环保型重负荷加工全合成切削液的研制

通过大量试验评价,筛选出重负荷加工全合成切削液所需的油性剂、极压剂、防锈剂、pH值稳定剂、消泡剂等添加剂并进行合理配伍。采用四球机法和攻丝扭矩法对研制全合成切削液进行润滑性能测试,采用IP287铸铁屑防锈试验法进行铸铁屑防锈性能测试。结果表明,研制的全合成切削液具有优异的润滑性、极压性、防锈性、冷却性、清洗性和生物稳定性,其各项指标与进口同类产品相当。实际应用结果表明,研制的全合成切削液可用于替代乳化液、微乳液和油基切削液,能满足不同材料的重负荷切削加工工艺要求。     

机械制造用微乳切削液的研制及应用

以富马酸、二乙醇胺、五氧化二磷为原料合成富马酸二乙醇酰胺磷酸酯(FEP)作为极压剂,以妥尔油酸、二乙醇胺为原料合成妥尔油酸二乙醇胺(BP)作为极压抗磨添加剂,并对基础油、防锈剂、表面活性剂、杀菌剂等添加剂进行筛选研究,合成机械制造用微乳切削液。该产品具有优良的润滑性、防锈性、冷却性、清洗性、杀菌性,在机械制造行业中,可满足各种进口、国产设备及各种材质机加工工艺,是一种环保型的长效金属切削液。     

极压微乳化切削液的研制与应用

按照微乳液调配理论，研制了一种由表面活性剂、润滑剂、防锈剂、稳定剂、低粘度矿物油、杀菌剂和水等组成的透明极压微乳化切削液，详细探讨了防锈剂、油性剂、极压剂、表面活性剂等添加剂的选择；讨论了这种微乳化切削液的性能、特点及应用情况。应用结果表明：研制的极压微乳化切削液是透明稳定的，具有优良的防锈性、润滑性、冷却性和清洗性；产品不含对人体有害的氯化石蜡和亚硝酸钠等物质。     

L—MAF高抗磨性水基微乳化切削液的研制

釆用全新的乳化剂与极压剂的配伍方法,研制出一种由表面活性剂、润滑剂、极压剂、杀菌剂、助溶剂和水等组成的水基微乳化切削液.实验结果表明:该切削液具有良好的高抗磨性、防锈性和稳定性,其抗磨性能明显高于国外同类产品.     

通用型高性能微乳切削液的研制

介绍微乳液的形成原理和稳定性的高低温评价方法。阐述微乳切削液的制备工艺和使用性能调整方法。研制一种通用型高性能微乳切削液,其含油量30%,储存期长,防锈性和防腐性高,具有通用性,Falex评价值为20016N,极压性能较好。     

半合成极压切削液的研究与应用

半合成极压切削液是一种集乳化液和合成液优点于一体并具有良好极压性能的新一代切削液。按照微乳液调配理论,尤其利用HLB值方法,合理选择乳化剂、极压剂、防锈剂、润滑剂、稳定剂和杀菌防腐剂等多种添加剂并进行科学配伍。对产品进行理化性能测试、四球机承载能力试验、切削阻力试验等实验室评价和实际应用考察,研制了一种新型半合成极压切削液,广泛应用于数控机床、加工中心。     

全合成切削液的制备及极压剂与防锈剂的协同效应研究

制备一种水基全合成切削液,考察新型有机钼、有机硼极压剂与三乙醇胺硼酸酯防锈剂的协同作用。利用四球摩擦磨损试验机研究切削液的摩擦学性能;采用一级灰口铸铁进行单片、叠片防锈试验,考察全合成切削液的防锈性能;用激光共聚焦显微镜观察试件表面形貌并测量工件的表面粗糙度,研究极压剂对工件表面质量的影响。结果表明:2种极压剂有协同增效的作用,使用复合极压剂后,极压润滑系数(最大无卡咬载荷与摩擦因数的比值)增大,改善加工工件的表面质量;有机硼极压剂和三乙醇胺硼酸酯防锈剂共同作用可增强切削液的防锈作用;当切削液中添加复合极压剂与防锈剂时,与含有单一添加剂的切削液相比,其极压性能与防锈性能均有提高,表明防锈剂和极压剂在切削液中具有协同作用。     

一种新型微乳化绿色切削液研究

以低粘度润滑剂和自来水为基本原料,添加防锈剂、极压剂、消泡剂、表面活性剂,研制了一种新型微乳化绿色切削液。研制的微乳化绿色切削液稀释后适用于黑色等多种金属的切削、研磨等。具有良好的防锈、防腐、抗硬水稳定性能,且无毒无味、对皮肤无刺激,能满足工件加工的润滑性、防锈性和光洁度要求,并能延长其使用周期。     

采用正交试验法的环保型水基合成切削液配方优化设计

采用正交试验法优化设计了不含亚硝酸盐、磷、硫、苯酚等有害元素的环保型水基合成切削液。该配方采用羧酸酯、羧酸醇胺等有机防锈剂与其它无机防锈剂协同防锈,采用合成硼酸酯、硼酸盐和油酸三乙醇胺作为润滑剂和极压剂。该切削液具有优良的润滑性、防锈性、冷却性、清洗性、防腐性和可降解性。     

多功能长效极压乳化切削液的研制

筛选性能优良的基础油、油性剂、极压剂、防锈剂、乳化剂、杀菌防霉剂等添加剂,通过综合配伍优化,研制出多功能长效极压乳化切削液。通过理化性能、稳定性、粒径分布测试及四球机实验、攻丝扭矩实验和IP287铸铁屑防锈试验表明,研制的乳化切削液具有优异的存储稳定性、稀释液稳定性、润滑性、防锈性和均匀的粒径分布。实际应用表明,研制的乳化切削液具有多功能性,能用于铸铁、碳钢、合金钢、不锈钢等黑色金属以及铜、铝及其合金等有色金属的车、铣、钻、镗、拉削、攻丝等多种切削加工,且产品使用寿命长。     

绿色制造用高性能水基全合成切削液研究

为研制一种高性能的水基全合成切削液,通过试验筛选出对微生物稳定的润滑材料,如异构饱和脂肪酸、咆和醇酯、脂肪醇胺、PAG;为提高切削液的渗透性和冷却性,采用具有润滑、抑泡作用的聚醚型非离子和阴离子表面活性剂复配;选用具有极压抗磨性和防锈性的硼酸醇胺,以及选用铝缓蚀剂和消泡剂等.经过正交试验优化了配方,成功研制出一种长寿命、环保、高性能的水基全合成切削液,并进行推广应用,实现切削液的零排放以及制造业的绿色化.     

环境友好水基全合成金属加工切削液的研究

通过对各种环境友好添加剂筛选,选用异构脂肪酸醇胺盐和月桂酸正醇酯作为润滑添加剂,选用能对切削液泡沫有抑制作用的不同种类的聚醚(有效控制EO与PO比例的镶嵌聚醚)作为表面活性剂,选用硼酸醇胺盐作为极压抗磨添加剂和防锈剂,研制出环境友好水基全合成切削液,在不加杀菌剂的情况下,切削液的使用寿命达到一年以上。产品各项性能指标与国外同类高档产品相当,达到了环保、节能、降耗的效果。     

The lubricant-coating interaction in rolling and sliding contacts

The research presented in this paper was aimed at elaboration of a new technology for heavy-loaded machine elements, lubricated with ecological oils.The tribological experiments were performed using four-ball tester (scuffing resistance), cone-three balls pitting tester (fatigue life), as well as gear test rig (resistance of lubricated gears to scuffing). The tribosystems were lubricated with various base oil and vegetable-based eco-oil.The tested components were coated with standard single coatings (TiN, CrN) and low-friction coatings (a-C:H:W, MoS₂/Ti). The results obtained confirm that low-friction a-C:H:W coating has a great potential for application in heavy-loaded machine components. Under extreme-pressure conditions this coating can take over the functions of anti-wear/extreme-pressure (AW/EP) additives and through this it is possible to minimise the application of toxic lubricating additives and achieve “ecological lubrication”.     

废机油制备的乳化切削液及其性能研究

利用正交试验确定了乳化切削液的最佳配比;通过单因素试验分析了极压添加剂和油性剂的用量对切削液性能的影响,并确定其最佳用量;借助Tafel极化曲线确定了乳化切削液使用的最佳稀释浓度;按照乳化切削液行业标准要求对切削液进行综合测试,结果表明,该乳化切削液各项性能指标均符合行业标准,缓蚀性和润滑性方面优于部分市售切削液.     

油酸在水基金属加工液中的应用研究

以油酸和三乙醇胺、聚乙二醇400为原料合成了油酸三乙醇胺酯，其具有优良的润滑性、防锈性和水溶性，可解决水基金属加工液润滑性差的问题。经四球机检测：5％的油酸三乙醇胺水溶液的最大无卡咬负荷PB值可达800N，PD值超过1800N。     

超声波处理乳化液在金属切削中的试验研究

为了研究超声波处理对乳化液冷却润滑性能的影响,设计了用于切削试验的乳化液超声波处理系统,并在干切、未采用超声波处理乳化液和采用超声波处理乳化液三种条件下,采用YT15刀具车削45钢进行了对比试验。结果表明：使用超声波处理乳化液时,切削力可比干切和未采用超声波处理乳化液时分别减小10%~15%和5%~10%;变形系数也减小了,切屑形貌得到改善。通过测量液体粒度可知,超声波处理使乳化液的分子团粒径减小,乳化液进入切削区毛细管的可能性增大,说明超声波处理能够提高乳化液的冷却润滑作用效果,也可理解为间接地减少了乳化液的用量,有利于节能减排。     

切削液油雾形成机制及影响因素的实验研究

对切削液油雾产生的机制进行理论分析,并对切削液油雾形成的影响因素进行实验研究。实验在密闭的车床内进行,利用车床的供液系统采用浇注式供给磨削液,在油雾产生密集区域内安装有磨削液雾滴粒径的测量装置,该装置中的共聚焦显微镜可观察切削液雾滴在空气中的分布,精确扫描单颗雾滴的形态轮廓,通过计算机可计算出雾滴的分布和直径尺寸。分别控制主轴转速和切削液流量,探究对所形成的油雾浓度和平均直径的影响。实验结果表明:金属加工过程中主轴转速和切削液流量对切削液油雾特性的影响显著,随着主轴转速的增加,油雾的平均直径减小,而油雾浓度却呈上升趋势;随着切削液流量的增加,油雾的平均直径变大,并且油雾浓度同样呈上升趋势。     

The surface chemistry of chlorinated hydrocarbonextreme-pressure lubricant additives

Chlorinated or sulfurized hydrocarbons are commonly added to abase fluid to synthesize lubricants used under extreme-pressure(EP) conditions. It has been demonstrated that the interfacialtemperature in the EP regime varies linearly with the appliedload and that temperatures in excess of 1000 K can be attained.At these temperatures, both microbalance experiments carried outat high pressure as well as molecular beam experiments performedin ultrahigh vacuum reveal that chlorinated hydrocarbonsthermally decompose forming a film that consists of a layer ofiron chloride and which can also incorporate small (~50 Ådiameter) carbon particles. These particles may affect the coefficient of friction of the film. The lubricant fails andseizure takes place when the film is removed sufficientlyrapidly for metal-metal contact to occur so that EP lubricationis described as a dynamic phenomenon. Under appropriatecircumstances, sufficient carbon can be incorporated into theiron substrate that it becomes a carbide. In this case, seizureis prevented even when the halide layer is removed because ofthe hardness and high melting temperature of this carbide.Ultrahigh vacuum experiments also suggest that carbon diffusioninto the iron and presumably also ultimately carbide formation,is facilitated by co-adsorbed chlorine which may then explain the excellent extreme-pressure properties of carbon tetrachloride.Finally, a similar tribological model is successfully appliedto dimethyl disulfide where, in this case, FeS forms the anti-seizure layer.     

THE EFFECT OF THE CUTTING FLUID ON SURFACE ROUGHNESS IN BORING OF LOW CARBON STEEL-TECHNICAL COMMUNICATION

In spite of their environmental and human health problems, the cutting fluids still have been used widely in industry due to cutting fluid application can increase cutting performance in metal cutting. In this article, the effect of the cutting fluid on surface roughness in boring of AISI 1030 low carbon steel was investigated depending on BUE and chip formations and other cutting parameters, such as cutting speed, feed rate and tool nose radius. In most of boring experiments, the wet cutting did not show more preferable results than dry cutting. However, cutting fluid application with big nose radius and small feed rate improved the surface roughness up to 80%. This progress was attributed to a favorable chip formation as much as effective cooling.