WO2017094893A1 - ステンレス鋼板用潤滑塗料および潤滑ステンレス鋼板 - Google Patents
ステンレス鋼板用潤滑塗料および潤滑ステンレス鋼板 Download PDFInfo
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- WO2017094893A1 WO2017094893A1 PCT/JP2016/085940 JP2016085940W WO2017094893A1 WO 2017094893 A1 WO2017094893 A1 WO 2017094893A1 JP 2016085940 W JP2016085940 W JP 2016085940W WO 2017094893 A1 WO2017094893 A1 WO 2017094893A1
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- stainless steel
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- polyethylene wax
- acrylic resin
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- 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
- C10M2219/046—Overbasedsulfonic acid salts
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- 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
- C10M2223/00—Organic non-macromolecular compounds containing phosphorus as ingredients in lubricant compositions
- C10M2223/02—Organic non-macromolecular compounds containing phosphorus as ingredients in lubricant compositions having no phosphorus-to-carbon bonds
- C10M2223/04—Phosphate esters
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- 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
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- 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
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- 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
- C10N2050/023—Multi-layer lubricant coatings
- C10N2050/025—Multi-layer lubricant coatings in the form of films or sheets
Definitions
- the present invention relates to a paint imparting surface lubricity useful when pressing a stainless steel sheet, and a lubricated stainless steel sheet coated with the paint.
- Stainless steel sheet has higher strength than general mild steel, and is slid by receiving higher surface pressure from the mold during press processing. Excellent surface lubricity is required.
- lubricating oil is generally widely used. However, the lubricating oil may sag or it may be volatile and diffuse in the air, which may reduce the working environment. .
- Solid lubricating films In addition to the lubricating oil, there is a solid lubricating film obtained by adding a lubricant such as wax to a resin and drying it by baking.
- Solid lubricating films generally have better lubricity and anti-scoring properties than lubricating oils, and the work environment is kept good because the films themselves are not volatile.
- Waxes are widely used as lubricants, and those having a low melting point are often used because of their low friction coefficient.
- the wax has a drawback that it is difficult to solidify. When trying to improve the lubricity by adding a large amount of wax, even if an attempt is made to dry the paint in a baking oven or the like, the wax does not solidify and the film becomes sticky. There was a problem that remained.
- Patent Document 1 includes (a) a specific acrylic resin, (b) a metal soap or the like as a mixed lubricant, and (c) a polyethylene wax having a melting point Tm of 70 ⁇ Tm ⁇ 150 ° C.
- a film removal type lubricating steel sheet containing 3 to 20 wt% with respect to the solid content of a) is described.
- This document discloses an invention in which a lubricating steel sheet having a mixed lubricant of (b) metal soap or the like and (c) a specific high melting point polyethylene wax is excellent in deep drawability and galling resistance.
- Comparative Example 7 shows that the use of a single lubricant containing only a specific high melting point wax is inferior in galling resistance.
- a specific acrylic resin contains an organic solid wax having a melting point of 60 ° C. or more as a lubricant.
- (Claim 1) A stainless cold-rolled steel sheet excellent in workability and mold galling resistance (Claim 5). ) Is described.
- the wax content is described as about 1 to 10% by mass based on the total resin solid content of the coating composition (paragraph [0038]), and the wax used in the examples has a low melting point (68 ° C. to 107 ° C.
- the amount used is 2.04 to 11.1 parts by mass with respect to 100 parts by mass of the acrylic resin.
- Patent Document 2 since the high melting point wax has a high coefficient of friction, the invention was developed with a technical understanding that a relatively low melting point wax having a lower coefficient of friction is used to lower the coefficient of friction. It is. Although the invention of Patent Document 2 has an effect as a lubricated stainless steel plate, it still needs improvement at the time of continuous pressing or intense deep drawing in stainless steel.
- An object of the present invention is to solve the above-mentioned problems of the prior art and to provide a lubricating paint imparting excellent press workability to a stainless steel plate having a higher strength than general mild steel and a lubricated stainless steel plate using the same. To do.
- the present invention provides the following.
- a stainless steel containing an acrylic resin and polyethylene wax wherein the polyethylene wax has a melting point of 115 ° C. or higher, and contains 20 to 50 parts by mass of polyethylene wax with respect to 100 parts by mass of the acrylic resin.
- Lubricating paint for steel sheet (2) The lubricating paint for stainless steel sheets according to (1), further comprising 1 to 10 parts by mass of an organic calcium compound with respect to 100 parts by mass of the acrylic resin.
- a lubricated stainless steel sheet excellent in press workability deep drawing property and anti-squeeze resistance
- the lubricating paint for stainless steel sheets of the present invention is an acrylic resin-containing water-based paint, and contains a stainless steel containing a polyethylene wax having a melting point of 115 ° C. or higher in excess of 20 to 50 parts by mass with respect to 100 parts by mass of the acrylic resin.
- Lubricating paint for steel sheet is an acrylic resin-containing water-based paint, and contains a stainless steel containing a polyethylene wax having a melting point of 115 ° C. or higher in excess of 20 to 50 parts by mass with respect to 100 parts by mass of the acrylic resin.
- the acrylic resin used in the present invention is not particularly limited.
- fatty acids such as acrylic acid, methacrylic acid, maleic acid, maleic anhydride, itaconic acid, fumaric acid; Above 1.
- Fatty acids and amides such as ammonia; 4. Styrene, 5.
- 1. A polyoxyethylene added to the fatty acid of 1 above.
- Examples of the polymerization or copolymerization method include a solution polymerization method, an emulsion polymerization method, and a suspension polymerization method.
- a surfactant, a rust inhibitor, an extreme pressure agent, a pH adjuster and the like that are generally widely used in paints are generally added to 100 parts by mass of the acrylic resin. It can contain 10 mass parts or less.
- the solvent of the lubricating paint may be either an aqueous solvent or an organic solvent, but an aqueous solvent is preferable.
- the polyethylene wax used is not limited as long as it has a melting point of 115 ° C. or higher.
- the melting point is less than 115 ° C., when added in excess of 20 parts by mass with respect to 100 parts by mass of the acrylic resin, a solid is generated without being solidified after drying the paint.
- Use wax In particular, a high-density polyethylene wax having a melting point of 120 ° C. or higher (density 0.942 g / cm 3 or higher) is preferable, and a polyethylene wax having a melting point of 130 ° C.
- the melting point is preferably 145 ° C. or lower. If the melting point becomes too high, it becomes hard, and peeling of the film may increase due to contact with the mold during press working.
- a polyethylene wax having a melting point of 115 ° C. or higher is preferable when an emulsion is added to the acrylic resin-containing water-based paint because it is uniformly mixed in the acrylic resin-containing water-based paint and the properties of the resulting lubricating paint are excellent.
- the average particle size of the emulsified polyethylene wax is preferably less than 1.0 ⁇ m. This is because the smaller the average particle size, the more uniformly the polyethylene wax is dispersed in the film. In order to disperse more uniformly, it is more preferable that the average particle diameter is 0.2 ⁇ m or less.
- the friction coefficient as the film decreases, but if the friction coefficient is too small, the coil may be crushed by its own weight or may be dropped by carrying the plate, More preferably, it is 40 parts by mass or less, more preferably 30 parts by mass or less with respect to 100 parts by mass of the acrylic resin, and sufficient lubricity can be obtained by normal pressing of stainless steel.
- a surfactant, a rust inhibitor, an extreme pressure agent, a pH adjuster and the like widely used in paints can be contained in a total of 10 parts by mass or less with respect to 100 parts by mass of the acrylic resin.
- the solvent of the water-based paint is a solvent mainly composed of water and may contain a small amount of an organic solvent, but an aqueous solvent is preferable because the amount of volatile organic solvent generated in the lubricating paint can be reduced as much as possible.
- Patent Document 2 in a lubricating coating using a predetermined amount of a low melting point wax having a small coefficient of friction, in a high surface pressure pressing of a stainless steel plate, 20 parts per 100 parts by mass of the acrylic resin is used. Addition of a wax of less than part by mass may not provide sufficient mold galling resistance, and it is necessary to increase mold galling resistance in high surface pressure pressing of a stainless steel sheet.
- a high melting point polyethylene wax having a melting point of 115 ° C. or higher has a higher coefficient of friction than that of a low melting point polyethylene wax.
- Patent Document 1 observes a mold squeeze of a rectangular tube diaphragm, and Patent Document 2 evaluates it using a squeeze of an Erichsen cup (cylindrical diaphragm).
- the evaluation stage contact surface pressure between the mold and the plate
- Patent Document 2 which is “20 times with high surface pressure (about 200 MPa) for the same specimen”.
- Evaluation that “the coefficient of friction does not increase even when sliding continuously” is a suitable evaluation method for stainless steel. The reason for this is that, with stainless steel, the forming process may not be completed with a single press, and multiple press moldings may be performed. Therefore, the galling resistance of stainless steel is properly evaluated for the first time in a severe press molding evaluation method. it can. There is no prior art which has evaluated such severe press molding.
- Organic calcium compound In press forming of a stainless steel plate, forming may be performed by a plurality of presses without being completed by a single press. At that time, there is a phenomenon of mold galling in which the coating is damaged by the initial press, and then the friction coefficient increases.
- an organic calcium compound is added if necessary.
- the organic calcium compound one containing 6% by mass or more of calcium is used. For example, calcium stearate, calcium oleate, calcium laurate and the like, fatty acid calcium having a C 12 to C 18 fatty acid.
- overbased petroleum calcium sulfonates such as overbased calcium alkylbenzene sulfonates, overbased calcium calcium naphthalene sulfonates, overbased calcium alkylaryl sulfonates are used.
- the addition of 1 to 10 parts by mass of the organic calcium compound with respect to 100 parts by mass of the acrylic resin provides an effect of improving mold squeezing property. If it is less than 1 part by mass, the mold galling improvement effect cannot be obtained. The effect is saturated even if added over 10 parts by mass.
- the lubricating paint for a stainless steel plate of the present invention can be applied to all stainless steel plates regardless of the type of stainless steel, and a lubricated stainless steel plate having excellent deep drawing workability and mold galling resistance can be obtained. In particular, it is suitable for press working of ferritic stainless steel sheets that use drawing.
- the lubricating paint for stainless steel sheet of the present invention is applied to the surface of the stainless steel sheet and dried.
- the coating method is not limited, and examples thereof include spray coating, roll coater coating, dip coating, and brush coating coating.
- the solid content (acrylic resin + polyethylene wax + calcium compound) concentration of the paint of the present invention can be adjusted according to the coating method and the drying method used. The amount is preferably 1% by mass to 50% by mass.
- a general baking furnace or the like can be used as a method for drying the paint. However, since the lubricating paint of the present invention is easily solidified, it can be sufficiently solidified by simple hot air drying.
- the coating is performed on one side or both sides of the steel sheet depending on the intended use of the steel sheet.
- the amount of adhesion after drying is preferably 0.5 to 2.5 g / m 2 per side.
- the adhesion amount after drying is 0.5 g / m 2 to 2.5 g / m 2 , the film is hardly damaged, the mold galling resistance is excellent, the lubrication effect is sufficient, and the film peels off during sliding. There are few, and what peeled does not accumulate on a press metal mold
- ⁇ Evaluation method> 1 The friction coefficient was measured by sandwiching a test material having a thickness of 1.5 mm, a length of 200 mm, and a width of 20 mm between the apparatus shown in FIG. In the state, the drawing load was drawn in the drawing load direction 8, and the drawing load was measured by a sliding tester for measuring the drawing load. The coefficient of friction was obtained by pulling load / pressing load.
- the test conditions were as follows: mold: material SKD11, curvature R20, sample width 20 mm, sliding distance: 100 mm, drawing speed: 20 mm / s, and pressing load: 3920 N.
- Fluorescent X-ray shows whether or not the lubricant film has been transferred to the surface of the stainless steel plate without film after pressing the non-coated stainless steel with a surface pressure of 0.01 MPa on the stainless steel plate after the lubricant film is formed. It was evaluated by measuring the C count amount. When there was no increase in the amount of C, no stickiness was assumed. The case where there was an increase in the amount of C on the surface of the stainless steel plate without the coating was evaluated as sticky. 3. The deep drawability was evaluated by measuring the limit deep drawing ratio (LDR).
- the punch shoulder R was 3mm, punch feed speed 1mm / sec, wrinkle holding load 10kN, wrinkle holding shoulder R3mm. 4).
- the friction coefficient does not increase means that “the 20th friction coefficient is less than 0.15 even if the same test material slides 20 times at a high surface pressure (about 200 MPa) continuously”. The case was considered to have good mold galling resistance, and “0.15 or more” was evaluated as impossible.
- Comparative Example 5 it can be seen that when the low melting point polyethylene wax is added in a large amount with respect to 100 parts by mass of the acrylic resin, the lubricating coating becomes sticky.
- Comparative Examples 2 and 3 it can be seen that, when a low melting point wax is used, the coefficient of friction decreases, but the anti-mold galling property is low as a lubricating paint for stainless steel.
- the addition amount of the polyethylene wax of Comparative Examples 1, 2, 3, 4, and 6 is low, the LDR value is lower than that of the Examples, resulting in inferior deep drawability.
- a lubricated stainless steel plate having excellent workability such as deep drawing and anti-molding resistance can be obtained. If this is used, stainless steel sheets can be easily processed by press molding with high surface pressure, so the application of stainless steel with excellent corrosion resistance and high temperature characteristics can be expanded mainly in the fields of automobiles, home appliances and kitchens, and is industrially useful. .
- Ferritic stainless steel in particular, does not contain Ni and is therefore cheaper than austenitic stainless steel, and has the advantage that there is no concern about stress corrosion cracking (SCC). It is.
- Ferritic stainless steel contains a large amount of Cr compared to mild steel, so it has poor ductility and poor stretchability, so there is a problem that the formable range is limited. If a lubricating paint is used, a wide range of molding processing is possible, and industrial products can be obtained by taking advantage of the characteristics of the material.
- Test material 2 Lower mold 3: Upper mold 5: Curvature 6: Pushing load direction 8: Pulling load direction
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- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
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- Wood Science & Technology (AREA)
- Life Sciences & Earth Sciences (AREA)
- Materials Engineering (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- General Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Dispersion Chemistry (AREA)
- Lubricants (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
- Paints Or Removers (AREA)
- Laminated Bodies (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
Abstract
Description
加工時に潤滑性を得るために一般的には潤滑油が広く用いられているが、潤滑油は垂れ落ちたり、また揮発性があり空気中に拡散するなど、作業環境を低下させる場合があった。
ワックスは潤滑剤として広く用いられており、特に低融点のものは摩擦係数が低いために良く用いられている。しかし一方で、ワックスは固化しにくい欠点があり、ワックスを多く添加して潤滑性を向上させようとした場合、焼付け炉等で塗料を乾燥させようとしてもワックスが固化せずに皮膜にベタツキが残ってしまう問題があった。
特許文献2の発明は、潤滑ステンレス鋼板としての効果が得られたが、ステンレス鋼における連続プレス時や激しい深絞り成形時にはまだ改良の必要があった。
(1) アクリル系樹脂およびポリエチレンワックスを含み、前記ポリエチレンワックスの融点が115℃以上であり、前記アクリル系樹脂100質量部に対して20質量部超~50質量部のポリエチレンワックスを含有する、ステンレス鋼板用潤滑塗料。
(2) さらに、有機カルシウム化合物を、前記アクリル系樹脂100質量部に対して、1質量部~10質量部含有する(1)に記載のステンレス鋼板用潤滑塗料。
(3) 前記ポリエチレンワックスが中密度または高密度ポリエチレンワックスである(1)または(2)に記載のステンレス鋼板用潤滑塗料。
(4) 水系溶媒を用い、前記ポリエチレンワックスをエマルション化して添加する、(1)ないし(3)のいずれか1に記載のステンレス鋼板用潤滑塗料の製造方法。
(5) ステンレス鋼板上に、(1)ないし(3)のいずれか1に記載のステンレス鋼板用潤滑塗料を塗布し、熱風乾燥して、乾燥後の質量で片面当たり0.5~2.5g/m2の潤滑皮膜を形成する潤滑ステンレス鋼板の製造方法。
(6) 上記(1)ないし(3)のいずれか1に記載のステンレス鋼板用潤滑塗料を、乾燥後の質量で片面当たり0.5~2.5g/m2有する潤滑ステンレス鋼板。
本発明のステンレス鋼板用潤滑塗料は、アクリル系樹脂含有水性塗料であって、融点が115℃以上のポリエチレンワックスを、アクリル系樹脂100質量部に対して20質量部超~50質量部含有するステンレス鋼板用潤滑塗料である。
本発明に用いるアクリル系樹脂は、特に限定されない。好ましくは1.アクリル酸、メタクリル酸、マレイン酸、無水マレイン酸、イタコン酸、フマル酸等の脂肪酸、2.上記1.の脂肪酸をメチル化、エチル化、イソプロピル化、ブチル化、2-エチルヘキシル化等をしたエステル、3.上記1.の脂肪酸とアンモニア等のアミド、4.スチレン、5.上記1.の脂肪酸にポリオキシエチレンを付加したもの、の上記1.から5.からなる群から選ばれる1種類または2種類以上をモノマーとして重合または共重合したものを使用する。重合または共重合する方法としては、溶液重合法、エマルション重合法または懸濁重合法などが例示できる。アクリル系樹脂に添加する添加剤としては、一般的に塗料に広く用いられている界面活性剤、防錆剤、極圧剤、pH調整剤等を合計で前記アクリル系樹脂100質量部に対して10質量部以下含有することができる。潤滑塗料の溶媒は、水系あるいは有機溶剤のいずれでも良いが水系溶媒が好ましい。
用いるポリエチレンワックスは、融点115℃以上のポリエチレンワックスであれば限定されない。好ましくは中密度~高密度ポリエチレンワックス(密度0.930g/cm3以上)を使用する。融点が115℃未満であると、前記アクリル系樹脂100質量部に対して20質量部超えて添加した場合に、塗料乾燥後に容易に固化せずにベタツキが発生するため、融点115℃以上のポリエチレンワックスとする。特に融点が120℃以上の高密度ポリエチレンワックス(密度0.942g/cm3以上)が好ましく、さらに融点が130℃以上のポリエチレンワックスがより好ましい。融点は145℃以下であることが好ましい。融点が高くなりすぎると硬くなり、プレス加工時の金型との接触で皮膜の剥離が大きくなることがある。
融点115℃以上のポリエチレンワックスは、エマルション化したものをアクリル系樹脂含有水性塗料に添加するとアクリル系樹脂含有水性塗料に均一に混ざり、得られる潤滑塗料の特性が優れるので好ましい。
エマルション化されたポリエチレンワックスの平均粒径は1.0μm未満が好ましい。平均粒径が小さいほうがポリエチレンワックスが皮膜に均一に分散するためである。さらに均一に分散するためには、平均粒径が0.2μm以下であればより好ましい。
一般的に塗料に広く用いられている界面活性剤、防錆剤、極圧剤、pH調整剤などを合計で前記アクリル系樹脂100質量部に対して10質量部以下含有することができる。水性塗料の溶媒は、水を主体とする溶媒で、少量の有機溶媒を含んでも良いが潤滑塗料中の揮発性有機溶剤発生量を極力低減できるので水系溶媒が好ましい。
1)特許文献2の基本的技術思想として、摩擦係数の小さい低融点ワックスを所定量使用する潤滑塗料では、ステンレス鋼板の高面圧のプレス加工では、前記アクリル系樹脂100質量部に対して20質量部以下のワックスの添加では、十分な耐型かじり性が得られない場合があり、ステンレス鋼板の高面圧のプレス加工ではより耐型かじり性を上げる必要がある。
融点115℃以上の高融点ポリエチレンワックスはそれ自体の摩擦係数が低融点ポリエチレンワックスよりも高いため、低融点ポリエチレンワックスと同量程度添加したのでは摩擦抵抗が十分に低下しないという懸念があったが、高融点ポリエチレンワックスを用いる場合は前記アクリル系樹脂100質量部に対して20質量部を超えて添加すると、アクリル樹脂の比率が低くなるため摩擦係数の高いアクリル樹脂の寄与が下がるとともに、高融点ポリエチレンワックス摩擦係数低減効果が現れるので従来得られなかった優れた潤滑性が得られる。
この理由は不明であるが以下のことが考えられる。
高融点のワックスは、低融点のワックスと比較して粘度が高く、金型と鋼板との接触摺動時にその隙間に残存しやすいため、深絞り性および型かじりに対して効果があると推定される。
2)本願の型かじり性の評価は、実施例で説明するように特許文献1,2とは異なる評価方法である。特許文献1では角筒絞りの型カジリを観察し、特許文献2ではエリクセンカップ(円筒絞り)の型カジリで評価している。評価の段階(金型と板との接触面圧)としてはおよそ、本願>特許文献1>特許文献2であり、本願の「同じ供試材に対して高面圧(約200MPa)で20回連続して摺動しても摩擦係数が上昇しない」評価は、ステンレス鋼にとって好適な評価方法である。この理由はステンレス鋼では一回のプレスでは成形加工が完了せず複数回のプレス成型が行われる場合があるため、過酷なプレス成型の評価方法で初めてステンレス鋼の耐型かじり性を適切に評価できる。このような過酷なプレス成型の評価を行った従来技術はない。
ステンレス鋼板のプレス成形の際には、1回のプレスでは完了せずに、複数回のプレスで成形が行われる場合がある。その際に初期のプレスで塗装が損傷を受け、その後摩擦係数が上昇して行く型かじりという現象がある。耐型かじり性を向上させるために、必要により有機カルシウム化合物を添加する。
有機カルシウム化合物は、カルシウムを6質量%以上含有しているものを使用する。例えば、ステアリン酸カルシウム、オレイン酸カルシウム,ラウリン酸カルシウム等、脂肪酸がC12~C18の脂肪酸カルシウム。あるいは、過塩基性アルキルベンゼンスルフォン酸カルシウム、過塩基性アルキルナフタレンスルフォン酸カルシウム,過塩基性アルキルアリールスルフォン酸カルシウム等の過塩基性石油スルフォン酸カルシウムを使用する。
有機カルシウム化合物は、前記アクリル系樹脂100質量部に対して1~10質量部添加すると型かじり性改善効果が得られるため、必要に応じて添加する。1質量部未満であると、型かじり性改善効果が得られない。10質量部超えて添加しても効果は飽和する。
本発明のステンレス鋼板用潤滑塗料は、ステンレスの種類によらず全てのステンレス鋼板に適用でき深絞り加工性と耐型かじり性に優れる潤滑ステンレス鋼板が得られる。特に絞り加工が用いられるフェライト系ステンレス鋼板のプレス加工に適している。
本発明のステンレス鋼板用潤滑塗料をステンレス鋼板表面に塗布して乾燥する。塗布方法は、限定されないが、スプレー塗布、ロールコーター塗布、浸漬塗布、刷毛塗塗布等の方法が例示できる。本発明塗料の固形分(アクリル系樹脂+ポリエチレンワックス+カルシウム化合物)濃度は、用いられる塗布方法や乾燥方法に合わせて調製することができる。好ましくは1質量%~50質量%である。塗料の乾燥方法は、一般的な焼付け炉等を使用することが出来るが、本発明の潤滑塗料は固化しやすいため、簡易的な熱風乾燥で十分に固化させることが出来る。塗装は、鋼板の使用用途により鋼板の片面または両面に行うが、乾燥後の付着量は、片面当り0.5~2.5g/m2が好ましい。
乾燥後の付着量が0.5g/m2~2.5g/m2であると皮膜の損傷が起こりにくく、耐型かじり性が優れ、潤滑効果が十分で、摺動時の皮膜の剥がれが少なく、剥がれたものがプレス金型に堆積してプレス加工に悪影響を及ぼすことがない。より好ましくは0.8g/m2以上、2.0g/m2以下、さらに好ましくは1.5g/m2以下とする。
摩擦係数は測定方法による違いがあり、本発明で得られる潤滑皮膜の同一サンプルでも測定方法により絶対値が異なるため、絶対値では評価できないが、一般的には相対比較で高いとすべりが悪くなるため、プレス性は低下する。一方で低すぎると、鋼帯をコイルにした場合、コイルが自重でつぶれる場合があり、また滑りすぎて板のハンドリングに支障をきたす場合もある。
表1の組成のアクリル樹脂含有水性塗料を作製し、ステンレス鋼板(SUS444の(19mass%Cr-2mass%Mo-0.4mass%Nb)2D仕上げ)に、スプレーで均一に塗布し、ドライヤーの熱風で乾燥させる塗装を板の両面に実施し、その特性を評価した。なお、各塗料とも固形分(アクリル樹脂+ポリエチレンワックス+カルシウム化合物)濃度を10質量%に調整した。その結果を表1に示す。ポリエチレンワックスはエマルション化したものを水性塗料に混合して用いた。
1.摩擦係数は、図1に示す装置、すなわち曲率5がR20の上下の金型の間に、厚さ1.5mm×長さ200mm×幅20mmの供試材を挟み、押し付け荷重方向6で押し付けた状態で引抜荷重方向8に引抜き、引抜荷重を測定する摺動試験機で引抜荷重を測定した。摩擦係数は、引抜荷重/押し付け荷重、により求めた。試験条件は、金型:材質SKD11、曲率R20、サンプル幅20mm、摺動距離:100mm、引抜速度:20mm/s、押し付け荷重:3920Nで行った。金型と供試材の接触面積は約20mm2(20mm幅×約1mm)であり、面圧は約200MPa(=3920N/20mm2)となる。
2.ベタツキ有無、潤滑皮膜形成後のステンレス鋼板に、皮膜無しのステンレス鋼を面圧0.01MPaで押し付け、剥がしたのちに皮膜無しのステンレス鋼板の表面に潤滑皮膜が転写されていないかを、蛍光X線でCカウント量を測定することにより評価した。C量の増加は見られない場合、ベタツキ無しとした。皮膜無しのステンレス鋼板の表面にC量の増加があった場合をベタツキ有り、と評価した。
3.深絞り性は、限界深絞り比(LDR(=Limiting Drawing Ratio))測定により評価した。円板形の試験片に、円筒形のポンチ(直径d=33mm)を押し込み、破断することなく、絞り抜けする最大の試験片直径(D(mm))を求め、D/dの計算式で求めた。ポンチの肩Rは3mm、ポンチ送り速度1mm/秒、しわ押さえ荷重10kN、しわ押さえ肩R3mmで行った。
4.耐型かじり性は、図1に記載する摺動試験機を用い、1つの供試材を途中金型研磨なしで20回連続して摺動し、摩擦係数が上昇しない場合を耐型かじり性良好と評価した。摩擦係数が上昇しないとは、「同じ供試材に対して高面圧(約200MPa)で20回連続して摺動しても20回目の摩擦係数が0.15未満である」とし、この場合を耐型かじり性良好とし、「0.15以上」を不可と評価した。
A:ステアリン酸カルシウム
B:過塩基性石油スルフォン酸カルシウム
表1の樹脂の種類、
アクリル1:スチレン+メタクリル酸ブチル+メタクリル酸+エチレン性不飽和カルボン酸の共重合物(質量比25:30:24:21)
アクリル2:スチレン+メタクリル酸ブチル+メタクリル酸 の共重合物(質量比25:51:24)
表1のP系添加剤、
*)オレイルアシッドホスフェイト(極圧剤)
表1の結果から、実施例1~18では、高融点のポリエチレンワックスを前記アクリル系樹脂100質量部に対して従来の量より多い特定量添加すると、ステンレス鋼板に対して優れた加工性を有する潤滑塗料が得られることがわかる。表1の実施例1、3、5、6、15、17では有機カルシウム化合物を無添加としても耐型かじり性に優れるが、有機カルシウム化合物を添加するとさらに耐型かじり性が向上した。比較例1、4、6では高融点のポリエチレンワックスの量が樹脂に対して少ないと耐型かじり性が劣る。比較例5では低融点のポリエチレンワックスが前記アクリル系樹脂100質量部に対して多量に添加されると潤滑塗料がベタツクことがわかる。比較例2,3では、低融点ワックスを使用すると、摩擦係数は低くなるがステンレス鋼用の潤滑塗料としては耐型かじり性が低いことがわかる。また、比較例1、2、3、4、6のポリエチレンワックスの添加量が低い場合、LDR値が実施例より低く、深絞り性が劣る結果となっている。
Claims (5)
- アクリル系樹脂およびポリエチレンワックスを含み、前記ポリエチレンワックスの融点が115℃以上であり前記アクリル系樹脂100質量部に対して20質量部超~50質量部の前記ポリエチレンワックスを含有する、ステンレス鋼板用潤滑塗料。
- さらに、有機カルシウム化合物を、前記アクリル系樹脂100質量部に対して、1質量部~10質量部含有する請求項1に記載のステンレス鋼板用潤滑塗料。
- 水系溶媒を用い、前記ポリエチレンワックスをエマルション化して添加する、請求項1または2に記載のステンレス鋼板用潤滑塗料の製造方法。
- ステンレス鋼板上に、請求項1または2に記載のステンレス鋼板用潤滑塗料を塗布し、熱風乾燥して、乾燥後の質量で片面当たり0.5~2.5g/m2の潤滑皮膜を形成する潤滑ステンレス鋼板の製造方法。
- 請求項1または2に記載のステンレス鋼板用潤滑塗料を、乾燥後の質量で片面当たり0.5~2.5g/m2有する潤滑ステンレス鋼板。
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