CN114410371B - 一种具有多次沉降性能的水基全合成磨削液及其制备方法 - Google Patents
一种具有多次沉降性能的水基全合成磨削液及其制备方法 Download PDFInfo
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Abstract
本发明提供了一种具有多次沉降性能的水基全合成磨削液及其制备方法,其中,水基全合成磨削液,包括以下重量份的各组分:复合沉降剂0.5‑3份、抗杂油剂1‑5份、防锈剂3‑20份、腐蚀抑制剂2‑6份、碱值储备剂5‑30份、润滑剂1‑15份、杀菌剂1‑5份,余量为水。本发明所述的水基全合成磨削液除具有良好的防锈性、润滑性外,还对磨削加工过程中产生的金属磨屑及砂轮磨屑具有多次且长效的沉降效果,有效提升了加工工件表面质量。
Description
技术领域
本发明属于金属加工液领域,尤其是涉及一种具有多次沉降性能的水基全合成磨削液及其制备方法。
背景技术
金属加工液是指在金属加工过程中所使用的润滑冷却介质,是金属加工过程重要的配套材料。金属加工液具有润滑、冷却、防锈和清洗等作用,能有效延长刀具的使用寿命,防止金属零件和机床锈蚀,并带走加工过程中产生的热量,有效清除零件和刀具表面的切屑和粉尘,从而改善加工质量,提高生产效率。
在金属磨削加工过程中会产生大量的金属屑和金属粉末,这些金属粉末极为细小,会悬浮在磨削液中;再加上设备长期使用,设备中的润滑油、导轨油等进入到磨削液中,使设备中的排屑装置难以将金属屑或金属粉末快速有效的排出,在循环利用时这些金属粉末会残留在被加工金属的表面,使加工表面容易产生划痕,导致加工精度降低及表面光洁度不高等问题。
在一些文献中提及磨削液的配方研制,并针对其沉降性进行过了一定研究,但仅限于单次沉降,并未考虑磨削液的多次沉降性能。由于磨削液在实际应用过程中需循环使用,因此,其对磨屑的多次沉降性能尤为重要。本发明研发的水基全合成磨削液不仅具有磨削液的一般使用性能,而且具有良好的多次沉降性,可在整个循环寿命周期内保持良好的沉降性能。
发明内容
有鉴于此,本发明旨在制备一种具有多次沉降性能的水基全合成磨削液,保证长期循环使用后仍具有良好的沉降性能,提高工件的表面光洁度和加工精度,延长磨削液的使用寿命。
为达到上述目的,本发明的技术方案是这样实现的:
一种具有多次沉降性能的水基全合成磨削液,以100重量份计,包括以下重量份的各组分:
复合沉降剂0.5-3份;
抗杂油剂1-5份;
防锈剂3-20份;
腐蚀抑制剂2-6份;
碱值储备剂5-30份;
润滑剂1-15份;
杀菌剂1-5份;
余量为水。
优选的,所述复合沉降剂为黄原酸酯、二硫代氨基甲酸盐衍生物、二氨基脲聚合物中的两种或两种以上。
优选的,所述复合沉降剂为黄原酸酯、二硫代氨基甲酸盐衍生物、二氨基脲聚合物按质量比(2±0.5):(2±0.5):(1±0.5)的混合物。发明人发现,传统的阳离子型沉降剂消耗快、作用时间短,易失效,且对非金属颗粒沉降效果不佳。本专利所选用的沉降剂其分子结构具多种类、多数量的吸附基团,对磨削液中的金属及非金属粉末磨屑均具有良好的多次吸附性能,可使磨屑发生硬团聚,进而产生多次沉降的效果。
优选的,所述所述抗杂油剂为酚醛胺聚氧丙烯聚氧乙烯醚、烷基酚醛树脂嵌段聚醚、咪唑啉改性共聚物中的至少一种。
优选的,所述抗杂油剂为酚醛胺聚氧丙烯聚氧乙烯醚、烷基酚醛树脂嵌段聚醚按照质量比1.5:2抗杂油效果最好。发明人发现,该类抗杂油剂由于较乳化剂有更高的活性,能迅速地穿过乳状液外相分散到油水界面上,替换或中和乳化剂,降低乳化水滴的界面张力和界面膜强度,使乳状液变得很不稳定,达到油水分离的目的,因此抗杂油剂能够有效阻止机床中导轨油、液压油及工件表面防锈油被磨削液乳化,杜绝了因杂油乳化而导致的磨削液粘度变大,进而引起的沉降性变差。
优选的,所述防锈剂包含有机防锈剂和无机防锈剂。有机防锈剂为三元羧酸;无机防锈剂为钼酸钠。
优选的,所述防锈剂为三元羧酸、钼酸钠按质量比(3±0.5):(1±0.5) 的混合物。发明人发现,该类防锈剂在碱性及中性条件下均具有良好的防锈效果,且不会对磨屑形成包裹,不影响复合沉降剂对磨屑的吸附,有助于磨屑沉淀,可提升磨削液的沉降性能。
优选的,所述腐蚀抑制剂包括但不限于醇醚磷酸酯、甲基苯并三氮唑。
优选的,所述腐蚀抑制剂为醇醚磷酸酯、甲基苯并三氮唑按质量比1: 0.5的混合物。
优选的,所述碱值储备剂包括但不限于单乙醇胺、异丁醇胺。
优选的,所述碱值储备剂为单乙醇胺、异丁醇胺的混合物。发明人发现,该类碱值储备剂可使磨削液体系长期维持在pH值为9.0-10.0的碱性环境,增强了磨削液的防锈、缓蚀及抗菌性能;有效改善磨屑在液槽及机床表面的粘壁情况,进一步提升磨削液沉降性能。
优选的,所述润滑剂包括但不限于丙三醇、反式嵌段聚醚、水溶性二甲基硅油中的一种或两种以上。
优选的,所述润滑剂为丙三醇、反式嵌段聚醚、水溶性二甲基硅油按照(3±0.5):(1±0.5):0.5的混合物。发明人发现,该类润滑剂在保证磨削液磨削效率的同时,可降低工件磨削表面的粗糙度。此外,水溶性二甲基硅油具有极低的表面张力,有效降低了磨削液整体的表面张力,提高了磨削液对磨屑颗粒的浸润性,减少了磨屑在磨削液表面的悬浮,加快了磨屑的沉降速度。
优选的,所述杀菌剂包括但不限于吡啶硫酮钠、异噻唑啉酮衍生物。
优选的,所述杀菌剂为吡啶硫酮钠、异噻唑啉酮衍生物按质量比(2± 0.5):0.5的混合物,吡啶硫酮钠主要是对真菌得灭杀,异噻唑啉酮衍生物用于细菌的灭杀。两者混合使用有效的防止磨削液中各类细菌的滋生。
制备上述具有多次沉降性能的水基全合成磨削液的方法,包括以下步骤:
(1)将配方量的水、防锈剂、腐蚀抑制剂、碱值储备剂混合,于50-70℃搅拌至完全溶解为澄清透明液体A;
(2)将配方量的复合沉降剂、抗杂油剂、润滑剂混合,于常温搅拌至完全溶解为均一液体B;
(3)将液体A加入液体B中,并加入配方量的杀菌剂继续常温搅拌至澄清透明,即得到具有多次沉降性能的水基全合成磨削液。
相对于现有技术,本发明所述的一种具有多次沉降性能的水基全合成磨削液具有以下有益效果:
(1)本发明中选用的沉降剂为复配方案,黄原酸酯和二硫代胺基甲酸盐类衍生物是通过“架桥”作用使悬浮微粒聚集成大颗粒而加速其沉降,且形成的聚集体较普通絮凝剂所形成的聚集体更加紧密牢固,因而有利于机械脱水;二氨基脲聚合物通过电中和使带负电的磨屑颗粒失去分散稳定性而加速沉降;因此本复合沉降剂不仅增强了磨削液与磨屑的结合能力,更利用了离子间的相互作用,促进磨屑与沉降剂之间的多次结合,保证了磨削液长期使用后仍具有良好沉降性能;
(2)抗杂油剂使磨削液具有更好的清洁度,加工设备和工件上的各类油脂混入磨削液中,在磨削高温作用下易形成乳化液,提升磨削液的粘度,使磨屑难于沉降;此时,物理除油不能有效的清除油脂,抗杂油剂促使油水分离再通过物理方法排出油脂,保证了磨削液的沉降性和洁净度;
(3)水溶性二甲基硅油用作润滑剂,不仅使磨削液具有良好的润滑效果,降低磨削区域温度,提高加工工件的表面质量,且因本身水溶性好、表面张力极低,降低了磨削液的表面张力,提升了磨屑的润湿性,进一步促进了磨屑颗粒的快速沉降;
(4)防锈剂采用三元羧酸、钼酸钠复配,减少了防锈剂对磨屑颗粒的包裹,保证了复合沉降剂能够对磨屑形成有效吸附,进一步提升了磨削液的沉降性能;
(5)本发明所述的一种水基全合成磨削液,对磨削过程中所形成的磨屑颗粒具有多次沉降性能,能够保证其在整个循环使用寿命周期内均能使磨屑快速沉降,减少了磨削过程中由于磨屑悬浮所带来的负面影响;此外,该磨削液具有磨削效率高、磨削质量好、防锈缓蚀性能出色、无刺激性气味、使用寿命长、安全环保的特点。
所述的一种具有多次沉降性能的全合成磨削液的制备方法与上述一种具有多次沉淀性能的水基全合成磨削液相对于现有技术所具有的优势相同,在此不再赘述。
具体实施方式
除有定义外,以下实施例中所用的技术术语具有与本发明所属领域技术人员普遍理解的相同含义。以下实施例中所用的试验试剂,如无特殊说明,均为常规生化试剂;所述实验方法,如无特殊说明,均为常规方法。
下面结合实施例来详细说明本发明。
一、制备方法
(1)将配方量的水、防锈剂、腐蚀抑制剂、碱值储备剂混合,于50-70℃搅拌至完全溶解为澄清透明液体A;
(2)将配方量的复合沉降剂、抗杂油剂、润滑剂混合,于常温搅拌至完全溶解为均一液体B;
(3)将液体A加入液体B中,并加入配方量的杀菌剂继续常温搅拌至澄清透明,即得到水基全合成磨削液。
二、实施例及对比例
表1磨削液实施例的配方组成
对比例4
市售进口品牌水基全合成磨削液。
对比例5
市售国产品牌水基全合成磨削液。
三、沉降性试验方法
(1)将粒度为1μm的铁粉及金刚石粉末按质量比1:1混合均匀;
(2)将混合粉末各称取1g,分别加入100ml的具塞量筒中;
(3)以去离子水分别将实施例1-5和对比例1稀释至5wt%;
(4)取各稀释液100ml,分别注入含混合粉末的具塞量筒中,盖好塞子,以相同力度上下往复摇晃量筒1min,使混合粉末完全分散于稀释液中;
(5)将量筒静置于桌面,观察粉末沉降情况;
(6)观察完毕后,滤去粉末,将清液注入新的含有1g混合粉末的具塞量筒中,继续以相同力度上下往复摇晃量筒1min,使混合粉末完全分散于稀释液中,静置,观察粉末沉降情况,该步骤重复5次。
四、沉降性评价方法
记录每次摇晃后静置10min时,量筒中稀释液的粉末沉降体积(即上层清液),沉降体积越大,沉降性能越好。
五、沉降性试验结果
表2实施例1-4和对比例1-5的沉降性实验结果
可以看到,在所进行的4次沉降试验中,沉降剂按照特定的组份和比例配制的实施例1、实施例2的沉降性均保持稳定,并未出现沉降性衰退的情况,增加各组分含量能够提升沉降效果,实施例3和实施例4改变沉降剂的组份和比例,沉降性出现的衰退现象,对比例1、对比例2和对比例3相同含量的单组份实验,沉降效果下降幅度较大,对比例4和对比例5初始时沉降性能良好,但随沉降次数增多,沉降性能有大幅下降。
六、抗杂油性试验方法
(1)取现场在用液压油和导轨油按体积比1:1混合均匀;
(2)将混合油品各称取5ml,分别加入到100ml的烧杯中;
(3)以去离子水分别将实施例6-8和对比例1稀释至5wt%;
(4)取各稀释液95ml,分别注入含混合油品的烧杯中,用均质分散机充分分散30min,使油品和稀释液混合均匀,此时混合液为浑浊乳化状态,将混合液倒入100ml量筒中。
七、抗杂油性评价方法
将装有混合液的量筒在室温下静置,观察混合油和磨削液的分离状态,混合油在上磨削液在下,混合油体积越大,抗杂油性越好。
八、抗杂油性试验结果
表3实施例5-10与对比例4和5的抗杂油性试验结果
可以看到,抗杂油剂按照实施例5中的组成和配比抗杂油效果最好,实施例6改变抗杂油剂组成效果降低,实施例7改变抗杂油剂配比抗杂油效果同样降低,实施例8、实施例9和实施例10相同含量的单组份实验,抗杂油效果明显的降低,对比例4和5有一定的油水分离效果,但是效果明显较差。
以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (12)
1.一种具有多次沉降性能的水基全合成磨削液,其特征在于:以100重量份计,包括以下重量份的各组分:
复合沉降剂0.5-3份;
抗杂油剂1-5份;
防锈剂3-20份;
腐蚀抑制剂2-6份;
碱值储备剂5-30份;
润滑剂1-15份;
杀菌剂1-5份;
余量为水;
所述复合沉降剂为黄原酸酯、二硫代氨基甲酸盐衍生物、二氨基脲聚合物中的两种或两种以上;
所述抗杂油剂为酚醛胺聚氧丙烯聚氧乙烯醚、烷基酚醛树脂嵌段聚醚、聚磷酸酯、咪唑啉改性共聚物中的至少一种;
所述防锈剂包含有机防锈剂和无机防锈剂;有机防锈剂为三元羧酸;无机防锈剂为钼酸钠;
所述腐蚀抑制剂为醇醚磷酸酯、甲基苯并三氮唑的混合物。
2.根据权利要求1所述的一种具有多次沉降性能的水基全合成磨削液,其特征在于:所述复合沉降剂为黄原酸酯、二硫代氨基甲酸盐衍生物、二氨基脲聚合物按质量比(2±0.5):(2±0.5):(1±0.5)的混合物。
3.根据权利要求1所述的一种具有多次沉降性能的水基全合成磨削液,其特征在于:所述抗杂油剂为酚醛胺聚氧丙烯聚氧乙烯醚、烷基酚醛树脂嵌段聚醚、咪唑啉改性共聚物中的至少两种。
4.根据权利要求1所述的一种具有多次沉降性能的水基全合成磨削液,其特征在于:所述防锈剂为三元羧酸、钼酸钠按质量比(3±0.5):(1±0.5)的混合物。
5.根据权利要求1所述的一种具有多次沉降性能的水基全合成磨削液,其特征在于:所述腐蚀抑制剂为醇醚磷酸酯、甲基苯并三氮唑按质量比1:0.5的混合物。
6.根据权利要求1所述的一种具有多次沉降性能的水基全合成磨削液,其特征在于:所述碱值储备剂包括但不限于单乙醇胺、异丁醇胺。
7.根据权利要求1所述的一种具有多次沉降性能的水基全合成磨削液,其特征在于:所述碱值储备剂为单乙醇胺、异丁醇胺的混合物。
8.根据权利要求1所述的一种具有多次沉降性能的水基全合成磨削液,其特征在于:所述润滑剂包括但不限于丙三醇、反式嵌段聚醚、水溶性二甲基硅油中的一种或两种以上。
9.根据权利要求1所述的一种具有多次沉降性能的水基全合成磨削液,其特征在于:所述润滑剂为丙三醇、反式嵌段聚醚、水溶性二甲基硅油按照(3±0.5):(1±0.5):0.5的混合物。
10.根据权利要求1所述的一种具有多次沉降性能的水基全合成磨削液,其特征在于:所述杀菌剂包括但不限于吡啶硫酮钠异噻唑啉酮衍生物。
11.根据权利要求1所述的一种具有多次沉降性能的水基全合成磨削液,其特征在于:所述杀菌剂为吡啶硫酮钠、异噻唑啉酮衍生物按质量比(2±0.5):0.5的混合物。
12.一种制备如权利要求1-11任意一项所述的具有多次沉降性能的水基全合成磨削液的方法,其特征在于:包括以下步骤:
S1.将配方量的水、防锈剂、腐蚀抑制剂、碱值储备剂混合,于50-70℃搅拌至完全溶解为澄清透明液体A;
S2.将配方量的复合沉降剂、抗杂油剂、润滑剂混合,于常温搅拌至完全溶解为均一液体B;
S3.将液体A加入液体B中,并加入配方量的杀菌剂继续搅拌至澄清透明,即得到具有多次沉降性能的水基全合成磨削液。
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