螺旋桨式搅拌头的机械搅拌方式进行反应釜中混合液均匀搅拌,搅拌头转速为150~250rmp/min。可以使物质尽可能充分混合,使物质分布均匀。
在充分搅拌呼和物质时配合使用超声波的方式进行混合液振荡,超声波对混合液进行分散,使物质充分混合。
实施例2:本实施例与实施例1不同之处在于,一种环保型水溶性金属加工切削液包括:26.0%自乳化合成脂、25.0%二元羧酸、25.0%的pH值调节剂、10.0%软化水、3.2%十二烷基胍盐酸盐、11.8%醇醚羧酸。
实施例3:本实施例与实施例1不同之处在于,一种环保型水溶性金属加工切削液包括:26.0%自乳化合成脂、25.0%二元羧酸、25.0%的pH值调节剂、10.0%软化水、4.0%十二烷基胍盐酸盐、10%醇醚羧酸。
实施例4:本实施例与实施例1不同之处在于,提供了一种环保型水溶性金属加工切削液的使用装置,如附图2所示,具体包括:机床1与用于加工的设备2,设备2通过螺栓固定安装在机床1上,机床1上设置有凹槽,凹槽中放置有切削液箱6,切削液箱6中填充有切削液,切削液顶部设有开口,开口用于添加切削液,切削液表面设有密封盖,密封盖用于封住开口,防止粉尘等杂质进入到切削液箱6中污染切削液。切削液箱6中设有搅拌轴7,切削液箱6上螺栓固定有带动搅拌轴7转动的电机11,电机11位于切削液箱6顶部,电机11的输出轴与搅拌轴7焊接在一起。搅拌轴7与切削液底部转动连接,搅拌轴7上焊接有螺旋叶片8,当搅拌轴7正转时,螺旋叶片8会使切削液向上运动,使切削液与空气接触;当搅拌轴7反转时,螺旋叶片8会使切削液向下运动,挤压切削液,使切削液的压力增大。
机床1上螺栓安装有抽液泵5,抽液泵5为galileo/伽利略不锈钢SB-3-1(防爆)抽油泵,抽液泵5一端与切削液箱6连通,另外一端连通有管道4,管道4连通有喷头3,管道4与喷头3均固定安装在机架上,喷头3用于向设备2喷切削液,切削液对设备2进行冷却降温。
还包括喷头3频率采集模块,喷头3频率采集模块用于采集喷头3的振动频率,本实施实例中采用振动传感器10进行频率采集,振动传感器10具体型号为6011975IM12-04NPS-ZW1。振动传感器10螺栓安装在喷头3表面,振动传感器10用于采集喷头3的振动频率。当喷头3喷出的切削液混合不均衡时,喷头3会受到不规则的冲击;当喷头3喷出的切削液混合均匀,呈胶体状态时,振动传感器10受到均匀的冲击。机床1上螺栓安装有PLC控制器,具体的控制器采用stm32f103c8t6的单片机,PLC控制器与振动传感器10和电机11均电连接。频率采集模块每30S采集获取一次喷头3频率数据,然后对比频率增长率,当频率增长率大于设定的频率增长率时,发送搅拌信号当PLC控制器上。
还包括烟雾识别模块,烟雾辨辨别模块用于采集设备2冒烟信息,当切削液的闪点太低或者温度过高,飞溅出的切削液会冒烟,切削液温度过高会对加工设备造成一定损伤,降温效果差。本实施例中烟雾识别模块采用华为Hikey970AI人工智能开发板,采用摄像头9进行拍摄设备2图片,摄像头9为C12网络摄像头,摄像头9将数据传送到华为Hikey970AI人工智能开发板中。烟雾识别模块每隔2秒截取一帧监控视频的图像,通过K-Meas算法对其中的烟雾团进行识别拟合得到疑似图形。烟雾识别模块内存储有通过卷积神经网络算法根据各种烟团图形训练出的烟团模型,烟雾识别模块将疑似图形输入到烟团模型中拟合得到烟团拟合度。在烟团拟合度大于第一阈值或烟升增长率大于第二阈值时输出识别辨认到烟团。若识别辨认到烟团,则在30秒内以5秒的间隔周期向分析模块发送烟情信号。
具体使用切削液对设备2降温时,频率采集模块对喷头3的振动频率进行采集,频率采集模块每30S采集获取一次喷头3频率数据,然后对比频率增长率,当频率增长率大于设定的频率增长率时,发送搅拌信号当PLC控制器上,PLC控制器收到搅拌信号使电机11启动,使电机11正转,电机11带动搅拌轴7与螺旋叶片8对切削液进行搅拌。烟雾辨辨别模块采集设备2冒烟信息,烟雾识别模块每隔2秒截取一帧监控视频的图像,通过K-Meas算法对其中的烟雾团进行识别拟合得到疑似图形。烟雾识别模块内存储有通过卷积神经网络算法根据各种烟团图形训练出的烟团模型,烟雾识别模块将疑似图形输入到烟团模型中拟合得到烟团拟合度。在烟团拟合度大于第一阈值或烟升增长率大于第二阈值时输出识别辨认到烟团。若识别辨认到烟团,则在30秒内以5秒的间隔周期向分析模块发送烟情信号到PLC控制器,PLC控制器控制反转,使搅拌轴7与螺旋叶转动,使切削液向下运动,使切削液的压力增大,使喷出的切削液降温效果增强。通过喷头3频率变化实时控制搅拌轴7对切削液进行搅拌,使切削液混合均匀,使切削液效果更好;通过烟雾识别模块对设备2处的切削液冒烟情况进行分析,从而控制搅拌轴7与螺旋叶正转或者反转,正当搅拌轴7正转时,螺旋叶片8会使切削液向上运动,使切削液与空气接触,增多切削液中气体量,节约成本;当搅拌轴7反转时,螺旋叶片8会使切削液向下运动,挤压切削液,使切削液的压力增大,使切削液的降温效果更好;通过对搅拌轴进行控制,进而控制切削液的温度,切削液温度变化减小,防止加工设备因切削液温度变化较大造成损伤,增加加工设备的使用寿命。
对比例1:本实施例与实施例1不同之处在于,一种环保型水溶性金属加工切削液包括:26.0%自乳化合成脂、25.0%二元羧酸、25.0%的pH值调节剂、14.0%软化水、0.0%十二烷基胍盐酸盐、10.0%醇醚羧酸。
对比例2:本实施例与实施例1不同之处在于,一种环保型水溶性金属加工切削液包括:26.0%自乳化合成脂、25.0%二元羧酸、25.0%的pH值调节剂、20.0%软化水、4.0%十二烷基胍盐酸盐、0.0%醇醚羧酸。
对比例3:本实施例与实施例1不同之处在于,一种环保型水溶性金属加工切削液包括:26.0%自乳化合成脂、25.0%二元羧酸、25.0%的pH值调节剂、24.0%软化水、0.0%十二烷基胍盐酸盐、0.0%醇醚羧酸。
为了方便直观的对比,我们将实施例1~4及对比例1~3中各组成分和含量进行列表说明,如表1所示:
将所有实施例和对比例制备的切削液进行抗菌试验,准备200mL的玻璃容器,分别装入实施例1~3和对比例1~3制备的切削液100ml,在37℃下放置2周,然后进行PH值、微生物检测试验,根据PH值的降低程度和微生物的繁殖程度判断试验液的腐败状态。具体结果如表2所示:
序号 | PH值 | 微生物数量(数量/ml) |
实施例1 | 3.5 | 60 |
实施例2 | 4 | 52 |
实施例3 | 6.7 | 20 |
对比例1 | 3 | 79 |
对比例2 | 4.5 | 24 |
对比例3 | 3.1 | 72 |
由实施例1、实施例2、实施例3、实施例4、对比例1、对比例2与对比例3得到,添加十二烷基胍盐酸盐能有效抑制切削液中细菌繁殖,减慢切削液腐败速度,能有效提高切削液的抗菌性。
对比例2中切削液SRB菌15天生长变化曲线如附图1所示,由实施例1~实施例3,对比例1~3可以证明,添加十二烷基胍盐酸盐可以有效抑制切削液中细菌滋生,提高了切削液的抗菌性。证明本方案添加十二烷基胍盐酸盐能有效的抑制细菌生长,提高切削液的稳定性,同时醇醚羧酸可以克服阴离子表面活性剂抗硬水性差和非离子表面活性剂钙皂分散能力的缺点,醇醚羧酸不会剧烈发泡,在酸碱环境下具有优良的抗电解质稳定性,可以提高切削液的抗硬化能力;对环境无污染,绿色环保;有效抑制细菌滋生减少对加工设备的腐蚀,提高加工设备使用寿命;不会剧烈发泡,起到更好的降温和冲洗效果,减少切削液的散失,降低成本;方便快速回收切削液。
以上所述的仅是本发明的实施例,方案中公知的具体结构及特性等常识在此未作过多描述。应当指出,对于本领域的技术人员来说,在不脱离本发明结构的前提下,还可以作出若干变形和改进,这些也应该视为本发明的保护范围,这些都不会影响本发明实施的效果和专利的实用性。本申请要求的保护范围应当以其权利要求的内容为准,说明书中的具体实施方式等记载可以用于解释权利要求的内容。
Claims (8)
1.一种环保型水溶性金属加工切削液,包括:20.0%~40.0%的自乳化合成脂、20.0%~30.0%的二元羧酸、25.0%~35.0的pH值调节剂、5.0%~25.0软化水、0.5%~8.0%十二烷基胍盐酸盐、5.0%~14.0%醇醚羧酸。
2.根据权利要求1所述的一种环保型水溶性金属加工切削液,其特征在于:还包括26.0%自乳化合成脂、25.0%二元羧酸、25.0%的pH值调节剂、10.0%软化水、4.0%十二烷基胍盐酸盐、10.0%醇醚羧酸。
3.根据权利要求1所述的一种环保型水溶性金属加工切削液的制备方法,其特征在于:包括以下步骤:步骤1:按照比例配置自乳化合成脂、二元羧酸、pH值调节剂、软化水、十二烷基胍盐酸盐与醇醚羧酸;步骤2:将自乳化合成脂添加到反应釜中,并加热至60℃~75℃;步骤3:将二元羧酸、十二烷基胍盐酸盐与醇醚羧酸均匀混合后添加到反应釜中;步骤4:将pH值调节剂和软化水添加到反应釜中,在5℃~10℃温度下搅拌均匀20~50min,即可制得切削液。
4.根据权利要求3所述的一种环保型水溶性金属加工切削液的制备方法,其特征在于:所述步骤1中乳化合成脂、二元羧酸与pH值调节剂质量比为1.04:1:1。
5.根据权利要求3所述的一种环保型水溶性金属加工切削液的制备方法,其特征在于:所述步骤1中软化水含有0.1%-0.3%的三聚磷酸钠或者二乙胺四醋酸铵。
6.根据权利要求3所述的一种环保型水溶性金属加工切削液的制备方法,其特征在于:所述步骤4中采用电磁搅拌的方式对反应釜中混合液均匀搅拌。
7.根据权利要求3所述的一种环保型水溶性金属加工切削液的制备方法,其特征在于:所述步骤4采用电动控制的带有螺旋桨式搅拌头的机械搅拌方式进行反应釜中混合液均匀搅拌,搅拌头转速为150~250rmp/min。
8.根据权利要求3所述的一种环保型水溶性金属加工切削液的制备方法,其特征在于:所述步骤4中配合使用超声波的方式进行混合液振荡。
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