CN1061367C - 金属材料的冷塑性加工用水系润滑剂 - Google Patents

金属材料的冷塑性加工用水系润滑剂 Download PDF

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CN1061367C
CN1061367C CN97117136A CN97117136A CN1061367C CN 1061367 C CN1061367 C CN 1061367C CN 97117136 A CN97117136 A CN 97117136A CN 97117136 A CN97117136 A CN 97117136A CN 1061367 C CN1061367 C CN 1061367C
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lubricant
water
oil
tunicle
hydrographic
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CN1171434A (zh
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村田元治
松村由男
西泽嘉彦
小山隆
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Nihon Parkerizing Co Ltd
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Nihon Parkerizing Co Ltd
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Abstract

提供了金属材料的冷塑性加工用水系润滑剂，该润滑剂是水系润滑剂，具有高的润滑性，可以代替将磷酸盐处理和草酸盐处理等化学被膜处理与反应型皂处理组合而成的润滑***。没有像上述润滑体系中的环境方面的问题，能以1个工序进行处理，被膜剥离容易，即使以浸渍法大量处理加工材料也不引起因附着不匀而产生的耐热胶着性降低。
该金属材料的冷塑性加工用水系润滑剂由下列成分组成：
(A)水溶性无机盐、(B)固体润滑剂、(C)选自矿物油、动植物油脂和合成油中的至少一种油成分(D)表面活性剂、以及(E)水，固体润滑剂和水溶性无机盐的重量比(B/A)是0.05/1-2/1，相对于水溶性无机盐和固体润滑剂的总量，油成分的重量比(C/(A+B))是0.05/1-1/1，固体润滑剂和油成分各自均匀分散和乳化。

Description

金属材料的冷塑性加工用水系润滑剂
本发明是关于冷塑性加工(锻造、拔管、拔丝等)钢铁、钛和钛合金、铜和铜合金、铝和铝合金等金属材料时使用的金属材料的冷塑性加工用水系润滑剂(以下，简称水系润滑剂)。
在金属材料的塑性加工例如钢管的冷拔加工中，为了降低被加工材料与拉模、芯棒等工具之间产生的摩擦，防止发生咬死或热胶着，容易进行拉拔加工，使用形成液状的被膜或形成固体状的被膜的润滑剂。
在这类的润滑剂之中，液状润滑剂的代表者是以矿物油、动植物油和合成油等作为基油为所谓油系润滑剂，一般使用从组装在加工装置上的润滑油供给装置直接流到工具或加工材料上的润滑方法。油系润滑油的使用多见于加工度较低的场合，在加工度较高的场合，使油的粘度上升，或者添加固体润滑剂和耐特压润滑油添加剂而使用。而固体被膜的代表者是与被加工材料反应、与基体形成良好附着的承载被膜的所谓化学被膜处理，对于碳钢和低合金钢，进行形成磷酸锌系被膜的磷酸盐被膜处理，对于不锈钢，进行形成草酸铁系的草酸盐被膜处理。在进行这些化学被膜处理后，通常进行反应型皂润滑处理，通过进行由这样的2个工序细成的润滑处理，能够将化学被膜的承载性和反应型皂润滑剂产生的润滑性组合起来，该润滑方法显示出极高的耐热胶着性。另外，在化学被膜处理后进行反应型皂润滑处理的场合，通常加工材料在拉拔加工之前，要在各种处理槽中进行浸渍处理，由于是反应型处理，所以不论加工材料彼此之间线状地接触部分有多少，润滑剂的附着不匀也是少的，采取以数10根单位集中进行处理的方式。
但是，随着加工条件的高速化、高压化和对环境方面、能源方面的要求，要求解决具有与将化学被膜处理和反应型皂润滑处理组合的润滑法同等或更高的润滑性能，而且在化学被膜方面发现的问题，例如作业环境的问题(例如，在80-90℃的高温使用酸系处理液，因此处理液的臭气和烟雾使环境恶化)，废弃物管理的问题等环境方面的问题，以及缩短工序、节能、节省场地等成本方面的问题，进而加工后的被膜剥离性的问题(通常要进行碱脱脂和酸洗处理)等的润滑剂。
在为解决这些问题的油系润滑剂的场合，在特公平4-1798中公开了“在配合氯化石蜡、磷酸酯等耐特压润滑油添加剂和异丁烯与正丁烯的共聚物及动植物油的润滑油中配合金属皂和固体润滑剂的冷加工用润滑剂”。但是，即使是这些高性能润滑油，与化学被膜处理后进行反应型皂润滑处理的润滑法相比，在加工性能上也有一些缺点，另外，由于大量使用耐特压剂(耐特压润滑油添加剂)，加工时产生臭气，并且在加工后的软化退火过程中氯和磷有可能对材料产生腐蚀。
另外，在水系润滑剂的场合，有直接以湿式使用和以干式被膜使用两种情况。直接以湿式使用的水系润滑剂，像上述油系润滑剂一样直接流到工具或加工材料上而使用，以干式被膜使用的水系润滑剂，是像上述化学被膜一样在处理槽中进行浸渍处理后，在干燥过程中使水分蒸发而得到固体被膜。前者，在特公昭58-30358中记载的“以碳酸氢盐(固形物)为主成分、向其中加入少量的分散剂、表面活性剂和固体润滑剂的金属管的冷加工或温加工用润滑剂”中已有描述，但没有达到代替化学被膜处理而广泛使用的程度。至于后者，“以水溶性高分子或其水性乳液作为基体材料，配合固体润滑剂和化学被膜形成剂的润滑被覆用组合物(特开昭52-20967)”和“组合使用的硼砂为主成分的被膜和钙皂及金属皂，对不锈钢丝进行拔丝加工的方法(特开昭50-147460)”等中已有描述，但是，在一次大量浸渍处理加工材料，然后进行强制干燥得到干燥被膜的情况下，必然产生由于加工材料的部分接触而引起的附着不匀，结果达不到解决在拉拔加工时容易引起热胶着的非反应型润滑剂的大缺点。
综上所述，目前还没有能够代替将磷酸盐处理和草酸盐处理等化学被膜处理与反应型皂处理组合而构成的润滑体系，以1个工序实现加工性能、环境、废弃物处理、节能、被膜剥离性等要求的润滑剂。
本发明是适应这样的要求而完成的，其目的在于，代替将磷酸盐处理和草酸盐处理等化学被膜处理与反应型皂处理组合而成的润滑体系，提供一种属于水系、具有高润滑性、没有上述的环境方面的问题、能以1个工序进行处理、被膜剥离容易、即使用浸渍法大量地处理加工材料也不产生由附着不均匀而引起的热胶着性降低的金属材料的冷塑性加工用水系润滑剂。
为了解决上述问题本发明人进行了深入研究，结果发现，以良好地附着于基体上、将润滑成分导入工具面上形成被膜的物质的水溶性无机盐作为基体材料，由该基体材料、作为润滑成分的固体润滑剂、作为润滑成分或润滑辅助物质的由矿物油、动植物油和合成油中选择的油成分、表面活性剂和水组成，水溶性无机盐、固体润滑剂和油成分之间的使用比例满足一定条件的水系润滑剂能解决上述问题。即，使用上述水系润滑剂作为金属的冷塑性加工时的润滑剂的场合，在进行浸渍等处理后的干燥工序中，金属表面上形成固体润滑剂分散的无机盐被膜，同时，油成分渗出到被膜的***部分而形成油膜。该油膜在赋予加工时的初期润滑的同时，弥补加工材料彼此间的接触部分的固体润滑剂附着不匀，从而显著改善耐热胶着性。
再者，仅以通常的碱脱脂剂进行的处理就能除去残留在塑性加工后的金属材料上的润滑成分。
这样，本发明是关于金属的冷塑性加工用水系润滑剂，该润滑剂由下列成分细成：
(A)水溶性无机盐；
(B)固体润滑剂；
(C)选自矿物油、动植物油脂和合成油中的至少一种油成分；
(D)表面活性剂；
(E)水；固体润滑剂与水溶性无机盐的重量比(B/A)是0.05/1-2/1，相对于水溶性无机盐和固体润滑剂的合计量，油成分的重量比(C/(A+B))是0.05/1-1/1，固体润滑剂和油成分各自均匀地分散并乳化。
以下详细地说明本发明。
(A)的水溶性无机盐，是构成用本发明的水系润滑剂形成的良好地附着在金属基体上的竖固被膜的主体，只要是作为金属材料的冷塑性加工的媒介物一般使用的水溶性无机盐就可以，没有特别的限制，例如可举出四硼酸钠(硼砂)、四硼酸钾、四硼酸铵等硼酸盐，硫酸钠、硫酸钾、硫酸铵等硫酸盐，硅酸钠、硅酸钾等硅酸盐，硝酸钠、硝酸钾等硝酸盐，其中以硼砂、四硼酸钾和硫酸钠最好。作为水溶性无机盐，上述的无机盐可以单独使用一种或2种以上组合使用。
(B)的固体润滑剂，均匀地分散在本发明的水系润滑剂中，在将该水系润滑剂涂敷在加工材料上时进行附着，在加热干燥使蒸发水分时产生的由水溶性无机盐构成的被膜中作为主要成分，有助于防止产生咬住的热胶着。这样的固体润滑剂，只要是进行金属材料的冷塑性加工时通常使用的固体润滑剂就可以，没有特别的限制，例如可举出金属皂、云母、钙化合物、金属硫化物、氮化物、金属氧化物、高分子固体等。金属皂是脂肪酸和金属的盐。作为脂肪酸可举出月桂酸、肉豆蔻酸、棕榈酸、硬脂酸、山萮酸、羟基硬脂酸等，其中以硬脂酸最好。作为金属可举出钙、铝、镁、钡、锌、铅、锂、钾等。作为这样的金属皂，硬脂酸钙最好。作为云母可举出绢云母、白云母、合成云母等。作为钙化合物可举出氢氧化钙、碳酸钙等。作为金属硫化物可举出二硫化钼、二硫化钨、二硫化硒等。作为氮化物可举出氮化硼等。作为金属氧化物可举出氧化钛、氧化锌、二氧化硅等。作为高分子固体可举出PTFE、尼龙、聚乙烯等。除此之外，可举出石墨、滑石、金属等。作为这些固体润滑剂，通常使用粉末状的固体润滑剂。它们之中，以下含有在退火时成为障碍的物质、而且润滑性优良的硬脂酸钙等金属皂和云母为佳。作为固体润滑剂，如上述的固体润滑剂可以单独使用，或者2种以上组合使用。
(C)的从矿物油、动植物油脂和合成油中选择的至少一种油成分，是用于在金属材料上涂敷本发明的水系润滑剂后、在经干燥而得到的由水溶性无机盐组成的干燥被膜上形成油膜，而且是用于弥补因产生固体润滑剂的附着不匀而使耐热胶着性降低部分的润滑性。
本发明中使用的油成分，其闪点、熔点和粘度最好是特定的范围。即，闪点在150-300℃为宜。对于强加工的冷塑性加工，加工后的金属材料的平均温度有时达到150℃以上，如果油成分的闪点在150℃以下，加工后产生大量的气体，有着火的危险。闪点超过300℃时，通常粘度高，熔点高，也不可取。熔点在-20～20℃为宜。熔点超过20℃时，水系润滑剂中的油的乳化性、再乳化性降低，处理液的稳定性往往下降。熔点在-20℃以下的油成分一般具有闪点降低的倾向。另外，油成分在40℃下的粘度在5-100cSt为宜。粘度在5cSt以下时，通常闪点降低，加工后产生大量的气体，有着火的危险，并且因为固体润滑粒子间的滑动降低，有润滑性降低的倾向。另一方面，粘度超过100cSt时，水系润滑剂中的油的分散性、再分散性降低，有降低水系润滑剂的稳定性的倾向。
作为矿物油，例如可举出机油、透平油、锭子油等，作为动植物油脂，例如可举出棕榈油、菜子油、椰子油、蓖麻油、牛脂、猪脂、鲸油、鱼油等，作为合成油，例如可举出酯油(例如，乙二醇、三甲醇丙烷等多元醇与硬脂酸、油酸等脂肪酸的酯)、硅油(例如，聚二甲基硅氧烷、聚二苯基硅氧烷)等。
本发明中使用的油成分是如上所述的矿物油、动植物油脂或合成油的单独一种或2种以上的组合，但作为油成分最好是满足上述的闪点、熔点和粘度范围。
另外，作为油成分的次要效果，可举出以下的效果，即，在加温下在金属材料上涂敷本发明的水系润滑剂的场合，通常在涂敷之前，用蒸汽加热管加热水系润滑剂，此时由于油成分的存在可以防止固体润滑剂向加热管上附着。
(D)的表面活性剂，是用于在本发明的水系润滑剂中使上述油成分在水中均匀地乳化，同时，使固体润滑剂均匀地分散在水中。作为表面活性剂，可以使用非离子表面活性剂、阴离子表面活性剂、两性表面活性剂和阳离子表面活性剂中的任一种。作为非离子表面活性剂，没有特别的限制，例如可举出由聚氧乙烯烷基醚、聚氧乙烯烷基苯基醚、聚乙二醇和高级脂肪酸(例如碳原子数12-18)构成的聚氧乙烯烷基酯，由山梨糖醇酐和聚乙二醇(或者环氧乙烷)与高级脂肪酸(例如碳原子数12-18)构成的聚氧乙烯山梨糖醇酐烷基酯等。作为阴离子表面活性剂，没有特别限制，例如可举出脂肪酸盐、硫酸脂盐、磺酸盐、磷酸酯盐、二硫代磷酸酯盐等。作为两性表面活性剂，没有特别的限制，例如可举出氨基酸型和甜菜碱型的羧酸盐、硫酸酯盐、磺酸盐、磷酸酯盐等。作为阳离子表面活性剂，没有特别的限制，例如可举出脂肪酸胺盐、季铵盐等。这些表面活性剂可以单独使用，或者2种以上组合使用。
(E)的水是作为固体润滑剂的分散介质，另外还作为使用表面活性剂使油成分均匀乳化时的介质，此外还作为水溶性无机盐的溶剂。
本发明的水系润滑剂，除上述的必须成分之外，也可以含有在通常的金属冷塑性加工用水系润滑剂中含有的脂肪酸、高级醇等油性提高剂，氯系、硫系等耐特压润滑油添加剂，消泡剂、防腐剂等。在本发明的水系润滑剂中，为了提高润滑性、防锈性，还可以含有胶体钛化合物。作为胶体钛化合物，例如可举出用氢氧化钠等中和硫酸与钛的化合物或者磷酸与钛的化合物而得到的白浊液。
在本发明的水系润滑剂中，固体润滑剂与水溶性无机盐的重量比(B/A)必须是0.05/1-2/1，较好是0.1/1-1.5/1，最好是0.3/1-1.5/1。具体地说，可根据需要塑性加工的金属材料的形状、加工条件、加工装置等条件进行设定。该重量比是0.05/1以下时，所得到的被膜的润滑性降低，在金属材料上发生咬住和热胶着。另外，该重量比超过2/1时，所得被膜与基体的附着性和被膜的硬度降低，金属材料表面上形成的干被膜在导入工具入口时容易脱溶，润滑性降低。
另外，相对于水溶性无机盐和固体润滑剂的合计量，油成分的重量比(C/(A+B))必须是0.05/1-1/1，最好是0.1/1-0.8/1。若该重量比在0.05/1以下时，油成分在干燥时渗出到被膜表面的作用降低，显著损害渗出的油成分弥补固体润滑剂附着不匀、耐热胶着性降低部分的润滑性这种本发明水系润滑剂的主要效果。该重量比若超过1/1时，油分向被膜表面上渗出不成问题，但所得被膜不能形成坚硬的固体被膜，因此润滑剂导入量降低，润滑性下降。
本发明的水系润滑剂中的(D)成分即表面活性剂的使用量，只要能达到使油成分在水中均匀乳化，同时使固体润滑剂在水中均匀分散的作用的最低量以上即可，没有特别限制，但用量过多时，容易产生泡，而且不经济，通常以水系润滑剂中的0.2-5％(重量)浓度为宜。
对于本发明的水系润滑剂中的固形分[即A+B+C+D+任意固形分(=上述的油性提高剂等任意添加成分的固形分)]浓度，没有特别限制，在调制、流通、保存时以20-45％(重量)为宜，在使用时以5-45％(重量)为宜。
对于本发明的水系润滑剂的制造方法，也没有特别限制，只要制成的水系润滑剂满足上述条件就可以，通常是通过下述过程进行制造，即，在使(A)水溶性无机盐溶解于水中后再使(B)固体润滑剂均匀分散的液体中，添加用(D)表面活性剂使(C)油成分在水中均匀乳化的液体，进行搅拌，使该体系中的固体润滑剂均匀分散、油成分均匀乳化。在进行固体润滑剂的分散、油成分的乳化和最终搅拌时，为了得到均匀、微细乳化的分散液，最好使用高速搅拌器进行强搅拌。
本发明的水系润滑剂，根据金属材料的种类、冷塑性加工的种类、金属材料的加工度，使用时可以用水稀释。稀释得到的水系润滑剂也包括在本发明的范围内。
本发明的水系润滑剂可以用来作为对由钢铁、钛或钛合金、铜或铜合金、铝或铝合金等金属构成的管材、线材、棒材等材料进行冷塑性加工(拔管、拔丝、锻造等)时使用的润滑剂，特别是用来作为拉拔钢管时使用的润滑剂。
在涂敷本发明的水系润滑剂之前，为了得到良好的结果，最好对要加工的金属材料依次进行脱脂(使用通常的碱脱脂剂)、水洗、酸洗(为了除去金属材料的氧化皮，提高被膜的附着性，使用盐酸等进行)、水性的前处理。在没有氧化皮附着的场合，不需要酸洗、水洗。这些前处理可按常规方法进行。
利用浸渍、浇涂等方法在要加工的金属材料上涂敷本发明的水系润滑剂。涂敷时的水系润滑剂的温度没有特别限制，一般是常温-90℃，浸渍时的时间也没有特别限制，一般进行至金属材料的温度与液温相同，例如5-10分钟。涂敷后进行轧液，然后用干燥炉等进行干燥，不作特别限制，但通常在60-150℃干燥涂膜，形成干燥被膜。
干燥被膜的最佳厚度，随金属材料的加工形态、加工度、表面粗糙度等而不同，一般是1-50g/m2，最好是5-40g/m2。干燥被膜的厚度过薄时，工具与金属材料的接触强烈，易引起热胶着，过厚时，干燥被膜的大部分不能进入加工面被排除，因此水系润滑剂的损失增大。
可以利用通常实施的方法进行使用本发明的水系润滑剂时的金属材料的塑性加工。
在进行金属材料的塑性加工时使用本发明的水系润滑剂的场合，塑性加工后的残留被膜的剥离是容易的。
在利用塑性加工进行成形的场合，通常采用重复进行润滑处理和塑性加工，逐步制造目的制品形状的制作方法，此时如果将已加工硬化的金属材料直接送到下一步塑性加工工序，加工负荷将会增大，甚至不能成形，因此要进行退火，以使金属材料软化。若退火时残存被膜，由于滑润剂中的成分会引起金属材料的渗碳、渗硫、渗磷等，会损害金属材料原有的耐蚀性和机械强度，这种情况是不利的。另外，在塑性加工后再次进行润滑处理时，若残留有以前的润滑被膜，则新形成的被膜的附着性低劣，也是不利的。
因此，通常在塑性加工后除去残留的被膜，在以往的将化学被膜处理和反应型皂处理组合而成的润滑体系中，残留被膜的去除至少需要碱脱脂处理和酸洗(盐酸酸洗和硫酸酸洗)处理。与此相反，在使用本发明的水系润滑剂的场合，通常仅用碱脱脂剂就可以除去残留的被膜。作为这样的碱脱脂剂，可以使用通常使用的产品，例如含有磷酸钠、硅酸钠、表面活性剂等的脱脂剂，具体地说，例如可以使用日本パ-カラィジング(株)制造的ファィンクリ-ナ-4360等。
本发明的水系润滑剂的作用机理尚不十分清楚，据认为，在金属材料上涂敷本发明的水系润滑剂然后加热干燥形成干燥被膜时，油成分成为乳浊液渗出到被膜的***部分，渗出的油成分弥补了干燥被膜附着较少的部分的润滑性。即，由于含有润滑辅助物质作为水系润滑剂的一个成分，在干燥过程中渗出到被膜的***部分，从而减低拉模、芯棒、冲头等工具与加工材料的摩擦，显著地减低热胶着现象。
另外，冷塑性加工后的残留被膜的容易剥离的原因尚不十分清楚，据认为，用碱脱脂剂容易剥离由水溶性无机盐组成的被膜，因此附着在该被膜上的固体润滑剂和油成分也一起被除去。
以下通过实施例具体地说明本发明的水系润滑剂。
实施例1-16
水系润滑剂的调制、涂敷和钢管拉拔试验
按表1所示的组成调制润滑剂。调制是在水中溶解水溶性无机盐后，使固体润滑剂均匀分散，向所得液体中添加用表面活性剂使油成分均匀乳化的液体，进行搅拌，使该体系中固体润滑剂均匀分散，油成分均匀乳化。使用高速搅拌器进行上述的分散、乳化。
调制水系润滑剂时使用的原料，水溶性无机盐都是试剂1级，硬脂酸钙使用30％固形分的水分散液，PTFE使用60％固形分的水分散液，机油使用40℃的粘度是46mm2/s的机油，棕榈油使用50℃的粘度是28mm2/s的精制棕榈油，酯油使用50℃的粘度是64mm2/s的、聚三甲醇丙烷和月桂酸、油酸的二聚物的缩合酯。另外，表面活性剂使用聚氧乙烯烷基醚，添加量为润滑剂总量的1％(重量)。
接着，将调制成的水系润滑剂涂敷在碳钢钢管或者不锈钢钢管上，然后干燥，将所得到的具有干燥被膜的钢管进行拉拔试验，根据管的内表面和外表面的损伤发生状况以及加工后的残留被膜的脱膜性评价润滑剂的性能。
至于拉拔材料，对于碳钢钢管使用外径25.4mm、壁厚3.0mm的STKM13A材料，对于不锈钢钢管使用外径25.0mm、壁厚2.5mm的SUS304材料。
在涂敷水系润滑剂之前，将这些钢管进行以下的前处理工序。碳钢钢管依次进行(1)-(4)的工序，不锈钢钢管依次进行(1)和(2)的工序。
(1)脱脂碱脱脂剂：日本パ-カラィジング(株)制造的ファィンクリ-ナ-4360，浓度：20g/L，温度：60℃，浸渍时间：10分钟。
(2)水洗在常温的自来水中浸渍
(3)酸洗工业用盐酸，浓度：17.5％(重量)，温度：常温，浸渍时间：10分钟
(4)水洗在常温的自来水中浸渍
使处理液温度达到50℃，利用浸渍进行水系润滑剂的涂敷。处理后的干燥是将处理材料放入隧道式的干燥箱中，使用以煤油作为热源的加热器，在100-120℃的温度进行1小时。
拉拔试验使用链式的10吨拉拔机，使用由超硬工具构成的拉模[富士ダィス(株)制超硬拉模(KD型)]和芯棒[富士ダィス(株)制超硬芯棒(MB型)]，以拉拔速度17m/min进行。STKM13A材料的面缩率(=断面收缩率)达到46％(拉拔后的外径是20mm、壁厚是2mm),SUS304材料的面缩率是43％(拉拔后的外径是20mm、壁厚是1.75mm)。设加工前的断面积为A0，加工后的断面积为A1，面缩率用下式表示：
面缩率(％)=(A0-A1)/A0×100
目视观察钢管的内表面和外表面的损伤发生状况，按下面表示的4级进行评价。
◎：毫无损伤发生，未看到精加工的不匀
○：没有损伤发生，但看到精加工的不匀
△：看到有轻微的损伤发生
×：看到明显的损伤发生
在上述评价中，所谓损伤是指在管的内表面或外表面上看到的波线上的热胶着伤，所谓精加工的不匀是指在拉拢后的表面上光泽部分和无光泽部分混合存在，显示光泽不同的状态。
使用碱脱脂剂(日本パ-カラィジング(株)制造的ファィンクリ-ナ-4360，浓度20g/L)进行加工后的残留被膜的脱膜性试验(温度60℃)，通过目视观察碱脱脂后的钢管，按以下的4级进行评价。
◎：浸渍5分钟，未能确认被膜残存
○：浸渍10分钟，未能确认被膜残存
△：浸渍10分钟，被膜仍残存
×：浸渍10分钟，被膜仍残存
拉拔试验的结果示于表1中。
比较例1-10
除按照表2所示的细成外，与实施例1-16同样操作，调制水系润滑剂，与实施例1-16同样地进行试验。
结果也示于表2中。在本发明的范围以外，所有拉拔试验后钢管的外表面和内表面都发生损伤，或者加工后的残留被膜的碱脱脂性有问题。
比较例11和12
将与实施例1-16中使月的同种钢管在表2在所示条件下进行化学法表面处理和反应型皂润滑处理。将得到的润滑处理钢管进行与实施例1-16相同的拉拔试验。
结果示于表2中。虽未发生损伤和精加工不匀，但拉拔加工后的残存被膜的脱膜性恶化。
实施例17-19
水系润滑剂的调制、涂敷和锻造试验
除按照表3所示的组成以外，与实施例1-16同样操作，调制水系润滑剂，将得到的水系润滑剂涂敷在碳钢上，然后干燥，对所得到的具有干燥被膜的碳钢进行反向冲孔试验，根据良好的冲孔深度评价水系润滑剂的性能。
进行反向冲孔试验的材料是市售的碳钢S45C正火材料(硬度：Hv180左右)，试片的形状为，直径φ30mm，高度16-40mm、以2mm间隔变化(13水准)。
通过浸渍、在水系润滑剂温度为80℃的条件下涂敷水系润滑剂。涂敷液的干燥，使用热风循环式干燥炉、在90-100℃进行1小时。
反向冲孔试验使用200吨曲柄式冲床，从安置在模具上、限制外周部的圆形试验片的上方进行冲孔，得到杯状成形物。调整冲床的不死点，使试片底部的残留带达到一定的10mm，根据试片高度，使加工部分的表面扩大比提高那样(形成更深的孔)进行设定，根据在不引起热胶着的情况下加工出的孔深度(良好的冲孔深度)评价水系润滑剂的性能。
模具：材质SKD11，试验片***部分的直径30.4mm。
冲头：材质SKH53，平刃口凸台直径21.2mm。
面缩率：50％
加工速度：30个冲程/分
反向冲孔试验图示于图1。
反应冲孔试验的结果示于表3中。
                     表1实施例及其评价结果
Figure 9711713600131
           表2比较例及其评估结果
Figure 9711713600141
        表3锻造试验的实施例及其评价结果
Figure 9711713600151
发明的效果
使用本发明的水系润滑剂，在金属材料的冷塑性加工中，以1个工序就能达到和以往的化学被膜/反应型皂处理同等的润滑性，同时，能够大大改善作业环境、处理液管理、废弃物等问题。使用本发明的水系润滑剂进行金属材料的冷塑性加工时，加工后的残留被膜的去除比化学被膜/反应型皂处理更容易。
附图的简单说明
图1是使用水系润滑剂进行的碳钢反向冲孔试验的示意图。

Claims (4)

1、金属材料的冷塑性加工用水系润滑剂，其特征是它由下列成分组成：
(A)水溶性无机盐；
(B)固体润滑剂；
(C)选自矿物油、动植物油脂和合成油中的至少一种油成分；
(D)表面活性剂；
(E)水；固体润滑剂和水溶性无机盐的重量比(B/A)是0.05/1-2/1，相对于水溶性无机盐和固体润滑剂的总量，油成分的重量比(C/(A+B))是0.05/1-1/1，所述表面治性剂(D)在水系润滑剂中的浓度为0.2-5重量％，所述水系润滑剂中，固体润滑剂和油成分各自均匀分散和乳化。
2、权利要求1所述的金属材料的冷塑性加工用水系润滑剂，其中，水溶性无机盐是选自硼砂、四硼酸钾和硫酸钠中的至少一种。
3、权利要求1所述的金属材料的冷塑性加工用水系润滑剂，其中，固体润滑剂是选自金属皂和云母中的至少一种。
4、权利要求1所述的金属材料的冷塑性加工用水系润滑剂，其中，相对于水溶性无机盐和固体润滑剂的总量，油成分的重量比(C/(A+B))是0.1/1-0.8/l。
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JP3517522B2 (ja) 2004-04-12
CA2258638A1 (en) 1997-12-24
KR100434573B1 (ko) 2004-07-16
TW367362B (en) 1999-08-21
EP0917559B1 (en) 2013-01-09
JPH108085A (ja) 1998-01-13
EP0917559A4 (en) 2001-02-07
KR980002222A (ko) 1998-03-30

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