CN116376625A - 一种水包油型铝合金专用切削液及其制备方法 - Google Patents
一种水包油型铝合金专用切削液及其制备方法 Download PDFInfo
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- 239000002173 cutting fluid Substances 0.000 title claims abstract description 57
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title claims abstract description 55
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 27
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- 229910021641 deionized water Inorganic materials 0.000 claims abstract description 13
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- 229940051841 polyoxyethylene ether Drugs 0.000 claims description 18
- 229920000056 polyoxyethylene ether Polymers 0.000 claims description 18
- 239000007788 liquid Substances 0.000 claims description 13
- 150000002191 fatty alcohols Chemical class 0.000 claims description 8
- ZSIAUFGUXNUGDI-UHFFFAOYSA-N hexan-1-ol Chemical compound CCCCCCO ZSIAUFGUXNUGDI-UHFFFAOYSA-N 0.000 claims description 8
- XEKOWRVHYACXOJ-UHFFFAOYSA-N Ethyl acetate Chemical compound CCOC(C)=O XEKOWRVHYACXOJ-UHFFFAOYSA-N 0.000 claims description 6
- IGFHQQFPSIBGKE-UHFFFAOYSA-N Nonylphenol Natural products CCCCCCCCCC1=CC=C(O)C=C1 IGFHQQFPSIBGKE-UHFFFAOYSA-N 0.000 claims description 6
- SNQQPOLDUKLAAF-UHFFFAOYSA-N nonylphenol Chemical compound CCCCCCCCCC1=CC=CC=C1O SNQQPOLDUKLAAF-UHFFFAOYSA-N 0.000 claims description 6
- 239000002736 nonionic surfactant Substances 0.000 claims description 5
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- ZEMPKEQAKRGZGQ-XOQCFJPHSA-N glycerol triricinoleate Natural products CCCCCC[C@@H](O)CC=CCCCCCCCC(=O)OC[C@@H](COC(=O)CCCCCCCC=CC[C@@H](O)CCCCCC)OC(=O)CCCCCCCC=CC[C@H](O)CCCCCC ZEMPKEQAKRGZGQ-XOQCFJPHSA-N 0.000 claims description 4
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- 235000010482 polyoxyethylene sorbitan monooleate Nutrition 0.000 claims description 4
- 229920000136 polysorbate Polymers 0.000 claims description 4
- 229920000053 polysorbate 80 Polymers 0.000 claims description 4
- 230000002421 anti-septic effect Effects 0.000 claims description 3
- 235000015112 vegetable and seed oil Nutrition 0.000 claims description 3
- 239000008158 vegetable oil Substances 0.000 claims description 3
- 239000004135 Bone phosphate Substances 0.000 claims description 2
- 229910019142 PO4 Inorganic materials 0.000 claims description 2
- 150000002148 esters Chemical class 0.000 claims description 2
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 2
- 239000010452 phosphate Substances 0.000 claims description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 claims description 2
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 abstract description 15
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- 229910001018 Cast iron Inorganic materials 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- 230000000274 adsorptive effect Effects 0.000 description 1
- 239000013556 antirust agent Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
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- 239000003153 chemical reaction reagent Substances 0.000 description 1
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Abstract
本发明提供了一种水包油型铝合金专用切削液及其制备方法,该切削液包括基础油2‑10份,乳化剂4‑40份,助乳化剂2‑10份,防腐添加剂0.5‑2份,缓冲剂2‑5份,pH调节剂2‑5份,稳定剂0.5‑2份,余量为去离子水;该制备方法包括制备分散相和连续相。该切削液具有粘度低、润滑性能优异、防腐蚀性能好、清洗性能好的优点;其中,分散相可以快速吸附于刀头及铝型材表面形成一层超薄的吸附性油膜,有效地降低刀头与铝合金的摩擦系数、隔绝工件与空气的接触,提高润滑性能和防腐蚀性能;水基连续相具有环保、冷却性好、易清洗等优势。
Description
技术领域
本发明涉及环保切削液技术领域,具体涉及一种水包油型铝合金专用切削液及其制备方法。
背景技术
断桥铝是一种能够隔绝室内外温度传递的材料,具有节能效果。随着人们节能环保意识的逐渐提高、对生活品质的追求越来越高,断桥铝材料被广泛应用于住宅、写字楼等建筑的门窗中,起到良好的隔热、隔冷作用。
断桥铝在加工过程中不可避免的要使用切削油或者切削液,切削油或切削液主要起到润滑、冷却、防腐蚀、清洗的作用。目前,小型门窗加工设备采用的切削油主要是以煤油为基础油配置而成,煤油的挥发性高、气味重,严重影响操作车间的环境;大型设备采用以矿物油、植物油为基础油复配润滑剂、抗磨剂等复配而成的切削油,此类切削油润滑性能优异,但降温、清洗作用较差,容易造成铝屑的融化黏连,影响刀具的使用寿命,同时矿物油不易降解,环保性较差。
环保型的水性切削液清洗、降温效果较好,但普遍存在润滑性差、易腐蚀设备、不稳定、阻塞过滤嘴等缺陷。因此,亟需一种可以在铝合金切削过程中既具有优异的润滑、防腐蚀、冷却、清洗作用又稳定环保的切削液。
发明内容
针对现有技术的上述不足,本发明提供了一种水包油型铝合金专用切削液及其制备方法,该切削液包括基础油、乳化剂、助乳化剂、防腐添加剂、缓冲剂、pH调节剂、稳定剂和去离子水;该制备方法包括制备分散相和连续相。该切削液具有粘度低、润滑性能优异、防腐蚀性能好、清洗性能好的优点;其中,分散相可以快速吸附于刀头及铝型材表面形成一层超薄的吸附性油膜,有效地降低刀头与铝合金的摩擦系数、隔绝工件与空气的接触,提高润滑性能和防腐蚀性能;水基连续相具有环保、冷却性好、易清洗等优势。
本发明的技术方案如下:
一种水包油型铝合金专用切削液,包括下述重量份数的组分:
基础油2-10份,乳化剂4-40份,助乳化剂2-10份,防腐添加剂0.5-2份,缓冲剂2-5份,pH调节剂2-5份,稳定剂0.5-2份,余量为去离子水;
润滑性能好、防腐蚀性能优异、稳定性好的水包油型环保切削液。
优选的,所述基础油为矿物油、植物油、合成酯中的一种或两种以上的组合物。
优选的,所述乳化剂为非离子表面活性剂。
优选的,所述非离子表面活性剂为脂肪醇聚氧乙烯醚(AEO)系列、蓖麻油聚氧乙烯醚(EL)系列、壬基酚聚氧乙烯醚(NP)系列中的一种或两种以上的组合物。
优选的,所述助乳化剂为吐温80、吐温85、op-10、正己醇、乙酸乙酯中的一种或两种以上的组合物。
优选的,所述防腐添加剂为二元酸、三元酸、磷酸酯防锈剂中的一种或两种以上的组合物。
上述水包油型铝合金专用切削液的制备方法,包括以下步骤:
(1)将乳化剂和助乳化剂在50℃恒温条件下搅拌15分钟,得到均匀透亮的混合液体;
(2)将基础油在持续搅拌的条件下加入到(1)所述的混合液体中,在50℃恒温条件下搅拌30分钟,得到均匀透亮的分散相;
(3)将定量的防腐添加剂、缓冲剂、pH调节剂和稳定剂在50℃、搅拌的条件下加入去离子水中,得到连续相;
(4)将(2)所得分散相在50℃、持续搅拌的条件下缓慢加入(3)所得连续相中,持续搅拌2小时得到均匀透亮的切削液。
使用时,将上述削液通过喷雾的形式喷淋到机床的刀头及铝型材表面。
水性切削液的优势是冷却性能好、清洗性能好,但是在由于其易溶解空气中的氧气、氯离子等腐蚀介质,因此其防腐蚀性能较差,容易引起设备、工件的腐蚀,同时其吸附性能较差,不易在工件及刀具表面形成润滑性的膜层,因此其润滑性能较油性切削油也较差。油性切削油可以在刀具及工件表面形成一层致密的油膜,提高润滑性及防腐蚀性能,但工件表面残留的油膜过多造成铝屑黏连及后续涂装加工工序的困难。本发明中,非离子表面活性剂与基础油可以形成稳定的、粒径在100nm以下的小液滴,同时根据基础油与乳化剂的HLB值调整其亲水亲油性,增加油性液滴在水相中的分散性,实验过程中,观察相变,由开始的油水分层,到最后形成的均匀微白色分散体系,得到以油滴为分散相、水为连续相的透明的水包油型分散体系,通过加入缓冲剂、pH调节剂、稳定剂增加水包油分散体系的稳定性,配置成功了具有优良润滑性能、强防腐能力、高稳定性的水包油切削液。
本发明提供的水性切削液,有效综合了水性切削液的冷却和清洗效果好的优点,以及油性切削油的润滑性和防腐性能好的优势,解决了目前铝合金切削技术所存在的技术难题。该水性切削液的连续相为水,水的流动性好,沸点低,可以有效地清洗铝型材切割过程中产生的铝屑并及时带走切割产生的热量;分散相为油,在切割过程中,随着水分的蒸发,油相可以吸附在刀具及铝合金表面起到润滑、防腐蚀的作用。由于油相是分散相,其量较少,仅仅会在刀具及铝合金表面形成一层保护性油膜,不会像油性切削油一样大量残留在工件表面,从而能够有效克服免现有技术存在的铝屑黏连而导致的后续的组装和涂装工艺难以进行的问题。
相对于现有技术,本发明的有益效果在于:
1、本发明的水包油切削液具有粘度低、润滑性能优异、防腐蚀性能好、清洗性能好的优点;粘度为8-10mm2/s,PB值为600-800N,铸铁屑防锈实验达0-1级。
2、观察发现,本发明的分散相可以快速吸附于刀头及铝型材表面形成一层超薄的吸附性油膜,有效地降低刀头与铝合金的摩擦系数、隔绝工件与空气的接触,提高润滑性能和防腐蚀性能。
3、本发明的连续相是去离子水,水基连续相具有环保、冷却性好、易清洗等优势。
附图说明
图1为油分散到水中形成的均匀的分散体系。
图2为使用三个月后切割的铝合金断面。
图3为使用三个月的金刚石锯片表面。
具体实施方式
为了使本技术领域的人员更好地理解本发明中的技术方案,下面将结合本发明的实施例,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都应当属于本发明保护的范围。
本发明以下实施例中,所用组分为工业级,均由麦克林试剂提供。
实施例1
一种水包油型铝合金专用切削液,包括下述重量的组分:
10号白油:2kg,脂肪醇聚氧乙烯醚AE0-3:5kg,壬基酚聚氧乙烯醚NP-7:8kg、吐温85:2kg,防腐添加剂1kg,缓冲剂2kg,pH调节剂3kg,稳定剂0.5kg,去离子水76.5kg;
上述切削液的制备方法,包括以下步骤:
(1)将脂肪醇聚氧乙烯醚AE0-3、壬基酚聚氧乙烯醚NP-7、吐温85在50℃恒温条件下搅拌15分钟,得到均匀透亮的混合液体;
(2)将10号白油在持续搅拌的条件下加入到(1)所述的混合液体中,在50℃恒温条件下搅拌30分钟,得到均匀透亮的分散相;分散相是粒径在100nm以内的乳化剂包裹的基础油的小液滴,可以在刀具及工件表面形成一层油膜,起到润滑、防腐作用;
(3)在另一容器中,将防腐添加剂、缓冲剂、pH调节剂和稳定剂在50℃、搅拌的条件下加入去离子水中,得到连续相;连续相是水相,可以快速的带走切割过程中的热量和工件表面残留的铝屑,起到冷却和清洗的作用;防腐添加剂进一步提高切削液的防腐蚀性能;缓冲剂和稳定剂起到稳定切削液的作用,防止其在使用过程中出现浑浊、絮状物等现象;
(4)将(2)所得分散相在50℃、持续搅拌的条件下,缓慢加入(3)所得连续相中,持续以700r/min的转速搅拌2小时得到均匀透亮、稳定的切削液,该水包油切削液,以油滴为分散相、水为连续相,见图1。
实施例2
一种水包油型铝合金专用切削液,包括下述重量的组分:
环烷基油:4kg,脂肪醇聚氧乙烯醚AE0-3:15kg,壬基酚聚氧乙烯醚NP-5:10kg、正己醇:4kg,防腐添加剂0.5kg,缓冲剂3kg,pH调节剂3kg,稳定剂1kg,去离子水59.5kg;
上述切削液的制备方法,包括以下步骤:
(1)将脂肪醇聚氧乙烯醚AE0-3、壬基酚聚氧乙烯醚NP-5、正己醇在50℃恒温条件下搅拌15分钟,得到均匀透亮的混合液体;
(2)将环烷基油在持续搅拌的条件下加入到(1)所述的混合液体中,在50℃恒温条件下搅拌30分钟,得到均匀透亮的分散相;分散相是粒径在100nm以内的乳化剂包裹的基础油的小液滴,可以在刀具及工件表面形成一层油膜,起到润滑、防腐作用;
(3)在另一容器中,将防腐添加剂、缓冲剂、pH调节剂和稳定剂在50℃、搅拌的条件下加入去离子水中,得到连续相;连续相是水相,可以快速的带走切割过程中的热量和工件表面残留的铝屑,起到冷却和清洗的作用。防腐添加剂进一步提高切削液的防腐蚀性能;缓冲剂和稳定剂起到稳定切削液的作用,防止其在使用过程中出现浑浊、絮状物等现象;
(4)将(2)所得分散相在50℃、持续搅拌的条件下,缓慢加入(3)所得连续相中,持续以700r/min搅拌2小时得到均匀透亮、稳定的切削液。
实施例3
一种水包油型铝合金专用切削液,包括下述重量的组分:
菜籽油:6kg,脂肪醇聚氧乙烯醚AE0-3:10kg,蓖麻油聚氧乙烯醚EL-30:10kg、吐温80:4kg,防腐添加剂1kg,缓冲剂2kg,pH调节剂2.5kg,稳定剂1kg,去离子水63.5kg;
上述切削液的制备方法,包括以下步骤:
(1)将脂肪醇聚氧乙烯醚AE0-3、蓖麻油聚氧乙烯醚EL-30、吐温80在50℃恒温条件下搅拌15分钟,得到均匀透亮的混合液体;
(2)将菜籽油在持续搅拌的条件下加入到(1)所述的混合液体中,在50℃恒温条件下搅拌30分钟,得到均匀透亮的分散相;分散相是粒径在100nm以内的乳化剂包裹的基础油的小液滴,可以在刀具及工件表面形成一层油膜,起到润滑、防腐作用;
(3)在另一容器中,将防腐添加剂、缓冲剂、pH调节剂和稳定剂在50℃、搅拌的条件下加入去离子水中,得到连续相;连续相是水相,可以快速的带走切割过程中的热量和工件表面残留的铝屑,起到冷却和清洗的作用。防腐添加剂进一步提高切削液的防腐蚀性能;缓冲剂和稳定剂起到稳定切削液的作用,防止其在使用过程中出现浑浊、絮状物等现象;
(4)将(2)所得分散相在50℃、持续搅拌的条件下,缓慢加入(3)所得连续相中,持续以700r/min搅拌2小时得到均匀透亮、稳定的切削液。
利用上述实施例配制的切削液分别进行铝合金切削试验,切削试验中采取单一变量法,除切削液不同外,进行切割实验的机床、使用的锯片、切割所用的铝合金、切削液的喷雾压力等其余各项参数均相同。待切削试验结束后清洗试验件后,观察各个切削试验中试件的已加工表面的粗糙度及刀具的磨损程度。
三个实施例所配置的切削液连续使用三个月后,切割面均光亮,见图,刀具仅出现轻微磨损,见图3。
尽管通过参考优选实施例的方式对本发明进行了详细描述,但本发明并不限于此。在不脱离本发明的精神和实质的前提下,本领域普通技术人员可以对本发明的实施例进行各种等效的修改或替换,而这些修改或替换都应在本发明的涵盖范围内/任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,可轻易想到变化或替换,都应涵盖在本发明的保护范围之内。因此,本发明的保护范围应所述以权利要求的保护范围为准。
Claims (7)
1.一种水包油型铝合金专用切削液,其特征在于,包括下述重量份数的组分:
基础油2-10份,乳化剂4-40份,助乳化剂2-10份,防腐添加剂0.5-2份,缓冲剂2-5份,pH调节剂2-5份,稳定剂0.5-2份,余量为去离子水。
2.如权利要求1所述的水包油型铝合金专用切削液,其特征在于,所述基础油为矿物油、植物油、合成酯中的一种或两种以上的组合物。
3.如权利要求1所述的水包油型铝合金专用切削液,其特征在于,所述乳化剂为非离子表面活性剂。
4.如权利要求3所述的水包油型铝合金专用切削液,其特征在于,所述非离子表面活性剂为脂肪醇聚氧乙烯醚系列、蓖麻油聚氧乙烯醚系列、壬基酚聚氧乙烯醚系列中的一种或两种以上的组合物。
5.如权利要求1所述的水包油型铝合金专用切削液,其特征在于,所述助乳化剂为吐温80、吐温85、op-10、正己醇、乙酸乙酯中的一种或两种以上的组合物。
6.如权利要求1所述的水包油型铝合金专用切削液,其特征在于,所述防腐添加剂为二元酸、三元酸、磷酸酯防锈剂中的一种或两种以上的组合物。
7.如权利要求1-6任一项所述的水包油型铝合金专用切削液的制备方法,其特征在于,包括以下步骤:
(1)将乳化剂和助乳化剂在50℃恒温条件下搅拌15分钟,得到均匀透亮的混合液体;
(2)将基础油在持续搅拌的条件下加入到(1)所述的混合液体中,在50℃恒温条件下搅拌30分钟,得到均匀透亮的分散相;
(3)将定量的防腐添加剂、缓冲剂、pH调节剂和稳定剂在50℃、搅拌的条件下加入去离子水中,得到连续相;
(4)将(2)所得分散相在50℃、持续搅拌的条件下缓慢加入(3)所得连续相中,持续搅拌2小时得到均匀透亮的切削液。
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CN106281630A (zh) * | 2016-08-17 | 2017-01-04 | 南通科星化工有限公司 | 一种微乳切削液及其制备工艺 |
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CN106281630A (zh) * | 2016-08-17 | 2017-01-04 | 南通科星化工有限公司 | 一种微乳切削液及其制备工艺 |
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