CN101490224A - 金属加工油剂组合物、金属加工方法以及金属加工品 - Google Patents
金属加工油剂组合物、金属加工方法以及金属加工品 Download PDFInfo
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Abstract
本发明提供一种油剂组合物,其含有从由天然油脂、其衍生物以及合成酯油组成的组中选出的基油、山梨糖醇酐脂肪酸酯、磷脂,并且适用于极微量油剂供给型金属加工法;并提供使用该油剂组合物的金属加工方法以及金属加工品。本发明的油剂组合物具有优异的润滑性和防锈性,适于通过极微量油剂供给型金属加工法加工铸铁、钢、不锈钢、非铁金属(Al合金、Mg合金)等金属材料。
Description
技术领域
本发明涉及金属加工油剂组合物,更详细地涉及适用于极微量油剂供给型金属加工法的油剂组合物,该油剂能够广泛地适用于切削加工、磨削加工、轧制加工、冲压加工、塑性加工等金属加工。本发明进一步涉及使用该油剂组合物的金属加工方法,以及由该金属加工方法得到的金属加工品。
背景技术
通常在切削、磨削加工中使用切削、磨削油剂。作为切削、磨削油剂的最重要的功能可举出润滑作用和冷却作用,通过这些作用,可以延长加工时使用的工具的寿命、提高被加工物处理面的精度、提高生产效率等,能够提高生产率。
以往在切削、磨削加工中,向加工部位供给较大量的切削、磨削油剂。但是,对于提高生产率有效的切削、磨削油剂也受到近年来重视环境问题的影响,而被指出存在废弃物、环境卫生、节能方面的问题。因此,作为对环境友好的金属加工方法,近年来对于切削、磨削加工的研究正向干法发展。将切削、磨削加工转向为干法时,虽然能够减轻上述环境问题,但无法获得切削、磨削油剂所需要的润滑性、冷却性这样的性能。
因此,需要冷却加工点,于是例如喷射经压缩的冷却空气等来冷却加工点。但是,即使采用这样的方法,也无法获得工具-被削材料之间的润滑性,所以要供给极微量的润滑油。作为加工方法,有非铁金属的加工方法(例如参照专利文献1)等,但是将以往公知的金属加工油剂组合物(例如参照专利文献2)用于铁系材料时,如果附近有水分的话就会结露而生锈,由于存在这些问题所以不能直接应用于冷风加工或喷雾切削等加工中。所以提出过防锈性优异的金属加工油剂组合物(例如参照专利文献3)。另外还已知添加了磷脂酰胆碱系的金属加工液(参照专利文献4)。
但是,从提高生产率和节能的角度出发,经常需要一种进一步提高加工性的、能够延长工具寿命、减少给油量的新型的金属加工油剂。
专利文献1:日本特开2001-239437
专利文献2:日本特开2000-256688
专利文献3:日本特开2004-300317
专利文献4:日本特开平9-57537
发明内容
本发明的目的是提供一种金属加工油剂组合物,该组合物适用于铸铁、钢、不锈钢、非铁金属(Al合金、Mg合金)等的金属加工,尤其适用于边供给极微量油剂边加工的金属加工法。
本发明的另一目的是提供一种在加工铸铁、钢、不锈钢、非铁金属(Al合金、Mg合金)等金属时润滑性和防锈性优异的金属加工油剂组合物。
本发明的再一目的是提供一种加工铸铁、钢、不锈钢、非铁金属(Al合金、Mg合金)等的金属加工方法以及金属加工品。
本发明人为了实现上述目的而深入研究的结果,发现含有从由天然油脂、其衍生物以及酯油组成的组中选出的基油、山梨糖醇酐脂肪酸酯、磷脂的油剂组合物具有优异的润滑性和防锈性,适于铸铁、钢、不锈钢、非铁金属等金属材料的极微量油剂供给型金属加工,以至完成了本发明。
本发明提供如下的金属加工油剂组合物、金属加工方法以及金属加工品。
1.一种油剂组合物,其为用于极微量油剂供给型金属加工法的金属加工油剂组合物,其特征在于,含有山梨糖醇酐脂肪酸酯和磷脂。
2.一种油剂组合物,其为用于极微量油剂供给型金属加工法的金属加工油剂组合物,其特征在于,(I)含有从由天然油脂、其衍生物以及合成酯油组成的组中选出的基油;(II)含有由山梨糖醇酐脂肪酸酯和磷脂构成的防锈剂。
3.根据上述1或2所述的油剂组合物,其特征在于,山梨糖醇酐脂肪酸酯含有从由山梨糖醇酐单油酸酯、山梨糖醇酐倍半油酸酯、山梨糖醇酐二油酸酯和山梨糖醇酐三油酸酯组成的组中选出的至少一种。
4.根据上述1~3中的任一项所述的油剂组合物,其特征在于,磷脂含有从由蛋黄卵磷脂和大豆卵磷脂等组成的组中选出的至少一种。
5.根据上述1~4中的任一项所述的油剂组合物,其特征在于,磷脂含有磷脂酰胆碱、磷脂酰乙醇胺和磷脂酰肌醇的混合物。
6.根据上述1~5中的任一项所述的油剂组合物,其特征在于,山梨糖醇酐脂肪酸酯的配合量是0.1~40质量%。
7.根据上述1~6中的任一项所述的油剂组合物,其特征在于,磷脂的配合量是0.1~40质量%。
8.根据上述1~7中的任一项所述的油剂组合物,其特征在于,极微量油剂供给型金属加工法是一边通过压缩流体供给表面被油膜覆盖的水滴一边加工金属材料的方法。
9.根据上述1~7中的任一项所述的油剂组合物,其特征在于,极微量油剂供给型金属加工法是一边用压缩流体供给经雾化的金属加工油剂一边加工金属材料的方法。
10.极微量油剂供给型金属加工方法,其特征在于,使用上述1~9中的任一项所述的组合物加工金属材料。
11.根据上述10所述的金属加工方法,其特征在于,边通过压缩流体供给被上述1~9中的任一项所述的组合物覆盖的水滴边加工金属材料。
12.根据上述10所述的金属加工方法,其特征在于,一边用压缩流体供给经雾化的上述1~9中的任一项所述的组合物一边加工金属材料。
13.通过上述10~12中的任一项所述的金属加工方法来得到的金属加工品。
本发明的金属加工油剂组合物和金属加工方法,能够有效地进行金属材料的切削加工、磨削加工、轧制加工、压力加工、塑性加工等。并且由于油剂使用量也极为微量,所以能够实现经济且对环境的负荷少的加工。由本发明的金属加工方法得到的金属加工品具有良好的加工精度等。
附图说明
图1是能够用于本发明方法的、用空气供给表面被油膜覆盖的水滴的装置的一例的示意图。
具体实施方式
下面详细说明本发明。
本发明是用于极微量油剂供给型金属加工法的油剂组合物,其特征在于,含有山梨糖醇酐脂肪酸酯和磷脂。本发明的另一特征是,(I)含有从由天然油脂、其衍生物以及合成酯油组成的组中选出的基油;(II)含有由山梨糖醇酐脂肪酸酯和磷脂构成的防锈剂。
本发明中用于油剂组合物的基油是选自由天然油脂、其衍生物以及合成酯油组成的组。
作为天然油脂,可以列举菜籽油、大豆油、蓖麻籽油、棕榈油、猪油等。另外,作为天然油脂衍生物,可以列举氢化菜籽油、氢化大豆油、氢化蓖麻籽油、氢化棕榈油、氢化猪油等氢化物,以及加成环氧烷的蓖麻籽油等。作为合成酯油,可以举出以多元醇酯为代表的酯系合成油。
本发明的基油中还可以含有环烷系和石蜡系矿物油;以聚α-烯烃、聚丁烯为代表的合成烃油;以烷基二苯基醚、聚丙二醇为代表的醚系合成油;硅油、氟化油等。但是,本发明的基油的主成分是从由天然油脂、其衍生物以及合成酯油组成的组中选出的物质,它们适宜占全部基油的70质量%以上、优选占80质量%以上、更优选占90质量%以上。从润滑性、对新生面的吸附性角度考虑,最优选酯油。酯油由于在分子内具有极性基团,所以能够在金属表面形成润滑性良好的吸附膜。
作为本发明中用于油剂组合物的山梨糖醇酐脂肪酸酯的脂肪酸成分,优选举出碳原子数8~22的饱和或不饱和脂肪酸、进一步优选举出碳原子数16~20的饱和或不饱和脂肪酸、最优选举出碳原子数16~20的不饱和脂肪酸。作为山梨糖醇酐脂肪酸酯最优选的具体例,可以举出山梨糖醇酐油酸酯,更具体地可举出山梨糖醇酐单油酸酯、山梨糖醇酐倍半油酸酯、山梨糖醇酐三油酸酯。特别优选山梨糖醇酐单油酸酯、山梨糖醇酐倍半油酸酯。
用于本发明油剂组合物的山梨糖醇酐脂肪酸酯,通常可以从市场买到。例如可以举出以下的市售品。作为山梨糖醇酐单油酸酯的市售品的例子,可以举出商品名Nonion SO-80R(日本油脂株式会社制造)、BLAUNON P-80(青木油脂工业株式会社制造)、Srobon S-80(东邦化学工业株式会社制造)、IonetS-80(三洋化成工业株式会社制造)、RHEODOL SP-O10(花王株式会社制造)等;作为山梨糖醇酐倍半油酸酯的市售品的例子,可以举出商品名NonionOP-83RAT(日本油脂株式会社制造)、Srobon S-83L(东邦化学工业株式会社制造)、RHEODOL AO-15(花王株式会社制造)等;作为山梨糖醇酐三油酸酯的市售品的例子,可以举出商品名Nonion OP-85R(日本油脂株式会社制造)、Ionet S-85(三洋化成工业株式会社制造)、RHEODOL SP-O30(花王株式会社制造)、Srobon S-85(东邦化学工业株式会社制造)等。
用于本发明油剂组合物的山梨糖醇酐脂肪酸酯的质量比率相对于全部组合物来说优选为0.1~40质量%、更优选为0.2~20质量%、最优选为0.5~10质量%。如果成分的量少于上述范围,则难以获得期望的润滑性和防锈性能;而即使多于上述范围,效果也不会随着添加量增加而提高,反而会对粘性和发泡性等产生不良影响,而且还不经济。
作为用于本发明油剂组合物的磷脂,可以举出蛋黄卵磷脂和大豆卵磷脂等。蛋黄卵磷脂和大豆卵磷脂等在市面有精制度高的粉状物质和精制度低的液状物质,通常被称为卵磷脂的是指膏状物质。该卵磷脂是磷脂酰胆碱、磷脂酰乙醇胺、磷脂酰肌醇等各种磷脂分子和甘油三酸酯(主要是大豆油)的混合物。
用于本发明油剂组合物的磷脂可以是任意形状,其中,膏状物质容易溶解于基油,适用于油剂的制造。磷脂通常可以从市场买到,在本发明中可以使用市售品。作为这种市售品的例子,可以举出商品名J lecithin CL(日本味之素株式会社制造)、Lecithin DX(日清制油株式会社制造)等。
在本发明的油剂组合物中,磷脂的质量比率相对于全部组合物来说优选为0.1~40质量%、更优选为0.2~20质量%、进一步优选为0.5~10质量%。如果成分的量少于上述范围,则难以获得期望的润滑性和防锈性能;而即使多于上述范围,效果也不会随着添加量增加而提高,反而会使粘性增高等,对物性方面造成不良影响,而且还不经济。
本发明的油剂组合物中,可以根据需要另行添加耐负荷添加剂、防锈防蚀剂、金属钝化剂、抗氧化剂等油剂组合物的通用成分。它们的添加量相对于全部组合物的质量优选为10质量%以下。
本发明的油剂组合物,可以通过在基油中按照规定量配合山梨糖醇酐脂肪酸酯例如山梨糖醇酐油酸酯、磷脂及其他任意成分来制造。
在用于实施本发明方法的极微量油剂供给型金属加工法中,作为极微量地供给油剂组合物的方式,优选下面举出的方法。
(1)通过压缩流体(例如空气)供给表面被油剂组合物覆盖的水滴的方法。
(2)通过压缩流体(例如空气)供给水和油剂组合物的混合雾的方法。
(3)将水和油剂组合物分别用不同的系统雾化后,通过压缩流体(例如空气)供给到相同地点的方法。
(4)将油剂组合物雾化后通过压缩流体(例如空气)供给的方法。
最优选(1)的方法。下面,通过(1)来进一步详细说明本说明,但本发明并不限于该方法。作为用于实现(1)的方法的供给装置,有例如日本特开2001-239437所公开的装置。在图1表示供给装置的一例示意性结构。在该装置中,采用与通常的喷雾相同的原理,制造出由在水滴表面形成油膜的微粒所构成的雾。此时,在靠近空气吸入口侧的一侧吸进油,在靠近吐出口侧的一侧吸进水,从而能够有效地在水滴上附上油膜。
作为边供给本发明的油剂组合物边加工金属材料的方法的例子,可以举出切削加工、磨削加工、剪切加工、立铣加工、轧制加工(component rolling)、压力加工、塑性加工等。作为金属材料的例子,可以举出铸铁、钢、不锈钢、非铁金属(例如Al合金、Mg合金)等。
本发明的油剂组合物的使用量为,对于1个喷嘴,每小时0.5~20mL、优选1~10mL程度的极微量即可,环境负荷也小,经济上也是有利的。水的使用量为,对于1个喷嘴,每小时500~2000mL、优选800~1500mL,例如1000mL程度。所用的水为自来水、工业用水即可。空气的供给量为每分钟25~250L程度,优选为50~100L程度。
进而,在本发明的加工方法中,适宜以极少量用尽的方式使用环境负荷小的本发明的油剂组合物。由此,能够减轻以至解决掉使用水溶性切削油剂的以往加工中存在问题,即水溶性切削油剂稀释液腐败、硬度上升等引起的分离等液体劣化、由其引起的加工性能低下、水溶性切削油剂稀释液的废液的环境负荷问题等。
下面,根据实施例进一步详细说明本发明,但下述实施例并不限制本发明,只要在不脱离本发明宗旨的范围内实施的变更都应包含在本发明的技术范围内。
实施例
调制表1~6所示处方的油剂组合物,边按照下述条件供给边进行切削试验,评价其切削性。
其中,比较例19的组合物与日本特开2004-300317号公报中记载的金属加工油剂组合物是相同的组成。
实施例1~14和比较例1~26中,由空气供给表面被油膜覆盖的水滴。设定油剂的供给量是10mL/H、水的供给量是1000mL/H、空气的供给量是100L/H。
在比较例27中,将市售的乳液型切削油剂(JIS K2241 A1种1号乳液型切削油剂)(5质量%)以吐出压1kg/cm2、供给量6L/min供给。
切削性评价
通过碳素钢(S45C)的车削加工来评价切削性。切削阻抗(N)与进给方向成直角(工具按压力),将低于比较例19的油剂的情况记为合格。
切削条件
工具:超硬6片刀刃,扭转角45度,前角14度,前端1R
被切削材料:SKD11(HRC53)(30×150×200mm)
切削速度:300m/min
进给:0.1mm/刀刃
半径切进深度:0.5mm
轴向切进深度:10mm
防锈性
用100号砂纸研磨铸造材料(FC200)和碳素钢(S45C),进而用240号砂纸将表面打成平滑的新生面。在其上涂布5.0g/m2油剂组合物,用橡皮球一滴一滴地滴下自来水共16处。以这种状态在常温静置24小时后,观察生锈状况。
防锈性评价基准(将○、□、△记为合格)
○:优(没有生锈)
□:良(1~4处生锈)
△:尚可(5~8处生锈)
×:不合格(9~16处生锈)
在表1~6表示实施例和比较例的配合处方和评价试验结果。
表1
表2
表3
表4
表5
表6
从表1~6的结果可以知道,含有山梨糖醇酐脂肪酸酯和磷脂两者的本发明的实施例1~14的油剂组合物,不仅切削阻抗低润滑性优异,而且防锈性也良好。
与此相对,不含有山梨糖醇酐脂肪酸酯和磷脂的比较例1为,切削阻抗高,防锈性不好。
另外,不含山梨糖醇酐脂肪酸酯和磷脂中的某一方的比较例2~8和21~26为,虽然切削阻抗低,但防锈性不好。
此外,含有由山梨糖醇酐脂肪酸酯和磷脂构成的组合之外的防锈剂的比较例9~19为,润滑性和防锈性中的至少一方差。
Claims (13)
1.一种油剂组合物,其为用于极微量油剂供给型金属加工法的金属加工油剂组合物,其特征在于,含有山梨糖醇酐脂肪酸酯和磷脂。
2.一种油剂组合物,其为用于极微量油剂供给型金属加工法的金属加工油剂组合物,其特征在于,含有(I)从由天然油脂、其衍生物以及合成酯油组成的组中选出的基油;(II)由山梨糖醇酐脂肪酸酯和磷脂构成的防锈剂。
3.根据权利要求1或2所述的油剂组合物,其特征在于,山梨糖醇酐脂肪酸酯含有从由山梨糖醇酐单油酸酯、山梨糖醇酐倍半油酸酯、山梨糖醇酐二油酸酯和山梨糖醇酐三油酸酯组成的组中选出的至少一种。
4.根据权利要求1~3中的任一项所述的油剂组合物,其特征在于,磷脂含有从由蛋黄卵磷脂和大豆卵磷脂等组成的组中选出的至少一种。
5.根据权利要求1~4中的任一项所述的油剂组合物,其特征在于,磷脂含有磷脂酰胆碱、磷脂酰乙醇胺和磷脂酰肌醇的混合物。
6.根据权利要求1~5中的任一项所述的油剂组合物,其特征在于,山梨糖醇酐脂肪酸酯的配合量是0.1~40质量%。
7.根据权利要求1~6中的任一项所述的油剂组合物,其特征在于,磷脂的配合量是0.1~40质量%。
8.根据权利要求1~7中的任一项所述的油剂组合物,其特征在于,极微量油剂供给型金属加工法是一边通过压缩流体供给表面被油膜覆盖的水滴一边加工金属材料的方法。
9.根据权利要求1~7中的任一项所述的油剂组合物,其特征在于,极微量油剂供给型金属加工法是一边用压缩流体供给经雾化的金属加工油剂一边加工金属材料的方法。
10.极微量油剂供给型金属加工方法,其特征在于,使用权利要求1~9中的任一项所述的组合物加工金属材料。
11.根据权利要求10所述的金属加工方法,其特征在于,一边通过压缩流体供给被权利要求1~9中的任一项所述的组合物覆盖的水滴,一边加工金属材料。
12.根据权利要求10所述的金属加工方法,其特征在于,一边用压缩流体供给经雾化的权利要求1~9中的任一项所述的组合物,一边加工金属材料。
13.通过权利要求10~12中的任一项所述的金属加工方法来得到的金属加工品。
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JP4594476B2 (ja) * | 2000-02-25 | 2010-12-08 | 協同油脂株式会社 | 非鉄金属材料の加工方法 |
JP2001354984A (ja) * | 2000-06-14 | 2001-12-25 | Asahi Denka Kogyo Kk | 金属加工油剤 |
TWI228540B (en) | 2001-04-06 | 2005-03-01 | Nippon Mitsubishi Oil Corp | Oil composition for very small amount oil supply type cutting and grinding operation |
US7435707B2 (en) * | 2002-05-23 | 2008-10-14 | The Lubrizol Corporation | Oil-in-water emulsions and a method of producing |
JP2004204214A (ja) * | 2002-11-08 | 2004-07-22 | Kao Corp | 鋼板冷間圧延油 |
JP4208626B2 (ja) * | 2003-03-31 | 2009-01-14 | 協同油脂株式会社 | 金属加工用油剤組成物 |
US20050197260A1 (en) * | 2004-02-05 | 2005-09-08 | Montana State University | Environmentally friendly grease composition |
-
2006
- 2006-06-30 JP JP2006181501A patent/JP2008007700A/ja active Pending
-
2007
- 2007-07-02 CA CA002656007A patent/CA2656007A1/en not_active Abandoned
- 2007-07-02 KR KR1020087031446A patent/KR20090015142A/ko not_active Application Discontinuation
- 2007-07-02 WO PCT/JP2007/063229 patent/WO2008001933A1/ja active Application Filing
- 2007-07-02 EP EP07768004A patent/EP2039740A4/en not_active Withdrawn
- 2007-07-02 CN CN200780026823XA patent/CN101490224B/zh not_active Expired - Fee Related
- 2007-07-02 US US12/306,813 patent/US8044004B2/en not_active Expired - Fee Related
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104830516A (zh) * | 2015-05-08 | 2015-08-12 | 上海中孚特种油品有限公司 | 一种极压型铝板铝带热轧乳液及其制备方法 |
CN104830516B (zh) * | 2015-05-08 | 2017-11-07 | 上海中孚特种油品有限公司 | 一种极压型铝板铝带热轧乳液及其制备方法 |
Also Published As
Publication number | Publication date |
---|---|
EP2039740A4 (en) | 2011-03-16 |
CA2656007A1 (en) | 2008-01-03 |
US8044004B2 (en) | 2011-10-25 |
EP2039740A1 (en) | 2009-03-25 |
JP2008007700A (ja) | 2008-01-17 |
KR20090015142A (ko) | 2009-02-11 |
WO2008001933A1 (fr) | 2008-01-03 |
CN101490224B (zh) | 2013-03-13 |
US20090298730A1 (en) | 2009-12-03 |
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