EP1608474A2 - Lubrifiants appropries pour l'hydroformage et pour d'autres applications de manipulation de metaux - Google Patents

Lubrifiants appropries pour l'hydroformage et pour d'autres applications de manipulation de metaux

Info

Publication number
EP1608474A2
EP1608474A2 EP03800331A EP03800331A EP1608474A2 EP 1608474 A2 EP1608474 A2 EP 1608474A2 EP 03800331 A EP03800331 A EP 03800331A EP 03800331 A EP03800331 A EP 03800331A EP 1608474 A2 EP1608474 A2 EP 1608474A2
Authority
EP
European Patent Office
Prior art keywords
lubricant
solid
surfactant
film lubricant
die
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP03800331A
Other languages
German (de)
English (en)
Inventor
Frank K. Botz
Paul B. Kutzko
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Henkel AG and Co KGaA
Original Assignee
Henkel AG and Co KGaA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Henkel AG and Co KGaA filed Critical Henkel AG and Co KGaA
Publication of EP1608474A2 publication Critical patent/EP1608474A2/fr
Withdrawn legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M173/00—Lubricating compositions containing more than 10% water
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • B21D26/035—Deforming tubular bodies including an additional treatment performed by fluid pressure, e.g. perforating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/053—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure characterised by the material of the blanks
    • B21D26/057—Tailored blanks
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M169/00—Lubricating compositions characterised by containing as components a mixture of at least two types of ingredient selected from base-materials, thickeners or additives, covered by the preceding groups, each of these compounds being essential
    • C10M169/04—Mixtures of base-materials and additives
    • C—CHEMISTRY; METALLURGY
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    • C10M169/00—Lubricating compositions characterised by containing as components a mixture of at least two types of ingredient selected from base-materials, thickeners or additives, covered by the preceding groups, each of these compounds being essential
    • C10M169/04—Mixtures of base-materials and additives
    • C10M169/041—Mixtures of base-materials and additives the additives being macromolecular compounds only
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    • C10M2201/00—Inorganic compounds or elements as ingredients in lubricant compositions
    • C10M2201/02—Water
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    • C10M2201/06—Metal compounds
    • C10M2201/062—Oxides; Hydroxides; Carbonates or bicarbonates
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    • C10M2203/00—Organic non-macromolecular hydrocarbon compounds and hydrocarbon fractions as ingredients in lubricant compositions
    • C10M2203/10—Petroleum or coal fractions, e.g. tars, solvents, bitumen
    • C10M2203/106—Naphthenic fractions
    • C10M2203/1065—Naphthenic fractions used as base material
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    • C10M2205/12—Oxidised hydrocarbons, i.e. oxidised subsequent to macromolecular formation
    • C10M2205/123—Oxidised hydrocarbons, i.e. oxidised subsequent to macromolecular formation used as base material
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    • C10M2205/143—Synthetic waxes, e.g. polythene waxes used as base material
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    • C10M2205/00—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions
    • C10M2205/16—Paraffin waxes; Petrolatum, e.g. slack wax
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    • C10M2205/16—Paraffin waxes; Petrolatum, e.g. slack wax
    • C10M2205/163—Paraffin waxes; Petrolatum, e.g. slack wax used as base material
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    • C10M2205/00—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions
    • C10M2205/17—Fisher Tropsch reaction products
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    • C10M2205/173—Fisher Tropsch reaction products used as base material
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    • C10M2205/18—Natural waxes, e.g. ceresin, ozocerite, bees wax, carnauba; Degras
    • C—CHEMISTRY; METALLURGY
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    • C10M2205/183—Natural waxes, e.g. ceresin, ozocerite, bees wax, carnauba; Degras used as base material
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    • C10M2207/02—Hydroxy compounds
    • C10M2207/021—Hydroxy compounds having hydroxy groups bound to acyclic or cycloaliphatic carbon atoms
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    • C10M2207/125—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms having hydrocarbon chains of eight up to twenty-nine carbon atoms, i.e. fatty acids
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    • C10M2209/10—Macromolecular compoundss obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C10M2209/103—Polyethers, i.e. containing di- or higher polyoxyalkylene groups
    • C10M2209/107—Polyethers, i.e. containing di- or higher polyoxyalkylene groups of two or more specified different alkylene oxides covered by groups C10M2209/104 - C10M2209/106
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M2209/00—Organic macromolecular compounds containing oxygen as ingredients in lubricant compositions
    • C10M2209/10—Macromolecular compoundss obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C10M2209/103—Polyethers, i.e. containing di- or higher polyoxyalkylene groups
    • C10M2209/108—Polyethers, i.e. containing di- or higher polyoxyalkylene groups etherified
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M2209/00—Organic macromolecular compounds containing oxygen as ingredients in lubricant compositions
    • C10M2209/10—Macromolecular compoundss obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C10M2209/103—Polyethers, i.e. containing di- or higher polyoxyalkylene groups
    • C10M2209/109—Polyethers, i.e. containing di- or higher polyoxyalkylene groups esterified
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M2209/00—Organic macromolecular compounds containing oxygen as ingredients in lubricant compositions
    • C10M2209/12—Polysaccharides, e.g. cellulose, biopolymers
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M2211/00—Organic non-macromolecular compounds containing halogen as ingredients in lubricant compositions
    • C10M2211/04—Organic non-macromolecular compounds containing halogen as ingredients in lubricant compositions containing carbon, hydrogen, halogen, and oxygen
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M2215/00—Organic non-macromolecular compounds containing nitrogen as ingredients in lubricant compositions
    • C10M2215/02—Amines, e.g. polyalkylene polyamines; Quaternary amines
    • C10M2215/04—Amines, e.g. polyalkylene polyamines; Quaternary amines having amino groups bound to acyclic or cycloaliphatic carbon atoms
    • C10M2215/042—Amines, e.g. polyalkylene polyamines; Quaternary amines having amino groups bound to acyclic or cycloaliphatic carbon atoms containing hydroxy groups; Alkoxylated derivatives thereof
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M2219/00—Organic non-macromolecular compounds containing sulfur, selenium or tellurium as ingredients in lubricant compositions
    • C10M2219/04—Organic non-macromolecular compounds containing sulfur, selenium or tellurium as ingredients in lubricant compositions containing sulfur-to-oxygen bonds, i.e. sulfones, sulfoxides
    • C10M2219/044—Sulfonic acids, Derivatives thereof, e.g. neutral salts
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
    • C10N2030/06—Oiliness; Film-strength; Anti-wear; Resistance to extreme pressure
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2040/00—Specified use or application for which the lubricating composition is intended
    • C10N2040/20—Metal working
    • C10N2040/24—Metal working without essential removal of material, e.g. forming, gorging, drawing, pressing, stamping, rolling or extruding; Punching metal
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2040/00—Specified use or application for which the lubricating composition is intended
    • C10N2040/20—Metal working
    • C10N2040/241—Manufacturing joint-less pipes
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2050/00—Form in which the lubricant is applied to the material being lubricated
    • C10N2050/01—Emulsions, colloids, or micelles
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2050/00—Form in which the lubricant is applied to the material being lubricated
    • C10N2050/015—Dispersions of solid lubricants
    • C10N2050/02—Dispersions of solid lubricants dissolved or suspended in a carrier which subsequently evaporates to leave a lubricant coating
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2060/00—Chemical after-treatment of the constituents of the lubricating composition
    • C10N2060/04—Oxidation, e.g. ozonisation

Definitions

  • This invention relates to lubricants used in metal forming processes and, in particular, to lubricants used in hydroforming processes.
  • Processes in which metal parts are manipulated or formed typically require lubricants to reduce equipment wear. These processes include such operations as bending, swaging, roll-tapping, drawing, and hydroforming. Hydroforming is a particularly important process in which a relatively complex metal part is fabricated.
  • hydroforming processes There are two types of hydroforming processes. One is used to form parts from sheet metal and the other is used to form parts from metal tubes. Many tube hydroforming applications are currently utilized by the automotive industry.
  • a workpiece tube is placed in a tool cavity.
  • the geometry of the die cavity corresponds to the external geometry of the produced part.
  • the tool cavity is closed by the ram movement of a press.
  • the tube ends are loaded by two punches moving along the tube axis, and an aqueous fluid is pumped into the tube.
  • an aqueous fluid is pumped into the tube.
  • the tube expands until the expanding tube wall contacts the inner surface of the die, and the part is formed.
  • the bending lubricant is used on the inside of the tube to bend the tube into a desired shape just prior to mounting the tube in the hydrofomiing tool cavity.
  • the pressure- side fluid is the aqueous hydraulic fluid used to transmit the pressure to the inside of the tube.
  • the die-side lubricant is the primary forming fluid in high-pressure hydroforming. It provides the lubricity between the workpiece and the die.
  • the demands on the die-side lubricant vary widely. Some light duty applications require little of the die-side lubricant. In the case of lower pressure applications, the pressure-side fluid may also be used simultaneously to transmit pressure inside the tube and to provide die-side lubrication. As the complexity of the application increases, the importance of the die-side lubricant increases. Furthermore, the die-side lubricants' compatibility with the pressure-side lubricant and the removal of the die-side lubricant from the newly formed part are important considerations.
  • the present invention discloses a liquid film die-side hydroforming lubricant that comprises an oil and a surfactant.
  • the liquid film die-side lubricant is typically already a liquid when applied to the workpiece tube.
  • the liquid film die-side lubricant has lubrication properties that are not substantially damaged by contact with the pressure-side fluid which usually contains water.
  • the liquid film die-side lubricant preferably has high viscosity.
  • a solid film die-side hydroforming lubricant comprises a wax such that the stress value within the die-side lubricant is at least 540 kPa at 0.75 sec after a compressive stress is imposed.
  • the solid film die-side lubricant is a liquid when applied to the workpiece tube. The applied liquid then either dries or cures into a solid lubricating film.
  • the solid film die-side lubricant has lubrication properties that are not substantially damaged by contact with the pressure-side fluid, which usually contains water.
  • the liquid film die-side lubricant preferably has high viscosity.
  • the die-side lubricant of the present embodiment is a solid at the time of emplacement
  • the die-side lubricant preferably has high hardness and optionally a high elasticity.
  • the solid film lubricant also optionally includes a wetting agent to improve the ability of the composition to wet metallic surfaces.
  • the resistance of a lubricant to damage to its lubrication properties by pressure-side fluid is most conveniently measured by measuring the coefficient of friction of two metal surfaces, lubricated with the die-side lubricant to be measured, in a sliding friction test at a pressure from 65 to 400 bars and in a twist compression test at a pressure from 675 to 2500 bars.
  • a die-side lubricant to be tested is first placed on one surface of a substrate of the same type of metal as is to be hydroformed in the same manner as if the substrate were to be hydroformed, but the substrate in this instance has a shape suitable for the intended method of measurement of coefficient of friction.
  • the die-side lubricant layer is sprinkled or otherwise gently wet with the intended pressure-side fluid for hydroforming or a surrogate for this pressure-side fluid, plain deionized or tap water often being an effective surrogate.
  • a volume of the pressure-side fluid or surrogate therefor that is not more than about twice the volume of the wetted die-side lubricant film itself should be used, and no substantial mechanical force such as would result from high pressure spraying should be used.
  • any remaining aqueous liquid is allowed to drain away under the influence of natural gravity, and the coefficient of friction of the substrate bearing the thus-drained die-side lubricant film is again measured.
  • the die-side lubricant has sufficient pressure-side fluid- resistance for the purposes of this invention when the coefficient of friction measured with the thus wetted and drained die-side lubricant film does not exceed the coefficient of friction measured under the same conditions with the originally emplaced and unwetted die-side lubricant film by an amount that is preferably more than about 50 percent of the value of the coefficient of friction for the originally emplaced and unwetted die-side lubricant film, more preferably more than about 30 percent of the value of the coefficient of friction for the originally emplaced and unwetted die-side lubricant film, and most preferably more than about 1.0 percent of the value of the coefficient of friction for the originally emplaced and unwetted die-side lubricant film.
  • the coefficient of friction is reduced by contact with the pressure-side fluid or surrogate therefor. All of the measurements involved in this determination of the pressure-side fluid resistance of a lubricant should be made at the intended temperature of the hydroforming process itself, or, if the latter is unknown, at a normal ambient human comfort temperature (between 18 and 23° C).
  • a liquid film die-side hydroforming lubricant is disclosed.
  • the liquid film die-side lubricant is typically already a liquid when applied to the workpiece tube.
  • the liquid film die-side lubricant has lubrication properties that are not substantially damaged by contact with the pressure-side fluid as defined above.
  • the liquid film die-side hydroforming lubricant includes an oil that has a kinematic viscosity measured at 40° C, that is at least, with increasing preference in the order given, 2.5, 5.0, 7.5, 10.0, 12.5, 15.0. 17.5, or 20 stokes.
  • Suitable commercially available oils include vegetable oils, blown (alternatively called “oxidized”) vegetable oils, polymers of vegetable oils, animal oils, and blown animal oils along with typical petroleum oils. Specific examples include blown canola oil, blown fish oil, canola oil, blown rapeseed oil, and naphthenic oil.
  • the liquid film die-side hydroforming lubricant ("liquid film composition") of the present invention optionally further include a surfactant.
  • the surfactant improves the cleaning properties of the lubricant, i.e., the ease of removing residual lubricant.
  • any surfactant may be utilized, preferably non-ionic surfactants are used.
  • the surfactant also preferably improves the lubricity of the liquid film when wetted. Though not restricting the improvement of lubricity to any particular mechanism, the surfactant appears to form an emulsified layer when wetted that enhances lubricity. However, the amount of surfactant is not so much that the liquid film is deteriorated during emulsification.
  • the surfactant is preferably present in an amount of 0.1 % to 10% of the total weight of the liquid film composition, more preferably in an amount of 1.0% to 5% of the total weight of the liquid film composition, and most preferably in an amount of about 2.5 % of the total weight of the liquid film composition.
  • Preferred surfactants include vegetable oil ethoxylates, ethoxylates of alkyl alcohols, ethoxylates of acetylenic diols, block copolymers of ethylene and propylene oxides, ethoxylates of alkyl carboxylates such as typical fatty acids, alkyl polyglycosides, and mixtures thereof.
  • Examples include but are not limited to Chemal DA-6, Chemal DA-9, Chemal LA- 4, Chemax CO-5, Chemax CO-16, Chemax CO-25, Chemax CO-30, Chemax CO- 36, Chemax CO-40, Chemax CO-80, and Chemax CO-200/50 commercially available from Chemax, Inc. located in Greenville, SC.
  • Suitable surfactants also include but are not limited to Surfynol 440 commercially available from Air Products, TOMAH E-14-5 (poly (5) oxyethylene isodecyloxypropylamine) and TOMAH E-14-2 commercially available from Tomah Products Inc.
  • NINOL 1 ICM a modified coconut diethanolamide surfactant sold by Stepan, Inc.
  • TRITON X-100 octylphenol ethylene oxide condensate; Octoxynol-9 commercially available from Union Carbide
  • APG 325 CS decyl polyglucoside
  • Other suitable non-ionic surfactants include block surfactants containing polyoxypropylene hydrophobe(s) and polyoxyethylene hydrophile(s). In order to properly function, the surfactant must be soluble or dispersible in the lubricant.
  • the blocks may be homopolymeric or copolymeric, for example copolymers derived from oxyalkylating with mixtures of ethylene oxide and propylene oxide.
  • Such surfactants are available from numerous sources, including the Pluronic ® , Tetronic ® , and Pluronic ® R polyether surfactants from BASF Corporation.
  • solid film composition a solid film die-side hydroforming lubricant
  • solid film composition a solid film die-side hydroforming lubricant
  • the solid film lubricant will be applied to a surface as a liquid which is subsequently dried and cured.
  • the resultant solid lubricant of the present invention preferably has a hardness as measured at 23-26° C by the American Society for Testing and
  • the solid film lubricant of the present invention includes solid lubricants that are characterized by one or more of the following properties when subjected to a compressive stress within the range from 1.50 to 2.00 percent over a time interval of 0.20 to 0.30 seconds at 23-26° C: - the stress value within the solid die-side lubricant
  • the residual stress within the solid die-side lubricant 100 sec after the compressive stress began to be imposed is at least, with increasing preference in the order given, 75, 80, 82, 84, 86, 88, or 90 percent of the maximum stress induced within the solid lubricant at any time up to 100 sec after the stress began to be imposed.
  • Preferred solid film lubricants include carnauba wax; candelilia wax; montan wax; microcrystalline waxes; solid alcohols, particularly primary alcohols having at least 18 carbon atoms per molecule; solid esters, particularly esters of primary alcohols having at least 18 carbon atoms per molecule with organic acids, especially unbranched monoacids, having at least 18 carbon atoms per molecule; and oxidized petroleum waxes.
  • the solid film die-side hydroforming lubricant of the present invention optionally further includes a surfactant.
  • a surfactant any surfactant may be utilized, preferably non-ionic surfactants are used.
  • the surfactant also preferably improves the lubricity of the solid film when wetted.
  • the surfactant is preferably present in an amount of 0.05 % to 10% of the total weight of the solid film composition, more preferably in an amount of 0.1 % to 5 % of the total weight of the solid film composition, and most preferably in an amount of about 1 % of the total weight of the solid film composition.
  • Preferred surfactants include vegetable oil ethoxylates, ethoxylates of alkyl alcohols, ethoxylates of acetylenic diols, block copolymers of ethylene and propylene oxides, ethoxylates of alkyl carboxylates such as typical fatty acids, alkyl polyglycosides, and mixtures thereof.
  • Suitable surfactants also include but are not limited to Surfynol 440 commercially available from Air Products , TOMAH E- 14-5 (poly (5) oxyethylene isodecyloxypropylamine) and TOMAH E-14-2 commercially available from Tomah Products Inc.
  • Non-ionic surfactants include block surfactants containing polyoxypropylene hydrophobe(s) and polyoxyethylene hydrophile(s). The blocks may be homopolymeric or copolymeric, for example copolymers derived from oxyalkylating with mixtures of ethylene oxide and propylene oxide.
  • Such surfactants are available from numerous sources, including the Pluronic ® , Tetronic ® , and Pluronic ® R polyether surfactants from BASF Corporation.
  • the solid film die-side lubricant optionally comprises a wetting agent. Utilization of such agents improves the ability of the dry film composition (which is a liquid when applied) to wet metals such as the various steel alloys (stainless steel, hot rolled steel, and cold rolled steel), aluminum alloys, titanium, and copper. It will be recognized by those skilled in the art, that many wetting agents are surfactants and many surfactants are wetting agents. Accordingly, a subset of the surfactants listed above will also function as wetting agents.
  • Suitable wetting agents include, but are not limited to, nonionic fluorosurfactants, anionic fluorosurfactants, ethoxylated tetramethyldecynediols, acetylenic gly col-based surfactants, dialkylsulfosuccinates, and mixtures thereof.
  • Suitable ethoxylated tetramethyldecynediols include members of the Surfynol 400 series such as Surfynol 440 and 420 commercially available from Air Products.
  • An exemplary acetylenic glycol-based surfactant is Dynol 604 commercially available from Air Products.
  • Suitable dialkylsulfosuccinates include dioctylsulfosuccinates.
  • the preferred wetting agent is a fluorosurfactant which includes both nonionic fluorosurfactants and an anionic fluorosurfactants. Most preferably the wetting agent is a nonionic fluorosurfactant.
  • Suitable nonionic fluorosurfactants include fluoroaliphatie ethoxylates and related derivatives.
  • Clariant Fluowet OTN and DuPont Zonyl FSN 100 are nonionic surfactants that performed well. Fluowet OTN is a proprietary fluoroaliphatie ethoxylate commercially available from Clariant.
  • Zonyl FSN 100 is a Telomer B monoether with polyethylene gly col which is a 1 : 1 mixture of poly(oxy-l,2-ethandiyl), -hydro- ⁇ -hydroxy-ether with -fluoro- ⁇ -(2- hydroxyethyl)poly(difluoromethylene).
  • Suitable anionic fluorosurfactants include fluoroalkylsulfonates and carboxylates with a range of counter ions that include potassium, sodium, and amines.
  • the fluorosurfactant is present in an amount of about 0.1 % to 1.0% by weight of the dry film composition. More preferably, the fluorosurfactant is present in an amount of about 0.1 % to 0.5 % by weight of the dry film composition.
  • the solid film die-side lubricant also optionally includes a corrosion inhibitor and/or a defoamer.
  • Suitable defoamers include neo-decanoic acid.
  • Suitable corrosion inhibitors include soaps or salts of carboxylic acids or organo-sulfonates.
  • Agents capable of adjusting the pH of the lubricant may also be included, such as, for example, amines (e.g., alkanolamines).
  • the coefficient of sliding friction between two metal surfaces with a layer between them of a die-side lubricant to be used in a process according to the invention preferably is not more than about 0.3 to 0.5, more preferably is not more than about 0.1 to 0.3, and most preferably is not more than about 0.04 to 0.1.
  • the die-side lubricant is preferably capable of being readily cleaned from the hydroformed object after hydroforming is complete, preferably with an aqueous-based cleaner.
  • the die-side lubricant is capable of being cleaned at a temperature not higher than 55 °C, more preferably a temperature not higher than 40 °C, and most preferably at a temperature not higher than 28 °C. This preference is not inconsistent with the need for pressure-side fluid resistance of the die-side lubricant as described above.
  • Typical aqueous based cleaners are either more acidic or more alkaline than most aqueous pressure-side fluids used in hydroforming. Furthermore, even if the cleaners are neutral, they usually contain other cleaning-promoting ingredients such as detersive surfactants that are not present in typical pressure-side fluids for hydroforming.
  • the die-side lubricant is also preferably easy to separate from the pressure-side fluid should the lubricant become contaminated by the pressure-side fluid. Accordingly, self-segregation of the die-side lubricant into a separate phase that can be skimmed or drained off from a reservoir of pressure-side fluid is highly desirable.
  • the lubricant is preferably easy to apply to the surface to be lubricated, without producing any hazard such as flammable, toxic, or noxious fumes, without requiring any equipment more complicated than simple spray, immersion, and/or roll coating, and without requiring any special drying equipment.
  • any hazard such as flammable, toxic, or noxious fumes
  • the lubricant is preferably easy to apply to the surface to be lubricated, without producing any hazard such as flammable, toxic, or noxious fumes, without requiring any equipment more complicated than simple spray, immersion, and/or roll coating, and without requiring any special drying equipment.
  • a die-side lubricant that is a solid when emplaced ready for use can be applied from a latex and allowed to dry in the ambient air without producing any fire hazard or unpleasant odor, there is a substantial practical advantage and therefore a preference for it over a solid die-side lubricant that must be melted to be applied and then quickly cooled
  • a process for hydrofo ⁇ ning a tube of a ductile solid material comprises the following steps: (I) providing a pressure-side fluid and an openable die having an interior surface of a shape to which it is desired to have the hydroformed part of the outer surface of the tube of ductile solid material conform after the tube has been hydroformed;
  • the average thickness of the die-side lubricant layer formed before hydroforming begins preferably is in the range 0.2 to 200 microns, more preferable in the range 1.0 to 100 microns, and most preferably about 15 microns. Uniformity of the die-side lubricant is not critical. The films may even be discontinuous ball-like lumps and aggregates evenly distributed over the surface of the part.
  • Preferred lubricants for use according to the invention can be readily removed from surfaces of metal ductile tubes, after hydrofo ⁇ ning is completed, by conventional alkaline cleaners.
  • a process according to the invention is particularly advantageous in "high pressure" hydroforming, in which the hydraulic pressure in step (N) of the process as described above is at least 340 bars and independently is particularly advantageous in hydroforming cold rolled steel, but is suitable for hydrofo ⁇ ning any other ductile solid as well. Hydroforming with these lubes is successful with hot-rolled steel, cold-rolled steel, and aluminum, both 5000 and 6000 series alloys.
  • the metal substrate was type ADKQ 95 hot-rolled steel, which is one of the most commonly hydroformed substrates.
  • the cornerfill test is designed to test the properties required by a die- side hyroforming lubricant in the expansion zone of a hydroforming process.
  • the exterior surface of a welded cylindrical steel tube was coated with test die-side lubricant and then mounted in a die with a square cross-section that was within one millimeter of touching the exterior cross-section of the cylindrical steel tube at the center of all four walls of the square die, with no weld line at or near one of these centers of the die walls.
  • the lubricant-coated exterior of the steel tube was then sprayed lightly with water before the die was closed.
  • the interior of the steel tube was then filled with a volume of a water-based pressure side fluid, and the pressure in the tube was then increased until the tube burst. Sensors detected the pressure at various stages of expansion, the maximum pressure before the tube burst, and the maximum expansion of the tube.
  • the burst tube was then removed from the die, and the tube burst location was noted. Then the dimensions of the burst tube were measured and the true thickness strain was calculated for seven locations: the four corners and the centers of the three walls of the square cross- section into which the tube had expanded that did not include the original welded area. Three of the properties measured in this type of test are generally considered relevant to performance in actual hydroforming. A higher burst pressure is better than a lower one; a low standard deviation of the true thickness strain is better than a higher one; and a burst near the center of the tube is better than a burst in any other part of the tube.
  • a twist compression test is designated to test the properties required by a die-side hydroforming lubricant in transition zones near the edges of expansion zones in hydroforming.
  • an annular tool was rotated under pressure over a flat plate of steel on which the test lubricant had been emplaced.
  • the pressure applied on the lubricated plate in one set of tests was 10,000 psi and in another was 15,000 psi. These pressures are typical of commercial hydroforming of hot rolled steel tubes.
  • a plot of the coefficient of friction as a function of time was generated. The results are reported at 1, 2, and 3 revolutions. The test was first conducted dry for each lubricant and then twice after the lubricant had been sprayed lightly with water. Only the average of the latter two of these measurements is reported below.
  • the sliding friction test measures the properties of the die-side lubricant that are important in the "end-feeding zone" of a hydroforming process.
  • the tube being hydroformed does not substantially expand or contract its eternal cross-section, although its walls may thin or thicken. Instead, part of the mbe moves laterally along the die to allow for expansion in another part of the die.
  • This end-feeding is very important in the production of some part designs by hydroforming.
  • the procedure used for this type of test for which values are reported here is described in American Society for Testing and Materials ("ASTM”) Procedure 4173-82, using a compressive pressure between the sliding workpieces of 69 bars ( 1000 psi). (This is officially an "obsolete” ASTM test method, but it is still useful for measuring the coefficient of friction in sliding friction.) The lower the coefficient of friction in sliding friction, the better is the lubricant in the end-feeding zone.
  • Examples 1-4 provides examples of the solid film lubricants of the present invention.
  • the monoethanolamine reduces the staining by the wax by the slightly acidic carnuba wax by raising the pH.
  • the sodium benzoate is a corrosion inhibitor.
  • the carnuba wax is characterized with a hardness of about 1 (ASTM-D-5), a particle size of about 0.15 microns, and a melting point of about 85 °C.
  • the microcrystalline wax is a mixture of two waxes of hardness 5 and 13 using ASTM D-5 and with melting points centered around 68 and 101 degrees C. Furthermore, the microcrystalline wax has a particle size of about 0.18 microns.
  • the Fischer-Tropsch wax is characterized with a hardness of about 1 (ASTM-D-5), a particle size of about 0.6 microns, and a melting point of about 98 °C.
  • the neodecanoic acid functions as both a corrosion inhibitor and defoamer.
  • the Fischer-Tropsch wax is characterized as set forth above for example 3.
  • the coefficient of friction (COF) was determined by the sliding friction test for various wetted and unwetted waxes. The results are summarized in Table 3. Surprisingly, the COF is reduced when the waxes are wetted.
  • Examples 5-8 provide examples of the liquid film compositions of the present invention.
  • the ethoxylated castor oil is water miscible and makes it easier to wash the composition in example 5.
  • the ethoxylated castor oil in provided in such an amount that the washability of the formulation improved but lubricity of the formulation is only minimally degraded. Small amounts of the ethoxylated castor oil actually improve lubricity.
  • Example 5 has a burst pressure of about 10,510 psi; a twist compression coefficient of friction at 10,000 psi of about 0.06; a twist compression coefficient of friction at 15,000 psi of about 0.05; and a sliding coefficient of about 0.065.
  • Tables 4 and 5 summarize the twist compression results for the composition described by example 5.
  • Example 8 has a burst pressure of about 10,510 psi; a twist compression coefficient of friction at 10,000 psi of about 0.06; a twist compression coefficient of friction at 15,000 psi of about 0.05; and a sliding coefficient of about 0.065
  • the coefficient of friction was determined for mixtures of blown canola oil and various surfactant.
  • the COF was measure both for neat (unwetted) and wetted mixtures. Table 6 summarizes the results. The coefficient of friction is surprisingly reduced in each case when wetted.
  • Chemal DA-6 is the surfactant ethoxylated decyl alcohol with 6 moles of ethoxylation for each mole of alcohol
  • Chemal DA-9 is the surfactant ethoxylated decyl alcohol with 9 moles of ethoxylation for each mole of alcohol
  • Chemal LA-4 is the surfactant ethoxylated lauryl alcohol with 4 moles of ethoxylation for each mole of alcohol
  • Chemax CO-5 is the surfactant ethoxylated castor glyceride with 5 moles of ethoxylation for each mole of castor glyceride
  • Chemax CO- 16 is the surfactant ethoxylated castor glyceride with 16 moles of ethoxylation for each mole of castor glyceride
  • Chemax CO-80 is the surfactant ethoxylated castor glyceride with 80 moles of ethoxylation for each mole of castor glyceride.
  • the COF was determined for neat (unwetted) and wetted mixtures of blown canola oil and the surfactant Chemax CO-40.
  • Table 7 summarizes the COF for varying amounts of Chemax CO-40 in blown canola oil, Z2, viscosity.
  • Chemax is an ethoxylated caster glyceride with 40 moles of ethoxylation for each mole of caster glyceride. Again, the wetted mixtures have lower COF than the neat mixture.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Lubricants (AREA)
  • Mounting, Exchange, And Manufacturing Of Dies (AREA)

Abstract

L'invention concerne un procédé d'hydroformage pour des parties métalliques faisant appel à des films lubrifiants liquides et solides. Les lubrifiants utilisés dans l'invention sont particulièrement utiles pour une lubrification côté poinçon. Le procédé comprend un étape dans laquelle une partie en métal ductile est recouverte soit d'un film lubrifiant liquide ou d'un film lubrifiant solide. Les lubrifiants liquides comprennent de préférence une huile et éventuellement un surfactant. Les lubrifiants solides comprennent de préférence de la cire dure et éventuellement un surfactant.
EP03800331A 2003-01-09 2003-12-30 Lubrifiants appropries pour l'hydroformage et pour d'autres applications de manipulation de metaux Withdrawn EP1608474A2 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US339523 2003-01-09
US10/339,523 US20030181340A1 (en) 2000-09-22 2003-01-09 Lubricants suitable for hydroforming and other metal manipulating applications
PCT/US2003/041577 WO2004062836A2 (fr) 2003-01-09 2003-12-30 Lubrifiants appropries pour l'hydroformage et pour d'autres applications de manipulation de metaux

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EP1608474A2 true EP1608474A2 (fr) 2005-12-28

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US (2) US20030181340A1 (fr)
EP (1) EP1608474A2 (fr)
AU (1) AU2003300073A1 (fr)
CA (1) CA2512682A1 (fr)
WO (1) WO2004062836A2 (fr)

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Also Published As

Publication number Publication date
AU2003300073A1 (en) 2004-08-10
CA2512682A1 (fr) 2004-07-29
US20030181340A1 (en) 2003-09-25
WO2004062836A3 (fr) 2005-12-08
WO2004062836A2 (fr) 2004-07-29
US20060128573A1 (en) 2006-06-15

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