emulsion
emulsion
Emulsion is a high performance semi-synthetic metal working fluid, particularly suitable for working aluminium and its alloys, but not for materials containing lead, such as some brass and tin metals. Product service life is very long, completely free from the leakage of oil, mixed with oil, it is best to use soft water for deployment. The emulsion is specially formulated without chlorine and is designed to solve various problems in the processing of aluminium and its alloys (e.g. chip bonding, tool wear, poor surface accuracy and surface contamination). It can be used in all kinds of operations, including stranding. Emulsion can also effectively prevent workpiece rust or chemical corrosion, but also effectively prevent bacterial erosion infection.
Chemical composition
Its main chemical components include: Water, base oils (mineral oils, vegetable oils, synthetic esters or mixtures of them), surfactants, anti-rust additives (zinc naphthenate, sodium petroleum sulfonate (also emulsifier), barium petroleum sulfonate, benzotriazole, Sorbitol monooleate, aluminum stearate), extreme pressure additives (polar compounds containing sulfur, phosphorus, chlorine and other elements), friction modifiers (anti-friction agents or oil additives), antioxidants.
Typical property
Flash point (concentrate)... no
20 oc when density (kg/L)... 0.89
PH (rising diluent)... 7.2-7.6
Emulsion stability... qualified
Foam... qualified
application
emulsion
Emulsion is a semi-synthetic processing liquid product containing mineral oil, which has the most advanced formulation technology, especially suitable for large-scale aluminum casting manufacturers. When replacing other ordinary soluble cutting oils with our products, the entire cooling circulation system should be thoroughly sterilized and cleaned.
Advantages of emulsion
1, the use of products can fully keep the environment clean, especially when compared with similar products, you will find: processed products can leave a layer of light liquid film, can be easily removed, convenient cleaning maintenance management.
2. The product effectively prevents the erosion effect of bacteria and fungi and saves the cost of storage and maintenance. The product also has good wetting adhesion characteristics, reduce the cutting fluid spill loss, but also clean the environment.
3, the product is particularly able to prevent metal welding, such as to prevent the accumulation of chips on the blade or workpiece welding; At the same time, it can effectively prevent the corrosion of common iron metal materials.
4, the product contains lubricating synergists, used to improve the surface quality of machining parts, and extend the life of the tool. It is compatible with most processed materials, including cast iron, steel, copper, aluminum alloys, and many plastics and compounds.
5, the user can use the existing technology, equipment, and according to the general treatment method to carry out the waste treatment of products.
Performance characteristics
The emulsion combines the lubricity and rust resistance of oil with the good cooling property of water, and has good lubrication and cooling property, so it is very effective for the high speed and low load metal cutting with a lot of heat generation. Compared with the oil based cutting liquid phase, the advantages of emulsion are greater heat dissipation, better cleaning, and the use of water dilution brought about by the economy, in addition, but also conducive to the operation of the site health and safety. In fact, in addition to the processing of particularly difficult materials, emulsion can be used for almost all light and medium load machining and most heavy load machining, emulsion can also be used for all grinding except thread grinding, groove grinding and other complex grinding. The disadvantage of emulsion is that bacteria and mold are easy to reproduce, so that the active ingredients in the emulsion produce chemical decomposition and odor, deterioration, so generally should be added to the organic fungicide with small toxicity.
Relevant data
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Dilution ratio
1, light load processing and grinding: 4 to 6 %
2, medium load processing and grinding: 6 to 8 %
3, heavy load processing and grinding: 8 to 12 percent
Maintenance and management
Emulsion is much more complex to maintain than oil-based cutting fluid. When preparing emulsion, water is first added to the tank, and then emulsified oil is added while stirring. Avoid adding water to oil, otherwise you will get water-in-oil emulsion, which has a large viscosity and is not suitable for general cutting use.
The water used to prepare the emulsion is very important. Hard water containing various minerals and salts often impedes the emulsification process. Emulsion prepared with hard water often quickly stratified, precipitated a lot of oil and water insoluble soap, affecting the use effect. In addition, if the water is too soft, bubbles may increase. Therefore, the preparation of emulsion to understand the water quality in advance, such as water quality is too hard must be pretreated, can be added in the water mass fraction of 0.1% ~ 0.3% sodium tripolyphosphate or sodium diethylamine acetate can play a role in reducing the hardness of water quality. But adding sodium tripolyphosphate too much will lead to the reproduction of bacteria, mold. So if the local tap water is too hard, it's best to use deionized water.
The fatty oils and unsaturated fatty acids contained in the emulsion are easily eroded by microorganisms. Encountered in the emulsion of microorganisms have three kinds of bacteria, fungi and algae, these three kinds of microbes have an adverse effect on the stability of the emulsion 㳖. Many emulsions contain fungicides, but the amount added is limited by oil solubility. When the emulsion is prepared, the concentration of the fungicide is further reduced, thus reducing its bactericidal effect. After the emulsion is eroded by microorganisms, the unsaturated fatty acids and other compounds in the emulsion are decomposed by microorganisms, destroying the balance of the emulsion, resulting in oil and soap extraction, increasing the acid value of the emulsion and causing the deterioration of the emulsion.
The rot of emulsion
1. Slight odor of corruption occurs;
2, the emulsion from milky white to gray brown;
3, pH value, rust resistance drops sharply;
4, emulsion oil and water separation, generating sediment or sludge and other substances, blocking the filter screen;
5, cutting, grinding performance decline;
6, the odor spread to the whole workshop, so that the operating environment deteriorated, had to replace the new cutting fluid.
To prevent the emulsion from spoiling, measures can be taken:
1, injection of new liquid, first of all to remove the material around the machine tool and liquid supply system such as debris and oil, and disinfection with fungicide before adding the new liquid. Not cleaning it out means introducing rotten bacteria into the new solution.
2, emulsion dilution to use tap water or soft water, avoid the use of Escherichia coli and inorganic salts of groundwater.
Replenishment should be managed to keep the emulsion working at the required concentration. The dilute concentration of the emulsion encourages the growth of bacteria.
3, when it is found that the pH value has a tendency to decrease, the pH value should be added to increase agents (such as sodium carbonate), so that the pH value is maintained at about 9. When the pH of the emulsion is above 9, it is difficult for microorganisms to reproduce.
4, holidays and other long-term shutdown, should be regularly pumped into the liquid box into the air, to prevent the reproduction of anaerobic bacteria, but also to remove odor.
5. While paying attention to preventing oil leakage from mixing, install a device that can quickly remove oil leakage from mixing.
6. Adopt effective chip removal method to avoid chip accumulation in liquid box.
7, if perceived signs of corruption, should immediately add fungicide to kill bacteria.