CN112342075A - 微乳化切削液 - Google Patents

微乳化切削液 Download PDF

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CN112342075A
CN112342075A CN202011108102.7A CN202011108102A CN112342075A CN 112342075 A CN112342075 A CN 112342075A CN 202011108102 A CN202011108102 A CN 202011108102A CN 112342075 A CN112342075 A CN 112342075A
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percent
cutting fluid
acid
microemulsified
fluid according
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张玉俊
喻翔
周宏升
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Shandong Wote Lubrication Technology Co ltd
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Abstract

本发明涉及金属切削液技术领域，公开了一种微乳化切削液，按照重量百分比计，包括以下组分：pH值调节剂3.00％～21.00％、防锈剂0.50％～4.00％、抑菌剂0.50％～2.00％、阴离子表面活性剂6.00％～18.00％、非离子表面活性剂1.00％～5.00％、缓蚀剂1.00％～4.00％、基础油4.00％～15.00％、水40％～50％。该微乳化切削液具有优良的防锈性、润滑性、特别对铝合金有极佳的缓蚀性，很好地解决了现有微乳化切削液存在的对不同铝合金加工缓蚀性差的问题，适合用于铝件、钢件等金属的加工，不含有对人体或环境产生不利影响的亚硝酸盐、有机酚等有毒化学品，是一种环保型的高效微乳化切削液。

Description

微乳化切削液
技术领域
本发明涉及金属切削液技术领域，特别涉及一种微乳化切削液。
背景技术
切削液是金属切削加工的重要配套材料，其在切削过程中的润滑作用，可以减小前刀面与切屑，后刀面与已加工表面间的摩擦，形成部分润滑膜，从而减小切削力、摩擦和功率消耗，降低刀具与工件坯料摩擦部位的表面温度和刀具磨损，改善工件材料的切削加工性能。同时通过它和因切削而发热的刀具、切屑和工件间的对流和汽化作用把切削热从刀具和工件处带走，从而有效地降低切削温度，减少工件和刀具的热变形，保持刀具硬度，提高加工精度和刀具耐用度。
现有生产中通常采用一种纯油性切削液，即添加剂和适量的机油或煤油制成的切削液，切削过程中时需要不断的将铅油涂抹到刀具上。由于此体系是纯油性，在金属切削过程中，工件容易与环境介质及切削液组分分解或氧化变质而产生的油泥等腐蚀性介质接触而腐蚀，与切削液接触的机床部件表面也会因此而腐蚀，且其冷却、清洗能力差，造成加工后工件清洗较困难的问题。改进后的乳化切削液在一定程度上可以缓解纯油性切削液清洗、冷却能力的不足，但其含油量仍然比较高，容易导致产品表面易滋生细菌，虽然可以加入杀菌剂来达到抑菌的作用，但是治标不治本，进而无法长期解决乳化液夏季发臭的现象。
进一步改进的微乳化切削液虽不易发臭，且也有较强的清洗、冷却的作用，但其润滑性差，无法达到加工要求，同时，微乳化切削液主要用于铝合金加工中，由于微乳化切削液的偏酸或偏碱而造成铝件氧化而发黑现象。
因此，亟需一种使用效果更好的微乳化切削液。
发明内容
本发明要解决的技术问题是提供一种微乳化切削液，能够解决清洗、冷却、润滑的问题，且使用寿命长，对铝合金加工有极佳的缓蚀效果的微乳化切削液。
为了解决上述技术问题，本发明的技术方案为：一种微乳化切削液，按照重量百分比计，包括以下组分：
pH值调节剂3.00％～21.00％；
防锈剂0.50％～4.00％；
抑菌剂0.50％～2.00％；
阴离子表面活性剂6.00％～18.00％；
非离子表面活性剂1.00％～5.00％；
缓蚀剂1.00％～4.00％；
基础油4.00％～15.00％；
水40％～50％。
优选的，所述pH值调节剂为单乙醇胺，二乙醇胺，三乙醇胺，二环己胺、环己胺，烷醇酰胺、脂肪醇酰胺中的一种或者几种的混合物，通过pH值调节剂将切削液的pH值调节为9.0～9.2，使切削液的pH值稳定在最佳值，这样不仅能有效抑制细菌的滋生繁殖避免切削液发臭的问题，同时能有效保护加工工件避免其被腐蚀。
优选的，所述防锈剂为脂肪族二元羧酸中的一种或一种以上的混合物，具体为辛二酸、壬二酸、葵二酸、十一碳二酸、十二碳二酸、十三碳二酸、十四碳二酸中的一种或几种的混合物。防锈剂能够在金属表面上形成一层润滑膜，可以抑制湿气及许多其它化学成份造成的腐蚀。
优选的，所述抑菌剂为硼酸盐、三嗪衍生物、吗啉衍生物、聚季铵盐、异噻唑啉酮中的一种或几种混合物，通过加入抑菌剂能够抑制微乳化液内细菌的滋生，能够自体抗菌，解决了夏季微乳化液发臭的问题。
优选的，所述非离子表面活性剂为脂肪醇聚氧乙烯醚、烷基酚聚氧乙烯醚、脂肪胺聚氧乙烯醚、聚氧乙烯山梨糖醇酐脂肪酸酯中的一种或几种混合物。由于非离子表面活性剂在溶液中不是以离子状态存在，所以它的稳定性高，不易受强电解质存在的影响，也不易受酸、碱的影响，与其他类型表面活性剂能混合使用，相容性好，在各种溶剂中均有良好的溶解性，在固体表面上不发生强烈吸附。且非离子表面活性剂有良好的耐硬水能力，有低起泡性的特点。
优选的，所述阴离子表面活性剂为油酸、油酸钾、油酸钠、妥尔油酸、蓖麻油酸、脂肪醇硫酸酯盐、脂肪醇聚氧乙烯醚硫酸钠、脂肪酸磺烷基酰胺、琥珀酸酯磺酸盐、脂肪醇硫酸盐中的一种或几种混合物。阴离子表面活性剂具有分散、乳化、泡沫、润湿的性能，可以降低乳化***中的界面张力，阻止絮凝，打碎胶团，改善涂料的遮盖力，流动性和流平性，解决了现有微乳化切削液润湿性差的问题。
优选的，所述缓蚀剂为铝合金缓蚀剂，由含氮氧化合物的杂环化合物中的一种或一种以上物质组成，具体可为硅酸盐、钼酸盐、聚磷酸盐、膦酸盐、膦羧酸、琉基苯并噻唑、磺化木质素、磷酸酯、改性磷酸酯中的一种或几种混合物。通过加入缓蚀剂，使微乳化切削液具备良好的稳定性，降低金属被腐蚀的机率，同时对细菌和霉菌具有抵抗能力，解决了现有乳化切削液容易发臭、变质的问题。
本发明所述微乳化切削液主要用于铝合金加工中，由于纯铝铝合金密度低，但强度比较高，接近或超过优质钢，塑性好，可加工成各种型材，具有优良的导电性、导热性和抗蚀性，工业上广泛使用，使用量仅次于钢。一些铝合金可以采用热处理获得良好的机械性能，物理性能和抗腐蚀性能。但是现有的微乳化切削液的偏酸或偏碱，容易造成铝件氧化而发黑现象，本申请通过pH值调节剂与铝合金缓蚀剂配合，使碱性的微乳化切削液在切割铝合金材料时，不会出现发黑问题，保持了铝合金切割面的光洁度和美观性。
同时，本发明还提供微乳化切削液的生产方法：
在常温下，具体为0～40℃范围内，首先向反应釜中加入适量的水，然后依次投料顺序如下：pH值调整剂、防锈剂、抑菌剂、阴离子表面活性剂、非离子表面活性剂，混合搅拌至透明即生产完成，其中投料间隔为8分钟，搅拌速度为60转/分钟。
相比于眼下大部分生产厂家需要进行生产中间体相比，本发明所述微乳化切削液的生产方法完全不需要中间体，而是一次性不间断投料加工直至产品成型为止，有效的提高了生产效率，避免了不必要的化学原料的浪费和减少了对环境的污染。
本发明的有益效果在于：采用上述技术方案，与现有的微乳化切削液相比，本发明所述的微乳化切削液具有优良的防锈性、润滑性、特别对铝合金有极佳的缓蚀性，很好地解决了现有微乳化切削液存在的对不同铝合金加工缓释性差的问题，适合用于铝件、钢件等金属的加工，不含有对人体或环境产生不利影响的亚硝酸盐、有机酚等有毒化学品，是一种环保型的高效微乳化切削液。
具体实施方式
下面结合实施例对本发明作进一步的详细说明，以下实施例是对本发明的解释而本发明并不局限于以下实施例。本发明对其加入量进行限定，只是便于本发明的实施，并不说明在本发明所限定的范围外不能实施。
以下结合具体实施方式介绍本发明所述的微乳化切削液。
实施例1：
本实施例所述的一种微乳化切削液，按重量份数包括如下组分：
pH值调节剂：20％、防锈剂：0.5％、抑菌剂：0.5％、非离子表面活性剂：1.5％、阴离子表面活性剂：10％、缓蚀剂：1％、基础油：10％、水：43.5％。
具体包括以下几种实施方式：
具体的，按照重量百分比计，其包括如下组分：三乙醇胺：20％；十一碳二酸：0.5％；钼酸盐：0.5％；脂肪醇聚氧乙烯醚：1.5％；蓖麻油酸、油酸混合物：10％；改性磷酸酯：1％；环烷基矿物油：10％；水：43.5％。
具体的，按照重量百分比计，其包括如下组分：二乙醇胺：20％；葵二酸：0.5％；三嗪衍生物：0.5％；妥尔油酸：10％；聚氧乙烯山梨糖醇酐脂肪酸酯：1.5％；硅酸盐：1％；中间基矿物油：10％；水：43.5％。
具体的，按照重量百分比计，其包括如下组分：三乙醇胺、二乙醇胺、单乙醇胺混合物：20％；辛二酸：0.5％；异噻唑啉酮：0.5％；脂肪胺聚氧乙烯醚：1.5％；脂肪酸磺烷基酰胺：1.5％；月桂基磷酸酯：1％；环烷基矿物油和蓖麻油不饱和脂肪酸酯：10％；水：43.5％。
实施例2：
本实施例所述的一种微乳化切削液，按重量份数包括如下组分：
pH值调节剂：15％、防锈剂：1％、抑菌剂：1％、非离子表面活性剂：5％、阴离子表面活性剂：18％、缓蚀剂：2％、基础油：8％、水：50％。
具体包括以下几种实施方式：
具体的，按照重量百分比计，其包括如下组分：三乙醇胺、单乙醇胺混合物：15％；壬二酸：1％；硼酸盐：1％；油酸：18％；烷基酚聚氧乙烯醚：2％；磷酸双酯：2％；聚α烯烃：8％；水：50％。
具体的，按照重量百分比计，其包括如下组分：环己胺、二乙醇胺混合物：15％；葵二酸：1％；聚季铵盐：1％；烷基酚聚氧乙烯醚：2％；油酸、油酸钾混合物：18％；琥珀酸酯磺酸盐：2％；聚磷酸盐：2％；葵花籽油：8％；水：50％。
具体的，按照重量百分比计，其包括如下组分：二乙醇胺、三乙醇胺：15％；十一碳二酸：1％；三嗪衍生物：1％；脂肪醇聚氧乙烯醚：2％；脂肪醇硫酸盐：2％；磷酸三酯：2％；棉籽油：8％；水：50％。
实施例3：
本实施例所述的一种微乳化切削液，按重量份数包括如下组分：
pH值调节剂：20％，防锈剂：3％，抑菌剂：2％，非离子表面活性剂：4％，阴离子表面活性剂：9％，缓蚀剂：3％，基础油：15％，水：44％。
具体包括以下几种实施方式：
具体的，按照重量百分比计，其包括如下组分：三乙醇胺、二环己胺：20％；十二碳二酸：3％；异噻唑啉酮：2％；脂肪醇聚氧乙烯醚：4％；油酸、琥珀酸酯磺酸盐：9％；磷酸三酯：3％；菜籽油：15％；水：44％。
具体的，按照重量百分比计，其包括如下组分：二环己胺：20％；十三碳二酸：3％；硼酸盐：2％；油酸钠、油酸混合物：9％；脂肪胺聚氧乙烯醚：4％；磷酸酯钾盐：3％；7号白油：15％；水：44％。
具体的，按照重量百分比计，其包括如下组分：环己胺：20％；十四碳二酸：3％；聚季铵盐：2％；油酸、聚氧乙烯山梨醇酐单油酸酯：9％；脂肪醇聚氧乙烯醚：4％；异辛醇醚磷酸酯：3％；环烷基矿物油：15％；水：44％。
现将本发明所述的微乳化切削液与市场上目前销售的同类产品进行性能试验对比，其结果如表1所示。
表1
Figure BDA0002727650100000071
注：与市场销售同类型产品比较：A:性能优异、B:性能相当、C:性能低劣。
1.润滑性能测试
环圈磨耗试验：利用磨耗试验及测定金属接触部分的磨耗面积来评价油品，磨耗面积越小，则润滑性能越优异，本试验采用标号为S-45C的碳钢，试验切削液的浓度为：20倍。所述润滑性能测试结果见表2。
表2
Figure BDA0002727650100000072
2.防锈性能测试
铸铁粉试验：用己烷和丙酮将铸铁粉FC-200的粉屑洗净、干燥，讲滤纸放置于直径为90mm的浅底盘，取10克的FC粉末置于滤纸上并导入各试料液将其完全浸泡为止，5分钟后，倒干试料，放置于室内，观察是否有生锈情况发生。所述防锈性能测试结果见表3。
表3
Figure BDA0002727650100000081
注：与市场销售同类型产品比较：A:无生锈；B:部分生锈；C:全面生锈。
3.耐腐败性能测试
pH值测定法：取相同份量的切削液，边搅拌边将0.1N盐酸溶液滴入各试料液中，至切削液的pH值达到8.5为止，再根据滴入盐酸溶液的量评价pH维持性，盐酸滴入的量越多，则表示pH维持性及腐败性能优异，本次试验切削液的浓度为：50倍。所述耐腐败性能测试结果见表4。
表4
Figure BDA0002727650100000082
4.铝缓蚀性能测试
将同等大小的铝件完全浸没在500g试料液中，观察铝件表面现象。所述铝缓蚀性能测试结果见表5。
表5
Figure BDA0002727650100000091
注：与市场销售同类型产品比较：A.无变色；B.部分变色；C.完全变色。
5.消泡性能测试
5.1搅拌式起泡试验
将试料液500g倒入搅拌机，搅拌30秒后，测量刚停止时的泡沫高度，及测量泡沫消失到页面所需的时间，本次试验切削液的浓度为：20倍。所述搅拌式起泡试验结果见表6。
表6
Figure BDA0002727650100000092
5.2均质混合器起泡试验
使用均质混合器，将各试料液500g倒入烧杯中，搅拌5分钟后，测量刚停止时的泡沫高度，及测量泡沫消失到液面所需时间。本次试验切削液的浓度为：20倍。所述搅拌式起泡试验结果见表7。
表7
Figure BDA0002727650100000093
由表1至表7可知，本发明提供的微乳化切削液与现有的微乳化切削液相比，具有优良的防锈性、润滑性、特别对铝合金有极佳的缓蚀性，很好地解决了现有微乳化切削液存在的对不同铝合金加工缓蚀性差的问题。且本发明的微乳化切削液适合用于铝件、钢件等金属的加工。且本发明的微乳化切削液不含有对人体或环境产生不利影响的亚硝酸盐、有机酚等有毒化学品，是一种环保型的高效微乳化切削液。
以上所述仅为本发明的较佳实施例，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，均应包含在发明的保护范围之内。

Claims (10)

1.一种微乳化切削液，其特征在于，按照重量百分比计，包括以下组分：
pH值调节剂3.00％～21.00％；
防锈剂0.50％～4.00％；
抑菌剂0.50％～2.00％；
阴离子表面活性剂6.00％～18.00％；
非离子表面活性剂1.00％～5.00％；
缓蚀剂1.00％～4.00％；
基础油4.00％～15.00％；
水40％～50％。
2.根据权利要求1所述的微乳化切削液，其特征在于，所述微乳化切削液的pH值调节为9.0～9.2。
3.根据权利要求1所述的微乳化切削液，其特征在于，所述pH值调节剂为下述物质中的至少一种：单乙醇胺、二乙醇胺、三乙醇胺、二环己胺、环己胺、烷醇酰胺、脂肪醇酰胺。
4.根据权利要求1所述的微乳化切削液，其特征在于，所述防锈剂为下述物质中的至少一种：辛二酸、壬二酸、葵二酸、十一碳二酸、十二碳二酸、十三碳二酸、十四碳二酸。
5.根据权利要求1所述的微乳化切削液，其特征在于，所述抑菌剂为下述物质中的至少一种：硼酸盐、三嗪衍生物、吗啉衍生物、聚季铵盐、异噻唑啉酮。
6.根据权利要求1所述的微乳化切削液，其特征在于，所述非离子表面活性剂为下述物质中的至少一种：脂肪醇聚氧乙烯醚、烷基酚聚氧乙烯醚、脂肪胺聚氧乙烯醚、聚氧乙烯山梨糖醇酐脂肪酸酯。
7.根据权利要求1所述的微乳化切削液，其特征在于，所述阴离子表面活性剂为下述物质中的至少一种：油酸、油酸钾、油酸钠、妥尔油酸、蓖麻油酸、脂肪醇硫酸酯盐、脂肪醇聚氧乙烯醚硫酸钠、脂肪酸磺烷基酰胺、琥珀酸酯磺酸盐、脂肪醇硫酸盐。
8.根据权利要求1所述的微乳化切削液，其特征在于，所述缓蚀剂为铝合金缓蚀剂。
9.根据权利要求8所述的微乳化切削液，其特征在于，所述铝合金缓蚀剂为下述物质中的至少一种：硅酸盐、钼酸盐、聚磷酸盐、膦酸盐、膦羧酸、琉基苯并噻唑、磺化木质素、磷酸酯、改性磷酸酯。
10.根据权利要求1所述的微乳化切削液，其特征在于，所述基础油为下述物质中的至少一种：矿物油、聚α烯烃、植物油、改性植物油或植物系油酸酯、饱和脂肪酸酯、不饱和脂肪酸酯。
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CN116751622B (zh) * 2023-06-15 2024-04-02 泰伦特生物工程股份有限公司 一种低气味高防锈缓蚀切削液及其制备方法

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