Patent Application
20250236808
The present invention relates to a water-soluble lubricant, an aqueous metalworking fluid obtained by blending dilution water to the water-soluble lubricant, and a metalworking method comprising a step of processing a workpiece comprising a member including metal (e.g., aluminum) using the aqueous metalworking fluid.
Lubricants are used in various situations, such as for lubrication of sliding parts in various equipment, for cooling heat-generating equipment such as engines, and for metalworking to improve workability during metalworking.
In recent years, water-soluble lubricants have become increasingly sought after for safety reasons, such as low risk of fire.
For example, Patent Literature 1 discloses a water-soluble metalworking oil comprising: at least one compound selected from a hydroxy acid, a polycondensate thereof and a dehydrated condensate of the hydroxy acid or the polycondensate thereof and a fatty acid, which has a specific acid value; an amine having an alicyclic group or an aromatic cyclic group; and a base oil.
Patent Literature 1: Japanese Patent Laid-Open No. 2012-67146
Under these circumstances, for example, there is a need for a novel water-soluble lubricant which allows metals to be highly corrosion resistant and which is highly compatible with various applications.
The present invention provides a water-soluble lubricant comprising a cyclic compound having a ring structure comprising at least one pre-determined substructure. Specifically, the present invention provides, for example, the following embodiments [1] to [14]:
[1] A water-soluble lubricant comprising a cyclic compound (A) having a ring structure (α) comprising at least one substructure represented by the following formula (i) or (ii):
The water-soluble lubricant according to a preferred embodiment of the present invention allows metals (e.g., a non-ferrous metal such as aluminum and aluminum alloy) to be highly corrosion resistant, and is highly compatible with a wide variety of applications. For example, the water-soluble lubricant according to a more preferred embodiment of the present invention can provide an aqueous metalworking fluid which allows metals to be highly corrosion resistant and which is highly compatible with FIPG (liquid gasket).
Concerning the numerical ranges described herein, the upper limits and the lower limits can be suitably combined. For example, when a numerical range is described as being “preferably 30 to 100, and more preferably 40 to 80”, the range of “30 to 80” and the range of “40 to 100” are also included in the numerical range described herein. Moreover, for example, when a numerical range is described as being “preferably 30 or more and more preferably 40 or more, and preferably 100 or less and more preferably 80 or less”, the range of “30 to 80” and the range of “40 to 100” are also included in the numerical range described herein.
In addition, for the numerical ranges shown in the present description, for example, the expression “60 to 100” means a range of “60 or more (60, or more than 60) and 100 or less (100, or less than 100)”.
As used herein, when, for example, an aqueous metalworking fluid is prepared by diluting with dilution water, the “water-soluble lubricant” means a stock solution before preparing an aqueous metalworking fluid. The water-soluble lubricant is suitable for transportation and storage before being used in metalworking, and is not intended to be directly used in metalworking. Furthermore, the “aqueous metalworking fluid” is prepared by mixing dilution water to a water-soluble lubricant, which is a stock solution, and is in a form suitably used in metalworking.
The water-soluble lubricant according to an embodiment of the present invention comprises a cyclic compound (A) having a ring structure (α) comprising at least one substructure represented by the following formula (i) or (ii):
The water-soluble lubricant according to an embodiment of the present invention is a lubricant that is “soluble in water”.
As used herein, “water-soluble” means a property where the amount of dissolution in 100 g of water at 25° C. is 20 g or more and the total light transmittance of the solution at 25° C. is 90% or more after adding 20 g of the target substance in 100 g of water at 25° C.
The water-soluble lubricant according to an embodiment of the present invention is a lubricant with the above property.
The water-soluble lubricant according to an embodiment of the present invention may be any of an emulsion-type classified as A1, a soluble-type classified as A2 and a solution-type classified as A3 as stipulated in JIS K2241: 2017.
The content of water and the type and the content of the base oil and additives can suitably be set to prepare the water-soluble lubricants classified as these A1, A2 and A3.
Thus, the water-soluble lubricant according to an embodiment of the present invention may also include water (B).
The water-soluble lubricant according to an embodiment of the present invention may also include a base oil (C).
The water-soluble lubricant according to an embodiment of the present invention comprises preferably one or more selected from an amine compound (D) and fatty acid (E), and more preferably at least the component (D) and the component (E).
The water-soluble lubricant according to an embodiment of the present invention may also include a component other than the components (A) to (E) as long as the effects of the present invention are not impaired.
In the water-soluble lubricant according to an embodiment of the present invention, the total content of the components (A) to (C) is preferably 108 by mass or more, more preferably 20% by mass or more, even more preferably 25% by mass or more, still more preferably 30% by mass or more and particularly preferably 35% by mass or more, and may be 40% by mass or more, 45% by mass or more, 50% by mass or more, 55% by mass or more, or 60% by mass or more, and may be 100% by mass or less, 95% by mass or less, 90% by mass or less, 85% by mass or less, 80% by mass or less, 75% by mass or less, 70% by mass or less, 65% by mass or less, or 60% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant.
In the water-soluble lubricant according to an embodiment of the present invention, the total content of the components (A) to (E) is preferably 20% by mass or more, more preferably 30% by mass or more, even more preferably 40% by mass or more, still more preferably 50% by mass or more, yet more preferably 60% by mass or more, and particularly preferably 70% by mass or more, and may be 75% by mass or more, 80% by mass or more, 85% by mass or more, or 90% by mass or more, and may be 100% by mass or less, 99.9% by mass or less, 99.5% by mass or less, or 99.0% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant.
In the following, the respective components contained in the water-soluble lubricant according to an embodiment of the present invention will be described.
The water-soluble lubricant according to an embodiment of the present invention comprises a cyclic compound (A) having a ring structure (α) comprising at least one substructure represented by the following formula (i) or (ii):
Since the water-soluble lubricant according to an embodiment of the present invention comprises a cyclic compound (A) having a ring structure (α) comprising at least one substructure represented by the above formula (i) or (ii), it can provide an aqueous metalworking fluid which improves corrosion resistance of metals (in particular, a non-ferrous metal such as aluminum or an aluminum alloy) and which is highly compatible with FIPG. The excellent compatibility of the aqueous metalworking fluid with FIPG eliminates adverse effects in the post treatment of workpieces after processing. By contrast, corrosion resistance of metals is not sufficiently improved with compounds which do not have the ring structure (α).
The substructure represented by the above formula (i) or (ii) may be a structure formed by dehydration condensation of a linear compound in the molecule.
For example, dehydration condensation of two carboxyl groups (—COOH) in the molecule, in a polycarboxylic acid having two or more carboxyl groups in the molecule gives a cyclic compound having a ring structure (α) comprising both of the substructures represented by the above formulas (i) and (ii). This cyclic compound is also included in the cyclic compound (A) used in an embodiment of the present invention.
It is preferable that the ring structure (α) in the cyclic compound (A) used in an embodiment of the present invention has at least one selected from an acid anhydride structure and a lactone structure in order to obtain a water-soluble lubricant which can provide an aqueous metalworking fluid which allows metals to be more corrosion resistant and has improved compatibility with FIPG. In particular, inclusion of a lactone structure is more preferred in order to obtain a water-soluble lubricant which can provide an aqueous metalworking fluid which has more improved compatibility with FIPG.
The ring structure (α) has preferably 5 to 20, more preferably 5 to 16, even more preferably 5 to 12, still more preferably 5 to 10, yet more preferably 5 to 8, and particularly preferably 5 or 6 ring forming atoms in order to obtain a water-soluble lubricant which can provide an aqueous metalworking fluid which allows metals to be more corrosion resistant and which has more improved compatibility with FIPG.
As used herein, the “number of ring forming atoms” in the ring structure (α) means the number of atoms constituting the ring structure (α) itself, and the number of atoms not constituting a ring (e.g., a hydrogen atom bonded to an atom constituting a ring) and atoms included in a substituent when the ring is substituted by a substituent are not included.
The component (A) used in an embodiment of the present invention preferably comprises one or more selected from a cyclic compound (A1) having a ring structure (α1) represented by the following formula (a-1) and a cyclic compound (A2) having a ring structure (α2) represented by the following formula (a-2) in order to obtain a water-soluble lubricant which can provide an aqueous metalworking fluid which allows metals to be more corrosion resistant and has more improved compatibility with FIPG. In particular, the component (A) more preferably comprises a cyclic compound (A1) in order to obtain a water-soluble lubricant which can provide an aqueous metalworking fluid which has more improved compatibility with FIPG.
At least one hydrogen atom in the above formula may be substituted by a substituent.
That is, the cyclic compound (A1) may be a compound having a ring structure (α1) represented by the above formula (a-1), or may be a compound in which at least one hydrogen atom in the ring structure (α1) is substituted by a substituent. Likewise, the cyclic compound (A2) may be a compound having a ring structure (α2) represented by the above formula (a-2), or may be a compound in which at least one hydrogen atom in the ring structure (α2) is substituted by a substituent.
Examples of substituents include a hydroxyl group, an alkyl group having 1 to 30 carbon atoms, an alkyl group having 1 to 30 carbon atoms and a hydroxyl group, an alkenyl group having 1 to 30 carbon atoms, a cycloalkyl group and an aryl group.
Examples of the alkyl groups include a methyl group, an ethyl group, a propyl group (n-propyl group and i-propyl group), a butyl group (n-butyl group, i-butyl group, s-butyl group and t-butyl group), a pentyl group (n-pentyl group, i-pentyl group and neopentyl group), a hexyl group, a heptyl group, an octyl group, a 2-ethylhexyl group, a nonyl group, a decyl group, an undecyl group, a dodecyl group, a tridecyl group, a tetradecyl group, a pentadecyl group, a hexadecyl group, a heptadecyl group and an octadecyl group.
The alkyl group may be a linear alkyl group or a branched alkyl group.
The alkyl group has 1 to 30 carbon atoms, or may have 1 to 24, 1 to 20, or 1 to 16 carbon atoms.
Examples of the alkyl groups having a hydroxyl group include the above linear alkyl group and the branched alkyl group in which at least one hydrogen atom is substituted by a hydroxyl group.
Examples of the alkenyl groups include an ethenyl group (vinyl group), a propenyl group, a butenyl group, a pentenyl group, a hexenyl group, a heptenyl group, an octenyl group, a nonenyl group, a decenyl group, a dodecenyl group, a tridecenyl group, a tetradecenyl group, a pentadecenyl group, a hexadecenyl group and an octadecenyl group.
The alkenyl group may be a linear alkenyl group or a branched alkenyl group.
The alkenyl group has 1 to 30 carbon atoms, or may have 1 to 24, 1 to 20, or 1 to 16 carbon atoms.
Examples of the cycloalkyl groups include a cyclopropyl group, a cyclobutyl group, a cyclopentyl group, a cyclohexyl group, a cycloheptyl group, a cyclooctyl group and an adamanthyl group. The cycloalkyl group may have 3 to 20, 5 to 12, or 5 or 6 ring forming carbon atoms.
Examples of the aryl groups include a phenyl group, a biphenyl group, a terphenyl group, a naphthyl group, an anthracenyl group, a phenanthryl group and a fluorene group. The aryl group may have 6 to 18, 6 to 15, or 6 to 12 ring forming carbon atoms.
At least one hydrogen atom that the above cycloalkyl group and the above aryl group have may also be substituted by a group selected from a hydroxyl group, an alkyl group having 1 to 10 carbon atoms and an alkenyl group having 1 to 10 carbon atoms.
Among them, in an embodiment of the present invention, the substituent that the ring structures (α1) and (α2) have may be a group selected from a hydroxyl group, an alkyl group having 1 to 30 carbon atoms and an alkyl group having 1 to 30 carbon atoms and a hydroxyl group, may be a group selected from a hydroxyl group, an alkyl group having 1 to 16 carbon atoms and an alkyl group having 1 to 10 carbon atoms and a hydroxyl group, or may be a group selected from a hydroxyl group, an alkyl group having 1 to 16 carbon atoms and a methylol group (—CH2OH).
In the ring structures (α1) and (α2), the position and the number of substituents may be suitably adjusted.
Examples of cyclic compounds (A1) used in an embodiment of the present invention include a compound represented by the following formula (a-11).
Furthermore, examples of cyclic compounds (A2) used in an embodiment of the present invention include a compound represented by the following formula (a-21).
In the above formulas (a-11) and (a-21), RA are each independently a substituent, and the form of the substituent is the same as the substituent that the ring structures (α1) and (α2) have.
In the water-soluble lubricant according to an embodiment of the present invention, the total content of the components (A1) and (A2) is preferably 50 to 100% by mass, more preferably 60 to 100% by mass, even more preferably 70 to 100% by mass, still more preferably 80to 100% by mass, yet more preferably 90 to 100% by mass, and particularly preferably 95 to 100% by mass based on the total amount (100% by mass) of the component (A) contained in the water-soluble lubricant.
In the water-soluble lubricant according to an embodiment of the present invention, the content of the component (A) is preferably 0.1% by mass or more, more preferably 0.2% by mass or more, even more preferably 0.3% by mass or more, still more preferably 0.4% by mass or more, and particularly preferably 0.5% by mass or more, and may be 0.6% by mass or more, 0.8% by mass or more, or 1.0% by mass or more, and may be 10.0% by mass or less, 9.5% by mass or less, 9.0% by mass or less, 8.5% by mass or less, 8.0% by mass or less, 7.5% by mass or less, 7.0% by mass or less, or 6.5% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant excluding water in order to obtain a water-soluble lubricant which can provide an aqueous metalworking fluid which allows metals to be more corrosion resistant and has more improved compatibility with FIPG.
While the content of the component (A) is also in the above range even when preparing an emulsion-type water-soluble lubricant classified as A1, a soluble-type water-soluble lubricant classified as A2 and a solution-type water-soluble lubricant classified as A3 as stipulated in JIS K2241: 2017, at least one of the lower limit and the upper limit may be in the range described below.
When an emulsion-type water-soluble lubricant classified as A1 as stipulated in JIS K2241: 2017 is prepared, the content of the component (A) may be 6.0% by mass or less, 5.5% by mass or less, 5.0% by mass or less, 4.5% by mass or less, 4.0% by mass or less, 3.5% by mass or less, 3.0% by mass or less, or 2.5% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
When a soluble-type water-soluble lubricant classified as A2 as stipulated in JIS K2241: 2017 is prepared, the content of the component (A) may be 1.2% by mass or more, 1.5% by mass or more, or 1.6% by mass or more, and may be 6.0% by mass or less, 5.5% by mass or less, 5.0% by mass or less, 4.5% by mass or less, or 4.0% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
When a solution-type water-soluble lubricant classified as A3 as stipulated in JIS K2241: 2017 is prepared, the content of the component (A) may be 1.2% by mass or more, 1.5% by mass or more, 1.6% by mass or more, 1.7% by mass or more, 2.0% by mass or more, 2.2% by mass or more, 2.5% by mass or more, 2.7% by mass or more, 3.0% by mass or more, 3.2% by mass or more, 3.5% by mass or more, 3.7% by mass or more, 4.0% by mass or more, 4.2% by mass or more, or 4.5% by mass or more based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
In the water-soluble lubricant according to an embodiment of the present invention, the content of the component (A) is preferably 0.1% by mass or more, more preferably 0.2% by mass or more, even more preferably 0.3% by mass or more, still more preferably 0.5% by mass or more, yet more preferably 0.7% by mass or more, and particularly preferably 1.0% by mass or more, and may be 10.0% by mass or less, 9.0% by mass or less, 8.0% by mass or less, 7.0% by mass or less, 6.0% by mass or less, 5.0% by mass or less, 4.5% by mass or less, or 4.0% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant in order to obtain a water-soluble lubricant which can provide an aqueous metalworking fluid which allows metals to be more corrosion resistant and has more improved compatibility with FIPG.
The water-soluble lubricant according to an embodiment of the present invention may also include water (B). By preparing a water-soluble lubricant including water, the resulting water-soluble lubricant is flame retardant and not hazardous, and handling properties in storage can be improved. By adjusting the content of water (B), a lubricant classified as a desired one of A1, A2 and A3 as stipulated in JIS K2241: 2017 may be prepared.
Water, which is component (B) used in one embodiment of the present invention, is not particularly limited, and may be, for example, distilled water, ion exchanged water, tap water, or water for industrial use.
The content of the component (B) in the water-soluble lubricant according to an embodiment of the present invention is preferably 0.1 part by mass or more, more preferably 1.0 part by mass or more, even more preferably 2.0 parts by mass or more, still more preferably 3.0 parts by mass or more, particularly preferably 4.0 parts by mass or more, and may be 4.5 parts by mass or more, 5.0 parts by mass or more, 5.5 parts by mass or more, 6.0 parts by mass or more, 6.5 parts by mass or more, or 7.0 parts by mass or more, and preferably 500 parts by mass or less, more preferably 470 parts by mass or less, even more preferably 450 parts by mass or less, still more preferably 420 parts by mass or less, and particularly preferably 400 parts by mass or less, and may be 350 parts by mass or less, 320 parts by mass or less, or 300 parts by mass or less based on 100 parts by mass of the total amount of the water-soluble lubricant excluding water.
While the content of the component (B) is also in the above range even when preparing an emulsion-type water-soluble lubricant classified as A1, a soluble-type water-soluble lubricant classified as A2 and a solution-type water-soluble lubricant classified as A3 as stipulated in JIS K2241: 2017, at least one of the lower limit and the upper limit may be in the range described below.
When an emulsion-type water-soluble lubricant classified as A1 as stipulated in JIS K2241: 2017 is prepared, the content of the component (B) may be 300 parts by mass or less, 200 parts by mass or less, 100 parts by mass or less, 80 parts by mass or less, 70 parts by mass or less, 60 parts by mass or less, 55 parts by mass or less, 50 parts by mass or less, 45 parts by mass or less, 40 parts by mass or less, 35 parts by mass or less, 30 parts by mass or less, 25 parts by mass or less, 20 parts by mass or less, 15 parts by mass or less, or 10 parts by mass or less based on 100 parts by mass of the total amount of the water-soluble lubricant excluding water.
When a soluble-type water-soluble lubricant classified as A2 as stipulated in JIS K2241: 2017 is prepared, the content of the component (B) may be 10 parts by mass or more, 30 parts by mass or more, or 50 parts by mass or more, and 300 parts by mass or less, 200 parts by mass or less, 100 parts by mass or less, 80 parts by mass or less, or 70 parts by mass or less based on 100 parts by mass of the total amount of the water-soluble lubricant excluding water.
When a solution-type water-soluble lubricant classified as A3 as stipulated in JIS K2241: 2017 is prepared, the content of the component (B) may be 10 parts by mass or more, 30 parts by mass or more, 50 parts by mass or more, 70 parts by mass or more, 100 parts by mass or more, 120 parts by mass or more, 130 parts by mass or more, 140 parts by mass or more, 150 parts by mass or more, 160 parts by mass or more, 170 parts by mass or more, 180 parts by mass or more, 190 parts by mass or more, or 200 parts by mass or more based on 100 parts by mass of the total amount of the water-soluble lubricant excluding water.
In the water-soluble lubricant according to an embodiment of the present invention, the content of the component (B) is preferably 1 to 99% by mass, more preferably 2 to 90% by mass, even more preferably 3 to 85% by mass, still more preferably 4 to 80% by mass, and particularly preferably 5 to 75% by mass based on the total amount (100% by mass) of the water-soluble lubricant.
The water-soluble lubricant according to an embodiment of the present invention may also include a base oil (C). By preparing an aqueous metalworking lubricant containing the base oil, the water-soluble metalworking fluid obtained therefrom can have more excellent metalworking properties. By adjusting the content of the base oil (C), a lubricant classified as a desired one of A1, A2 and A3 as stipulated in JIS K2241: 2017 may be prepared.
The base oil (C) used in an embodiment of the present invention is one or more selected from a mineral oil and a synthetic oil.
Examples of mineral oils include atmospheric residue obtained by performing atmospheric distillation on crude oil such as paraffinic crude oil, intermediate crude oil, and naphthenic crude oil; distillate obtained by performing vacuum distillation on such atmospheric residue; and refined oil obtained by performing on such distillate one or more refining treatments such as solvent deasphalting, solvent extraction, hydrocracking, solvent dewaxing, catalytic dewaxing, and hydrorefining.
Examples of synthetic oils include polyα-olefins such as α-olefin homopolymers or α-olefin copolymers (e.g., α-olefin copolymers having 8 to 14 carbon atoms, such as ethylene-α-olefin copolymers); isoparaffin; polyalkylene glycol; ester oils such as polyol esters, dibasic acid esters; ether oils such as polyphenyl ether; alkylbenzene; alkyl naphthalene; synthetic oils (GTL) obtained by isomerizing wax (GTL wax (Gas-To-Liquids WAX)) produced from natural gas by Fischer-Tropsch process or the like.
The base oil (C) used in an embodiment of the present invention has a kinematic viscosity at 40° C. of preferably 2.0 to 150 mm2/s, more preferably 3.0 to 120 mm2/s, even preferably 5.0 to 100 mm2/s, still more preferably 6.0 to 80 mm2/s, and particularly preferably 7.0 to 60 mm2/s in order to obtain a water-soluble lubricant which can provide an aqueous metalworking fluid with excellent workability.
The content of the component (C) in the water-soluble lubricant according to an embodiment of the present invention may be 0% by mass or more, 0.1% by mass or more, 1.0% by mass or more, 5.0% by mass or more, 7.0% by mass or more, or 10% by mass or more, and may be 99% by mass or less, 98% by mass or less, 95% by mass or less, 90% by mass or less, 85% by mass or less, 80% by mass or less, 75% by mass or less, 70% by mass or less, 65% by mass or less, or 60% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
While the content of the component (C) is also in the above range even when preparing an emulsion-type water-soluble lubricant classified as A1, a soluble-type water-soluble lubricant classified as A2 and a solution-type water-soluble lubricant classified as A3 as stipulated in JIS K2241: 2017, at least one of the lower limit and the upper limit may be in the range described below.
When an emulsion-type water-soluble lubricant classified as A1 as stipulated in JIS K2241: 2017 is prepared, the content of the component (C) may be 15% by mass or more, 20% by mass or more, 25% by mass or more, 30% by mass or more, 35% by mass or more, or 40% by mass or more based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
When a soluble-type water-soluble lubricant classified as A2 as stipulated in JIS K2241: 2017 is prepared, the content of the component (C) may be 50% by mass or less, 40% by mass or less, 30% by mass or less, 20% by mass or less, 15% by mass or less, or 12% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
When a solution-type water-soluble lubricant classified as A3 as stipulated in JIS K2241: 2017 is prepared, the content of the component (C) may be 50% by mass or less, 40% by mass or less, 30% by mass or less, 20% by mass or less, 15% by mass or less, 10% by mass or less, 5.0% by mass or less, 2.0% by mass or less, 1.0% by mass or less, 0.1% by mass or less, or 0.01% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
When preparing a solution-type water-soluble lubricant classified as A3, the component (C) may not be mixed.
The content of the component (C) in the water-soluble lubricant according to an embodiment of the present invention may be 0% by mass or more, 0.1% by mass or more, 1.0% by mass or more, 5.0% by mass or more, 7.0% by mass or more, or 10.0% by mass or more, and 95% by mass or less, 90% by mass or less, 85% by mass or less, 80% by mass or less, 75% by mass or less, 70% by mass or less, 65% by mass or less, 60% by mass or less, or 55% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant.
Preferably, the water-soluble lubricant according to an embodiment of the present invention also includes an amine compound (D). When the water-soluble lubricant containing the component (D) is combined with dilution water to be formed into an aqueous metalworking fluid, the aqueous metalworking fluid may have a good emulsion state and more increased antibacterial properties, antirust properties, workability, and the like.
The component (D) may be used alone, or two or more of them may be used in combination.
From the same point of view as above, the content of the component (D) in the water-soluble lubricant according to an embodiment of the present invention is preferably 1.0% by mass or more, more preferably 3.0% by mass or more, even more preferably 5.0% by mass or more, still more preferably 7.0% by mass or more, and particularly preferably 9.0% by mass or more, and may be 10% by mass or more, 12% by mass or more, or 15% by mass or more, and preferably 95% by mass or less, more preferably 90% by mass or less, even more preferably 87% by mass or less, still more preferably 85% by mass or less, and particularly preferably 82% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
While the content of the component (D) is also in the above range even when preparing an emulsion-type water-soluble lubricant classified as A1, a soluble-type water-soluble lubricant classified as A2 and a solution-type water-soluble lubricant classified as A3 as stipulated in JIS K2241: 2017, at least one of the lower limit and the upper limit may be in the range described below.
When an emulsion-type water-soluble lubricant classified as A1 as stipulated in JIS K2241: 2017 is prepared, the content of the component (D) may be 80% by mass or less, 70% by mass or less, 60% by mass or less, 50% by mass or less, 40% by mass or less, 30% by mass or less, 25% by mass or less, or 20% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
When a soluble-type water-soluble lubricant classified as A2 as stipulated in JIS K2241: 2017 is prepared, the content of the component (D) may be 20% by mass or more, 30% by mass or more, or 40% by mass or more, and may be 80% by mass or less, 70% by mass or less, or 60% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
When a solution-type water-soluble lubricant classified as A3 as stipulated in JIS K2241: 2017 is prepared, the content of the component (D) may be 20% by mass or more, 30% by mass or more, 40% by mass or more, 50% by mass or more, 55% by mass or more, 60% by mass or more, 65% by mass or more, or 70% by mass or more based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
From the same point of view as above, the content of the component (D) in the water-soluble lubricant according to an embodiment of the present invention is preferably 1.0% by mass or more, more preferably 2.0% by mass or more, even more preferably 5.0% by mass or more, still more preferably 7.0% by mass or more, and particularly preferably 10% by mass or more, and preferably 60% by mass or less, more preferably 50% by mass or less, even more preferably 40% by mass or less, still more preferably 35% by mass or less, and particularly preferably 30% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant.
The component (D) used in an embodiment of the present invention may be any of monoamine having an amino nitrogen atom in a molecule, diamine having two amino nitrogen atoms in a molecule, and polyamine having 3 or more amino nitrogen atoms in a molecule.
Polyamine also includes a cyclic compound having a triazine skeleton, such as hexahydro-1,3,5-tris-(2-hydroxyethyl)triazine.
Among them, it is preferable that the component (D) used in an embodiment of the present invention includes monoamine in order to obtain a water-soluble lubricant which can provide an aqueous metalworking fluid with more improved antibacterial properties, antirust properties, workability, and the like.
Monoamines used as the component (D) in an embodiment of the present invention are classified into primary amines represented by the following formula (i), secondary amines represented by the following formula (ii) and tertiary amines represented by the following formula (iii) depending on the number of substituents R.
In the above formulae, R each independently represents a substituent. A plurality of R may be the same or may be different from each other. Examples of the substituent include an alkyl group, a hydroxyalkyl group, an alkenyl group, a cycloalkyl group, a phenyl group, and a benzyl group.
Examples of the alkyl group that can be selected as a substituent R include a methyl group, an ethyl group, a propyl group (a n-propyl group, an i-propyl group), a butyl group (a n-butyl group, an i-butyl group, a s-butyl group, a t-butyl group), a pentyl group (a n-pentyl group, an i-pentyl group, a neopentyl group), a hexyl group, a heptyl group, an octyl group, a 2-ethylhexyl group, a nonyl group, a decyl group, a undecyl group, a dodecyl group, a tridecyl group, a tetradecyl group, a pentadecyl group, a hexadecyl group, a heptadecyl group, and an octadecyl group.
The alkyl group may be a linear alkyl group or may be a branched alkyl group.
From the same viewpoint as above, the number of carbon atoms of the alkyl group is preferably 1 to 30, more preferably 1 to 20, even more preferably 1 to 10, yet more preferably 1 to 6, and particularly preferably 1 to 4.
Examples of the hydroxyalkyl group that can be selected as a substituent R include groups obtained by replacing at least one hydrogen atom of the above alkyl groups with a hydroxyl group.
The alkyl group that constitutes the hydroxyalkyl group may also be a linear alkyl group or may be a branched alkyl group.
From the same viewpoint as above, the number of carbon atoms of the hydroxyalkyl group is preferably 1 to 30, more preferably 1 to 20, even more preferably 1 to 10, yet more preferably 1 to 6, and particularly preferably 2 to 4.
Examples of the alkenyl group that can be selected as a substituent R include an ethenyl group (a vinyl group), a propenyl group, a butenyl group, a pentenyl group, a hexenyl group, a heptenyl group, an octenyl group, a nonenyl group, a decenyl group, a dodecenyl group, a tridecenyl group, a tetradecenyl group, a pentadecenyl group, a hexadecenyl group, and an octadecenyl group.
The alkenyl group may be a linear alkenyl group or may be a branched alkenyl group.
From the same viewpoint as above, the number of carbon atoms of the alkenyl group is preferably 1 to 30, more preferably 1 to 20 carbon atoms, even more preferably 1 to 10 carbon atoms, yet more preferably 1 to 6 carbon atoms, and particularly preferably 1 to 3 carbon atoms.
Examples of the cycloalkyl group that can be selected as a substituent R include a cyclopropyl group, a cyclobutyl group, a cyclopentyl group, a cyclohexyl group, a cycloheptyl group, a cyclooctyl group, and an adamantyl group.
From the same viewpoint as above, component (D) used in one embodiment of the present invention preferably contains alkanolamine having at least one hydroxyalkyl group.
Examples of alkanolamine include primary alkanolamine in which R in the above formula (i) is a hydroxyalkyl group, secondary alkanolamine in which at least one R in the above formula (ii) is a hydroxyalkyl group, and tertiary alkanolamine in which at least one R in the above formula (iii) is a hydroxyalkyl group.
Examples of primary alkanolamines include ethanolamine, n-propanolamine, isopropanolamine, n-butanolamine, isobutanolamine (2-amino-2-methyl-1-propanol) and t-butanolamine.
Examples of secondary alkanolamine include monoethanolamine such as N-methylethanolamine, N-ethylethanolamine, N-propylethanolamine, N-butylethanolamine, N-octylethanolamine, N-stearylethanolamine, N-oleylethanolamine, N-cyclohexylethanolamine, N-phenylethanolamine, and N-benzylethanolamine; monopropanolamine such as N-methylpropanolamine, N-ethylpropanolamine, N-propylpropanolamine, N-butylpropanolamine, N-octylpropanolamine, N-stearylpropanolamine, N-oleylpropanolamine, N-cyclohexylpropanolamine, N-phenylpropanolamine, and N-benzylpropanolamine; diethanolamine, and dipropanolamine.
Examples of tertiary alkanolamine include monoethanolamine such as N-dimethylethanolamine, N-diethylethanolamine, N-dipropylethanolamine, N-dibutylethanolamine, N-dioctylethanolamine, N-distearylethanolamine, N-dioleylethanolamine, N-dicyclohexylethanolamine, N-diphenylethanolamine, and N-dibenzylethanolamine; monopropanolamine such as N-dimethylpropanolamine, N-diethylpropanolamine, N-dipropylpropanolamine, N-dibutylpropanolamine, N-dioctylpropanolamine, N-distearylpropanolamine, N-dioleylpropanolamine, N-dicyclohexylpropanolamine, N-diphenylpropanolamine, and N-dibenzylpropanolamine; diethanolamine such as N-methyldiethanolamine, N-ethyldiethanolamine, N-propyldiethanolamine, N-butyldiethanolamine, N-octyldiethanolamine, N-stearyldiethanolamine, N-oleyldiethanolamine, N-cyclohexyldiethanolamine, N-phenyldiethanolamine, and N-benzyldiethanolamine; dipropanolamine such as N-methyldipropanolamine, N-ethyldipropanolamine, N-propyldipropanolamine, N-butyldipropanolamine, N-octyldipropanolamine, N-stearyldipropanolamine, N-oleyldipropanolamine, N-cyclohexyldipropanolamine, N-phenyldipropanolamine, and N-benzyldipropanolamine; triethanolamine, and tripropanolamine.
The content of alkanolamine may be 5% by mass or more, 10% by mass or more, 20% by mass or more, 30% by mass or more, 35% by mass or more, or 40% by mass or more, and may be 100% by mass or less, 95% by mass or less, 90% by mass or less, 85% by mass or less, 80% by mass or less, 75% by mass or less, 70% by mass or less, or 65% by mass or less based on the total amount (100% by mass) of component (D) contained in the water-soluble lubricant.
From the same viewpoint as above, component (D) used in one embodiment of the present invention preferably contains alicyclic amine.
Examples of alicyclic amine include primary alicyclic amine wherein R in the above formula (i) is a cycloalkyl group, secondary alicyclic amine wherein at least one R in the above formula (ii) is a cycloalkyl group; and tertiary alicyclic amine wherein at least one R in the above formula (iii) is a cycloalkyl group.
Examples of primary alicyclic amine include N-cyclohexylamine.
Examples of secondary alicyclic amine include monocyclohexylamine such as N-methylcyclohexylamine, N-ethylcyclohexylamine, N-propylcyclohexylamine, and N-oleylcyclohexylamine; monocyclohexylalkanolamine such as N-cyclohexylethanolamine and N-cyclohexylpropanolamine; and N-dicyclohexylamine.
Examples of tertiary alicyclic amine include dialkylmonocyclohexylamine such as N-dimethylcyclohexylamine, N-diethylcyclohexylamine, N-dipropylcyclohexylamine, N-dioleylcyclohexylamine, and N-dicyclohexylamine; monocyclohexyldialkanolamine such as N-cyclohexyldiethanolamine and N-cyclohexyldipropanolamine; monoalkyldicyclohexylamine such as N-methyldicyclohexylamine, N-ethyldicyclohexylamine, N-propyldicyclohexylamine, and N-oleyldicyclohexylamine; dicyclohexylalkanolamine such as N-dicyclohexylethanolamine and N-dicyclohexylpropanolamine; and tricyclohexylamine.
The content of alicyclic amine may be 10% by mass or more, 20% by mass or more, 25% by mass or more, 30% by mass or more, or 35% by mass or more, and may be 100% by mass or less, 95% by mass or less, 90% by mass or less, 85% by mass or less, 80% by mass or less, 75% by mass or less, 70% by mass or less, or 65% by mass or less based on the total amount (100% by mass) of component (D) contained in the water-soluble lubricant.
Preferably, the water-soluble lubricant of one embodiment of the present invention further contains a fatty acid (E).
Containing component (E), the water-soluble lubricant is capable of becoming an aqueous metalworking fluid having more increased emulsion stability, antirust properties, workability, and the like.
In the water-soluble lubricant of one embodiment of the present invention, one component (E) may be used singly, or two or more may be used in combination.
From the same point of view as above, the content of the component (E) in the water-soluble lubricant according to an embodiment of the present invention is preferably 1.0% by mass or more, more preferably 2.0% by mass or more, even more preferably 5.0% by mass or more, still more preferably 7.0% by mass or more, and particularly preferably 10% by mass or more, and preferably 70% by mass or less, more preferably 60% by mass or less, even more preferably 50% by mass or less, still more preferably 40% by mass or less, and particularly preferably 30% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
While the content of the component (E) is also in the above range even when preparing an emulsion-type water-soluble lubricant classified as A1, a soluble-type water-soluble lubricant classified as A2 and a solution-type water-soluble lubricant classified as A3 as stipulated in JIS K2241: 2017, at least one of the lower limit and the upper limit may be in the range described below.
When an emulsion-type water-soluble lubricant classified as A1 as stipulated in JIS K2241: 2017 is prepared, the content of the component (E) may be 12% by mass or more, 15% by mass or more, 17% by mass or more, 20% by mass or more, or 22% by mass or more based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
When a soluble-type water-soluble lubricant classified as A2 as stipulated in JIS K2241: 2017 is prepared, the content of the component (E) may be 12% by mass or more or 15% by mass or more, and may be 25% by mass or less, 22% by mass or less, or 20% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
When a solution-type water-soluble lubricant classified as A3 as stipulated in JIS K2241: 2017 is prepared, the content of the component (E) may be 25% by mass or less, 22% by mass or less, 20% by mass or less, 17% by mass or less, or 15% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
From the same point of view as above, the content of the component (E) in the water-soluble lubricant according to an embodiment of the present invention is preferably 0.1% by mass or more, more preferably 0.5% by mass or more, even more preferably 1.0% by mass or more, still more preferably 1.5% by mass or more, and particularly preferably 2.0% by mass or more, and preferably 60% by mass or less, more preferably 50% by mass or less, even more preferably 40% by mass or less, still more preferably 35% by mass or less, and particularly preferably 30% by mass or less based on the total amount (100% by mass) of the water-soluble lubricant.
In the water-soluble lubricant according to an embodiment of the present invention, the mass ratio of the content of component (D) to the content of component (E) [(D)/(E)] is preferably 0.01 to 10.0, more preferably 0.05 to 9.0, even more preferably 0.1 to 8.5, still more preferably 0.2 to 8.0, yet more preferably 0.3 to 7.5, and particularly preferably 0.5 to 7.0 in order to obtain a water-soluble lubricant which can provide an aqueous metalworking fluid having excellent stock solution stability and more improved workability.
Examples of component (E) used in one embodiment of the present invention include fatty acid, hydroxy fatty acid, aliphatic dicarboxylic acid, dimer acid of fatty acid, and polymerized fatty acid of hydroxy unsaturated fatty acid.
Examples of the fatty acids include a saturated aliphatic monocarboxylic acid such as octanoic acid, 2-ethylhexanoic acid, trimethylhexanoic acid, decanoic acid, neodecanoic acid, undecanoic acid, dodecanoic acid, tridecanoic acid, pentadecanoic acid, heptadecanoic acid, nonadecanoic acid, myristic acid, palmitic acid, stearic acid, arachic acid, behenic acid and isostearic acid, and unsaturated aliphatic monocarboxylic acid such as octenoic acid, nonenoic acid, decenoic acid, undecenoic acid, oleic acid, elaidic acid, erucic acid, nervonic acid, linoleic acid, γ-linolenic acid, arachidonic acid, α-linolenic acid, stearidonic acid, eicosapentaenoic acid and docosahexaenoic acid.
A mixture of unsaturated fatty acid may be used, such as tall oil fatty acid, soybean oil fatty acid, palm oil fatty acid, linseed oil fatty acid, rice bran oil fatty acid, and cottonseed oil fatty acid.
The number of carbon atoms in the fatty acid is preferably 8 to 30, more preferably 10 to 25, and even more preferably 10 to 20.
Examples of the hydroxy fatty acid include hydroxylauric acid, hydroxymyristic acid, hydroxypalmitic acid, hydroxystearic acid, hydroxyarachic acid, hydroxybehenic acid, and hydroxyoctadecenoic acid.
The number of carbon atoms of the hydroxy fatty acid is preferably 8 to 30, more preferably 10 to 25, and even more preferably 10 to 20 carbon atoms.
Examples of the aliphatic dicarboxylic acid include sebacic acid, dodecanedioic acid, dodecylsuccinic acid, laurylsuccinic acid, stearylsuccinic acid, and isostearylsuccinic acid.
The number of carbon atoms of the aliphatic dicarboxylic acid is preferably 8 to 30, more preferably 10 to 25, and even more preferably 10 to 20 carbon atoms.
Examples of the hydroxy unsaturated fatty acid constituting a polymerized fatty acid of the hydroxy unsaturated fatty acid include ricinoleic acid (12-hydroxyoctadec-9-enoic acid). A fatty acid mixture containing recinoleic acid, such as castor oil, may be used.
Examples of the polymerized fatty acid of the hydroxy unsaturated fatty acid include condensed fatty acid that is a dehydrative polycondensation product of hydroxy unsaturated fatty acid, and condensed fatty acid obtained by dehydratively condensing an alcoholic hydroxyl group of condensed fatty acid that is a dehydrative polycondensation product of hydroxy unsaturated fatty acid and monocarboxylic acid.
The component (E) has an acid value of usually 0 mgKOH/g or more, preferably 5 to 120 mgKOH/g, more preferably 10 to 100 mgKOH/g, and even more preferably 15 to 90 mgKOH/g in order to obtain a water-soluble lubricant which can provide an aqueous metalworking fluid having more improved workability.
While the acid value of the component (E) is also in the above range even when preparing an emulsion-type water-soluble lubricant classified as A1, a soluble-type water-soluble lubricant classified as A2 and a solution-type water-soluble lubricant classified as A3 as stipulated in JIS K2241: 2017, at least one of the lower limit and the upper limit may be in the range described below.
When an emulsion-type water-soluble lubricant classified as A1 as stipulated in JIS K2241: 2017 is prepared, the component (E) may have an acid value of 20 mgKOH/g or more, 30 mgKOH/g or more, 40 mgKOH/g or more, or 50 mgKOH/g or more.
When a soluble-type water-soluble lubricant classified as A2 as stipulated in JIS K2241: 2017 is prepared, the component (E) may have an acid value of 20 mgKOH/g or more, or 30 mgKOH/g or more, and may have an acid value of 70 mgKOH/g or less, or 50 mgKOH/g or less.
When a solution-type water-soluble lubricant classified as A3 as stipulated in JIS K2241: 2017 is prepared, the component (E) may have an acid value of 70 mgKOH/g or less, 50 mgKOH/g or less, 40 mgKOH/g or less, or 30 mgKOH/g or less.
The hydroxyl value of component (E) is preferably 0 to 80 mgKOH/g, more preferably 0 to 60 mgKOH/g, and even more preferably 0 to 40 mgKOH/g.
From the above viewpoint, the ratio of the acid value to the hydroxyl value of component (E) [acid value/hydroxyl value] is preferably 1.5 to 50, more preferably from 2.0 to 40, and even more preferably from 2.5 to 30.
Herein, the acid value means a value measured in accordance with JIS K 2501:2003 (indicator photometric titration method), the hydroxyl value means a value measured in accordance with JIS K 0070:1992.
The water-soluble lubricant according to an embodiment of the present invention may also include a nonionic surfactant. By including the nonionic surfactant, a water-soluble lubricant which can provide an aqueous metalworking fluid having more improved emulsion stability and workability can be obtained.
In the water-soluble lubricant according to an embodiment of the present invention, one nonionic surfactant may be used alone, or two or more of them may be used in combination.
From the above point of view, the content of the nonionic surfactant in the water-soluble lubricant according to an embodiment of the present invention is preferably 0.5 to 30.0% by mass, more preferably 1.0 to 30.0% by mass, even more preferably 1.5 to 20.0% by mass, still more preferably 2.0 to 15.0% by mass, and particularly preferably 2.5 to 10.0% by mass based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
From the above point of view, the content of the nonionic surfactant in the water-soluble lubricant according to an embodiment of the present invention is preferably 0.1 to 15.0% by mass, more preferably 0.5 to 12.0% by mass, even more preferably 1.0 to 10.0% by mass, still more preferably 1.5 to 8.0% by mass, and particularly preferably 2.0 to 6.0% by mass based on the total amount (100% by mass) of the water-soluble lubricant.
The nonionic surfactant used in an embodiment of the present invention has a HLB of preferably 6.0 or more, more preferably 7.0 or more, even more preferably 8.0 or more, still more preferably 9.0 or more, and particularly preferably 10.0 or more, and 18.0 or less, preferably 17.0 or less, more preferably 16.0 or less, even more preferably 15.0 or less, and still more preferably 14.5 or less in order to obtain a water-soluble lubricant which can provide an aqueous metalworking fluid having more improved emulsion stability and workability.
Herein, HLB means a value calculated by Griffin's method.
Examples of the nonionic surfactant used in one embodiment of the present invention include alkylene glycol, polyoxyalkylene alkyl ether, polyoxyalkylene aryl ether, polyoxyalkylenealkylamine (a cocoamine alkylene oxide adduct), an alkylphenol alkylene oxide adduct, a higher alcohol alkylene oxide adduct, a polyoxyalkylene fatty acid ester, a fatty acid ester of glycerin and pentaerythritol, a fatty acid ester of sucrose, a fatty acid ester of a polyoxyalkylene adduct of polyhydric alcohol, alkyl polyglycoside, and fatty acid alkanolamide.
Among them, the nonionic surfactant used in an embodiment of the present invention preferably includes one or more selected from polyoxyalkylene alkyl ether and polyoxyalkylene alkylamine in order to obtain a water-soluble lubricant which can provide an aqueous metalworking fluid with more improved emulsion stability and workability.
The total content of the polyoxyalkylene alkyl ether and polyoxyalkylene alkylamine is preferably 50 to 100% by mass, more preferably 70 to 100% by mass, even more preferably 80 to 100% by mass, still more preferably 90 to 100% by mass, and particularly preferably 95 to 100% by mass based on the total amount (100% by mass) of the nonionic surfactant contained in the water-soluble lubricant.
The water-soluble lubricant according to an embodiment of the present invention may also include one or more selected from an anionic surfactant and cationic surfactant.
Examples of the anionic surfactant include polyoxyethylene alkyl ether carboxylic acids, alkylbenzene sulfonic acids, α-olefinsulfonic acids, and salts thereof.
The acid value of anionic surfactants is preferably 20 to 250 mgKOH/g, more preferably 30 to 200 mgKOH/g, even more preferably 40 to 190 mgKOH/g, and yet more preferably 50 to 180 mgKOH/g.
Examples of cationic surfactants include alkyltrimethylammonium salts, dialkyldimethylammonium salts, and alkyldimethylbenzylammonium salts.
The water-soluble lubricant according to an embodiment of the present invention comprises the component (A) and thus allows metals to be highly corrosion resistant even if the water-soluble lubricant does not contain a phosphorus-containing compound as an anti-tarnish agent. Furthermore, studies by the present inventors have revealed that phosphorus-containing compounds reduce compatibility with FIPG.
By contrast, since the water-soluble lubricant according to an embodiment of the present invention comprises the component (A), the water-soluble lubricant can maintain good compatibility with FIPG even if it contains a phosphorous-containing compound. However, in order to obtain a water-soluble lubricant which can provide an aqueous metalworking fluid with more improved compatibility with FIPG, it is preferable that the water-soluble lubricant according to an embodiment of the present invention contains substantially no phosphorus-containing compound.
Examples of phosphorus-containing compounds include phosphate, phosphite, thiophosphate, a salt thereof, phosphine and tricresyl phosphate.
As used herein, “containing substantially no phosphorus-containing compound” is a definition that rejects an embodiment in which a phosphorous-containing compound is intentionally included, and the term does not reject an embodiment in which a phosphorous-containing compound is unintentionally mixed as an impurity in other components. Even in consideration of the embodiment of unintentional mixing of the phosphorous-containing compound, it is preferable that the content of the phosphorous-containing compound is as small as possible in order to obtain a water-soluble lubricant which can provide an aqueous metalworking fluid having more improved compatibility with FIPG.
The content of the phosphorus-containing compound is specifically preferably less than 10 parts by mass, more preferably less than 1 part by mass, even more preferably less than 0.1 part by mass, still more preferably less than 0.01 part by mass, and particularly preferably less than 0.001 part by mass based on 100 parts by mass of the total amount of the component (A) contained in the water-soluble lubricant.
The water-soluble lubricant according to an embodiment of the present invention may also include additives in addition to the above components (A) to (F) as needed, as long as the effects of the present invention are not impaired.
Examples of other additives include petroleum sulfonates, extreme pressure agents other than phosphorus extreme pressure agents, metal deactivators, emulsification aids, antibacterial agents, antifoaming agents, antioxidants, and oily agents.
One of these various additives may be used singly, or two or more may be used in combination.
The content of the respective additives in the water-soluble lubricant according to an embodiment of the present invention is suitably set depending on the type and the function of the components, and is preferably 0.01 to 40% by mass, more preferably 0.07 to 30% by mass, and even more preferably 0.1 to 20% by mass based on the total amount (100% by mass) of the water-soluble lubricant excluding water.
The content of the respective additives in the water-soluble lubricant according to an embodiment of the present invention is suitably set depending on the type and the function of the components, and is preferably 0.01 to 20% by mass, more preferably 0.03 to 15% by mass, and even more preferably 0.05 to 10% by mass based on the total amount (100% by mass) of the water-soluble lubricant.
Examples of petroleum sulfonates include calcium sulfonate, sodium sulfonate, and magnesium sulfonate.
Examples of extreme pressure agents other than phosphorus extreme pressure agents include a chlorine extreme pressure agent such as chlorinated paraffin, chlorinated fatty acid and chlorinated fat oil; and a sulfur extreme pressure agent such as sulfurized olefin, sulfurized lard, alkyl polysulfide and sulfurized fatty acid.
Examples of metal deactivators include benzotriazoles, imidazolines, pyrimidine derivatives, and thiadiazoles.
Examples of emulsifying aids include unsaturated fatty acid esters such as methyl oleate, ethyl oleate, and propyl oleate; and aromatic alcohols such as 2-phenoxyethanol and 2-phenylethyl alcohol.
Examples of antibacterial agents include triazine compounds, alkylbenzimidazole compounds, and metal pyrithione salts.
Examples of antifoaming agents include silicone antifoaming agents, fluorosilicone antifoaming agents, and polyacrylates.
Examples of antioxidants include amine antioxidants such as alkylated diphenylamine, phenylnaphthylamine, and alkylated phenylnaphthylamine; and phenolic antioxidants such as 2,6-di-t-butylphenol, 4,4′-methylenebis (2,6-di-t-butylphenol), isooctyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate, and n-octadecyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate.
Examples of oily agents include alcohols such as lauryl alcohol, myristyl alcohol, palmityl alcohol, stearyl alcohol, and oleyl alcohol.
The method for producing a water-soluble lubricant of an embodiment of the present invention is not particularly limited, and is preferably a method comprising the step of blending the above component (A) and, optionally, the components (B) to (E) and various other additives. The order of blending the respective components can be suitably set.
The characteristic of the water-soluble lubricant according to an embodiment of the present invention is that the water-soluble lubricant can provide an aqueous metalworking fluid which allows metals to be more corrosion resistant.
Thus, it is preferable to use the water-soluble lubricant according to an embodiment of the present invention for metalworking of workpieces.
The workpiece is not particularly limited, and examples thereof include a workpiece composed of the metal described later.
However, in consideration of the above characteristic of the water-soluble lubricant according to an embodiment of the present invention, the water-soluble lubricant according to an embodiment of the present invention is suitable for use in metalworking of a workpiece comprising a member including a non-ferrous metal, and more suitable for use in metalworking of a workpiece comprising a member including aluminum.
Another characteristic of the water-soluble lubricant according to an embodiment of the present invention is that the water-soluble lubricant can provide an aqueous metalworking fluid which is also highly compatible with FIPG.
Thus, it is preferable to use the water-soluble lubricant according to an embodiment of the present invention, for example, for metalworking of workpieces treated using a formed-in-place gasket after metalworking.
The aqueous metalworking fluid according to an embodiment of the present invention is obtained by using the above water-soluble lubricant according to an embodiment of the present invention as a stock solution, and blending dilution water to the water-soluble lubricant.
Dilution water may be any of, for example, distilled water, ion exchanged water, tap water, or water for industrial use.
The amount of dilution water added when preparing the aqueous metalworking fluid, preferably, is suitably regulated so as to attain a desired dilute concentration.
The dilute concentration of the aqueous metalworking fluid of one embodiment of the present invention is preferably 1 to 50% by volume, more preferably 3 to 40% by volume, and even more preferably 5 to 30% by volume.
Herein, the “dilute concentration of the aqueous metalworking fluid” means a value calculated from the following equation:
“Dilute concentration of aqueous metalworking fluid (% by volume)”=[Volume of water-soluble lubricant before dilution]/[[Volume of water-soluble lubricant before dilution]+[Volume of dilution water]]×100
The aqueous metalworking fluid according to a preferred embodiment of the present invention allows metals to be more corrosion resistant and has higher compatibility with FIPG than conventional aqueous metalworking fluids, and can be suitably used in metalworking.
The target workpiece to be processed in metalworking using the aqueous metalworking fluid according to an embodiment of the present invention is not particularly limited. Examples thereof include a workpiece composed of metal selected from the group consisting of iron, titanium, aluminum, titanium alloy, alloy steel, nickel-based alloy, niobium alloy, tantalum alloy, molybdenum alloy, tungsten alloy, stainless steel, aluminum alloy, and high-manganese steel. Among these, the aqueous metalworking fluid is particularly suitable for a workpiece comprising a member including a non-ferrous metal, and more suitable for a workpiece comprising a member including aluminum.
Accordingly, the present invention can also provide [1] and [2] below:
[1] A method of use comprising applying the above aqueous metalworking fluid of one embodiment of the present invention to apply to a processing of a workpiece.
[2] A metalworking method comprising a step (1) of processing a workpiece by using the above aqueous metalworking fluid of one embodiment of the present invention.
The workpiece set forth in [1] and [2] is as described above, and is preferably a workpiece comprising a member including a non-ferrous metal, and is more preferably a workpiece comprising a member including aluminum. The methods set forth in [1] and [2] can effectively reduce corrosion of the workpiece.
In [1] and [2], examples of processing of the workpiece include cutting, grinding, punching, polishing, spinning, drawing, and rolling.
In the method of use according to [1] and the metalworking method according to [2], the aqueous metalworking fluid is used such that the above water-soluble lubricant of one embodiment of the present invention is blended with dilution water and then fed to, and thus brought into contact with, the workpiece. The aqueous metalworking fluid provides lubrication between the workpiece and the work tool. Moreover, the aqueous metalworking fluid is also used to remove swarf, prevent rust of the workpiece, cool the tool and the work piece, and the like.
In addition, the aqueous metalworking fluid according to an embodiment of the present invention has excellent compatibility with FIPG as described above.
Thus, it is preferable that in the above method of use [1], the workpiece is treated using a formed-in-place gasket after metalworking.
Furthermore, it is preferable that the above method for metalworking [2] comprises a step (2) of carrying out a treatment using a formed-in-place gasket after the step (1).
Even if the treatment using a formed-in-place gasket is carried out with the aqueous metalworking fluid according to an embodiment of the present invention being attached a workpiece, the aqueous metalworking fluid has excellent compatibility with FIPG, and workability in metalworking can be improved.
Next, the present invention will now be described in more detail by way of Examples, but the present invention is not limited to these Examples in any way.
In the following Examples, the methods for measuring and calculating the following physical property values are as follows:
(1) Kinematic viscosity, viscosity index
Measured and calculated in accordance with JIS K 2283:2000.
Calculated based on Griffin's method.
(3) Acid value (indicator photometric titration method)
Measured in accordance with JIS K 2501:2003 (indicator photometric titration method).
(4) Hydroxyl value
The hydroxyl value was measured according to JIS K0070: 1992.
Details of each component used in the preparation of the water-soluble lubricant used in Examples, Comparative Examples and Reference Examples are as follows.
The respective components of the types shown in Tables 1 to 4 were added and mixed in the amount shown in the Tables to prepare the respective water-soluble lubricants. Details of each component used in the preparation of the water-soluble lubricant are as described above. The water-soluble lubricants prepared in Examples 1 to 8, Comparative Examples 1 to 7 and Reference Examples 1 and 2 correspond to the solution-type oil classified as A3 as stipulated in JIS K2241: 2017, and the water-soluble lubricants prepared in Examples 9 to 16, Comparative Examples 8 to 14 and Reference Examples 3 and 4 correspond to an emulsion-type oil classified as A1 as stipulated in JIS K2241: 2017.
The water-soluble lubricants prepared were subjected to the following metal corrosion test. The results of the test are shown in Tables 1 to 4.
The water-soluble lubricants prepared in Examples and Comparative Examples were diluted 20-fold with ion exchange water to prepare an aqueous metalworking fluid with a concentration of 5% by volume.
An A6061 test piece and an ADC 12 test piece, i.e., aluminum alloy with both surfaces polished, were placed in a screw bottle, respectively, and then the aqueous metalworking fluid prepared was poured thereinto in such an amount that half of the test pieces was submerged in the fluid. Then the bottles were closed and allowed to stand in an environment of 60° C. for 2 hours.
After allowing to stand, whether the part of the test pieces which was submerged in the aqueous metalworking fluid (the submerged part) and the part of the test pieces which was not submerged therein (the gas phase part) were tarnished or not was visually compared with the test pieces before submerging. The tarnish resistance of aluminum was evaluated based on the following criteria.
Tables 1 to 4 show that since the aqueous metalworking fluids prepared by diluting the water-soluble lubricant prepared in Examples 1 to 16 with ion-exchanged water included the cyclic compound (A) having a pre-determined ring structure (α), both the A6061 test piece and the ADC12 test piece were not tarnished, and the tarnish resistance of aluminum was excellent as in the water-soluble lubricants of Reference Examples 1 to 4.
By contrast, for the aqueous metalworking fluids prepared by diluting the water-soluble lubricant prepared in Comparative Examples 1 to 14 with ion-exchanged water, which did not include the cyclic compound (A), at least one of the A6061 test piece and the ADC12 test piece was tarnished, and it was indicated that the tarnish resistance of aluminum had problems.
Examples 17 to 18, Reference Examples 5 and 6 The respective components of the types shown in Table 5 were added and mixed in the amount shown in the Table to prepare the respective water-soluble lubricants. Details of each component used in the preparation of the water-soluble lubricant are as described above. The water-soluble lubricants prepared correspond to the emulsion-type oil classified as A1 as stipulated in JIS K2241: 2017.
The water-soluble lubricants prepared were diluted 10-fold with ion exchange water to prepare an aqueous metalworking fluid with a concentration of 10% by volume. The aqueous metalworking fluid was subjected to the following FIPG compatibility test.
Two A1050 plates (length 100 mm×width 25 mm×thickness 1.6 mm) were prepared, and an area having a length of 10 mm and a width of 25 mm at an end of one surface of the A1050 plates was polished with No. 240sandpaper by reciprocating 10 times in the longitudinal direction and the horizontal direction, respectively, at a pressing force of 5 N to form an FIPG application part. Then the resultant was immersed in acetone and ultrasonically cleaned to give a test piece.
TB 1292D/TB 1293D (product name, ThreeBond Co., Ltd., two-component silicone-based liquid gasket)
(i) Two test pieces were immersed in the aqueous metalworking fluid, which was the object to be measured, for 5 seconds, and then the test pieces were set in a constant temperature bath at 23° C. and a relative humidity of 50% in such a manner that the longitudinal direction of the test pieces was the vertical direction. The test pieces were dried by allowing to stand in the environment for 1 hour.
(ii) A coating was formed by applying FIPG to the FIPG application part of one of the test pieces, with the area having a length of 10 mm and a width of 25 mm, so that the thickness after drying was 1.0 mm. The FIPG application part of the other test piece was bonded to the coating, and the resultant was allowed to stand in a constant temperature bath at 23° C. and a relative humidity of 50% for 24 hours to cure FIPG. A tensile test sample (1), which was two test pieces (11) and (12) bonded via FIPG (20) as shown in
(iii) The tensile test sample (1) was set on a tester, and the end of the two test pieces (11) and (12) was fixed, and the maximum shear stress when pulling the sample in vertical directions differing by 180° under the following tensile test conditions was measured. The shear stress was measured 7 times and the average value was determined as the maximum shear stress when using the aqueous metalworking fluid, which was the object to be measured. The average values of the maximum shear stress are shown in Table 5.
When operations (ii) and (iii) were carried out without immersing the two test pieces in the aqueous metalworking fluid of above (i) and the average value of the maximum shear stress was calculated, the average value of the maximum shear stress was “0.53 MPa.”
FIPG compatibility was evaluated based on the average value of the maximum shear stress measured according to the following criteria. The results of evaluation are shown in Table 5.
A: Average value of maximum shear stress of 0.35 MPa or more
F: Average value of maximum shear stress of less than 0.35 MPa.
Table 5 shows that since the aqueous metalworking fluids prepared in Examples 17 and 18 included the cyclic compound (A) having a pre-determined ring structure (α), the aqueous metalworking fluids kept good compatibility with FIPG, with an average value of the maximum shear stress of 0.35 MPa or more. By contrast, although the aqueous metalworking fluid as in Reference Example 5 prepared by diluting the water-soluble lubricant containing polyoxyethylene alkyl ether phosphoric acid had good tarnish resistance of aluminum as shown in Tables 2 and 4, but had poor FIPG compatibility.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2022-028519 | Feb 2022 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2023/004482 | 2/10/2023 | WO |
