Emulsion is a high performance semi syntheticMetalworking fluidIt is especially suitable for the processing of aluminum metals and their alloys, but not suitable for materials containing lead, such as some brass and tin metals.The product has a long service life and is completely free from the influence of oil leakage and oil mixing. It is best to use soft water for blending.The emulsion adopts a special formula without chlorine, which is specially used to solve various problems (such as chip adhesion, tool wear, poor surface precision of workpiece, and surface pollution) during the processing of aluminum metal and its alloys.It can be applied to all operations including reaming.Emulsion can also effectively prevent rust or chemical corrosion of processing workpiece, and can also effectively prevent bacterial corrosion and infection.
Its main chemical components include: water, base oil (mineral oil, vegetable oil, synthetic ester or their mixture)surface active agent Anti rust additives (zinc naphthenate, sodium petroleum sulfonate (also emulsifier)Barium petroleum sulfonate、Benzotriazole，SorbitolMonooleate, aluminum stearate), extreme pressure additives (polar compounds of sulfur, phosphorus, chlorine and other elements), friction modifiers (antifriction agents or oil additives)antioxidant。
Emulsion is a kind of emulsion containingmineral oilIt has the most advanced formula technology and is especially suitable for large-scale aluminum casting manufacturers.When using our products to replace other common soluble productsCutting oilThe whole cooling circulation system shall be thoroughly sterilized and cleaned.
Emulsion advantages
1. The product can fully keep the environment clean. Especially when compared with similar products, you will find that the processed product can leave a light liquid film, which can be easily removed, facilitating cleaning, maintenance and management.
2. The product effectively prevents the erosion of bacteria and fungi, and saves the cost of storage and maintenance.The product also has good wetting and adhesion characteristics, reducingcutting fluidThe splash loss also cleans the environment.
3. The product is particularly capable of preventing metal welding adhesion, such as preventing the accumulated welding of chips on the blade or workpiece;At the same time, it can effectively prevent corrosion of ordinary iron metal materials.
4. The product contains lubricant synergist, which is used to improve the surface quality of processing parts and extend theTool life。It is compatible with most processing materials, including cast iron, steel parts, copper, aluminum alloys, and a variety of plastics and compounds.
5. Users can use the existing technology and equipment to dispose the products according to the general disposal method.
Performance characteristics
Emulsion combines the lubricity and rust resistance of oil with the better cooling performance of water, and has better lubrication and cooling performance, so it is very effective for high-speed and low load metal cutting with a lot of heat generation.AndOil based cutting fluidIn contrast, emulsion has the advantages of greater heat dissipation, better cleaning performance, and the economy brought by dilution with water. In addition, it is also conducive to the health and safety of the operation site.In fact, except for materials that are extremely difficult to process, emulsion can be used for almost all light and medium load cutting and most heavy load machining. Emulsion can also be used for all grinding processes except for complex grinding such as thread grinding and groove grinding.The disadvantage of emulsion is that bacteria and mold are easy to reproduce, which will make the effective ingredients in emulsion smell and deteriorate due to chemical decomposition, so it is generally necessary to add less toxicOrganic fungicide。[1]
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Dilution ratio
1. Light duty machining and grinding: 4 to 6%
2. Medium load machining and grinding: 6 to 8%
3. Heavy duty machining and grinding: 8 to 12%
Maintenance and management
Maintenance ratio of emulsionOil based cutting fluidIt's much more complicated.When preparing emulsion, first add water into the water tank, and then add emulsified oil while stirring.Avoid adding water to oil, otherwise water in oil emulsion will be obtained. This kind of emulsion has high viscosity and is not suitable for general cutting.
The water used to prepare emulsion is very important, and hard water containing various minerals and salts will often hinder the emulsification process.Emulsions prepared with hard water often quickly delaminate, leaving out a large amount of oil and insoluble soap, affecting the use effect.In addition, if the water quality is too soft, the foam may increase.Therefore, the water quality should be known in advance when preparing emulsion. If the water quality is too hard, it must be pretreated. Add 0.1%~0.3%Sodium tripolyphosphateOr sodium diethylamine acetate can reduce the hardness of water.However, adding too much sodium tripolyphosphate will lead to the reproduction of bacteria and mold.So if the local tap water is too hard, it is better to useDeionized water。
Fatty oil andUnsaturated fatty acidIt is easily eroded by microorganisms.Microbes often encountered in emulsion include bacteria, mold and algae, which have adverse effects on the stability of emulsion.Many emulsions contain bactericides, but their addition is limited by oil solubility.When the emulsion is prepared, the concentration of bactericide is further reduced, thus reducing its bactericidal effect.After the emulsion is corroded by microorganisms, the unsaturated fatty acids and other compounds in the emulsion are decomposed by microorganisms, which destroys the balance of the emulsion, resulting in oil and soap separation. The acid value of the emulsion increases, causing the emulsion to deteriorate.
Deterioration of emulsion
1. Slight corruption odor occurs;
2. Emulsion changes from milky white to grayish brown;
3. The pH value and rust resistance decrease sharply;
4. Oil water separation of emulsion generates sediment or sludge and blocks the filter screen;
5. Cutting and grinding performance decline;
6. The odor spread to the whole workshop, which worsened the operating environment and forced the replacement of new cutting fluid.
To prevent emulsion corruption, the following measures can be taken:
1. When injecting new liquid, first remove the cuttings, oil stains and other substances around the machine tool and in the liquid supply system, and disinfect them with disinfectant before adding new liquid.If it is not cleaned, putrid bacteria will be put into the new liquid.
2. Dilute the emulsion with tap water or soft water, and avoid using water containingEscherichia coliAnd groundwater with more inorganic salts.
Make up liquid management shall be carried out to keep the emulsion working at the specified concentration, and the thin concentration of emulsion will facilitate the propagation of bacteria.
3. When it is found that the pH value tends to decrease, pH enhancers (such as sodium carbonate) should be added to keep the pH value at about 9.When the pH value of emulsion exceeds 9, it is difficult for microorganisms to reproduce.
4. In case of long-term shutdown such as holidays, air shall be regularly pumped into the tank to prevent the reproduction of anaerobic bacteria and remove odor.
5. While paying attention to preventing oil leakage from mixing, install a device that can quickly remove oil leakage.
6. Effective chip removal method shall be adopted to avoid chip accumulation in the fluid tank.
7. If you notice signs of corruption, you should immediately add bactericide to kill the bacteria.[2]
