Note: Descriptions are shown in the official language in which they were submitted.
B~6
HIGH PRODUCTION RATE CUTTING FLU~D AND COOLANT
-
This invention relates to a composition of matter ;
adapted for use both as a coolant and lubricating agent in
metal cutting, and more particularly pertains to a superior
cutting and cooling fluid which is based on non-petroleum oil
and is a water-in-oil emulsion which is capable of sustaining
high production rates for long periods of time.
In the machining of metals in operations such as
cutting, threading, tapping, grinding, honing, lapping,
milling, and the like, it is customary to flood the tool and
work with a coolant to carry away heat from the tool and
work, and normally such coolants are also so compounded as
to lubricate the operation. Because of the high unit
pressures involved, particularly in high-speed operations,
the cutting fluid, if used also as a lubricant, must be an
exceptionally capable lubricant. Many of such previously
known fluids are petroleum oil-based fluids which are oil-in-
water emulsions. The present invention relates to non-
petroleum-based cutting fluids.
It is an object of this invention to provide a
novel cutting and coolant fluid in the form of a water-in-oil
emulsion capable of being used either as formed or in dilute
form, preferably as formed, which will be effective as a
coolant and lubricant under the conditions noted. Another
object is to provide a composition which gives excellent
lubrication and cooling in a single fluid through use of
water-in-oil emulsions which lubricate by virtue of an
,~ .
- 1 -
.,
,
. . ,. ~ .. . .
89~L~
external oil phase and cool by heat capacity and by virtue
of the heat of vaporization of water. Another object i5 to
provide a stable, non-corrosive, rust-inhibiting, metal-
processing lubricant and coolant which has excep-tionally long
use life and can be degreased with water instead of
conventional solvents. The cutting fluid embodied herein
has been found to have an emollient effect on the hands of
workers exposed to it.
The design of modern metal-cutting machines often
requires that the lubricant be the coolant. In the present
invention, the water is present in an invert emulsion which
- means that the oil is the external phase to wet the metal
surfaces and the cutting fluid provides lubrication superior
to that of other emulsions. This overcomes the most common
complaint of poor lubrication for soluble cutting fluid.
When approaching the problem of providing an
. .
efficient and long-lasting lubricant-coolant, it must be
remembered that the efficiency of a coolant is dependent upon
its specific heat, i.e.., the amount of heat energy required
to raise the temperature of a unit weight of the material
one degree at temperatures below the vaporization temperature
and in some cases its heat of vaporization. While oils are
known to be good lubricants, they generally are poor coolants
as compared to water because the specific heat of mineral
oil, for example, is only about 0.5 that of water. On the
other hand, it is well known that except under special
conditions, water is not a good lubricant. In the instant
case, the fluid does not cool alone because of the specific
.~
-- 2 --
`
,
(4883)
!. 1(18~3916
- h~at Or the water it contalnsg lt provldeR ~uperlor cooling
becawe th~ water 18 converted to ~tea~n, ab~orbing heat due
to vaporiæ~ion Or the l~quld. It i~ thu~ required to add
m~keup w~ter to ~he ~uld a~ it i8 belng u~ed ln the cutting
5 oper~tion by mean8 well known,
Thc composltlon~ o~ thls in~ren~ion p~ d~ naximum
lubrlcatlon prope~tles and at the s~ne tlme act as eff'icient
coolan~. The compo8itlon8 oi~ thi~ lnvention maln~ain
st~ility under ~lent and operating conditlon~ over ~
10 con~lderable range o~ water conte~t and worki~; conditlon~,
The composltion~ of thi~ invention readlly re- emulsl~y water
which i~ added as ~nakeup i':'or that lost by ~raporlz~tlon durlng
the coolant functlon.
Th~ combination of ethoxylated ~a~tor oil and a
,
15 ~atty a~id ~mide or dietha~ol ~mine constltute~ an e~flcient
emul~ er ~y~t~m when used ln con~unction with an oily
material o~ a ~p~cl~ic type. Awcil iary conv~r~tion~l
emul~i~iers ~uch aB xosin ~cid ~alt~ ~nd sodl~ petroleum
.~ 5Ul~Ollate can be u~ed as ad~unct~, but are not e~sentlal.
20 The o~ly mat~rial ~onnirlg the ~xternal pha~e o~ th~
COmpO8i~iOlU Q~ thi~ lnv~n~lon pre~rably 18 mad~ up o~
chemlc~l~ protridi~g activ~ ~peciea (S~, Cl) known to b~
ctlve lubrica~ing ag2nt~ in motal cuttlng (~ urlz~d
~st~r~,. sul:~uri~d lard oilg chlorln0.ted p~ra~ , etc. ~,
: . 25 Natural ~at~, ~uch a~ re~ined lard oil, al~o c~n ba u~ed,
Pr~f~rr~d are those oily materlals of the ~or~going typ~
whlch are of r~latively low ~riscosity (30-lO00 SSU at 100F) .
~ h~ composltlons Or thi~ in~ention ean also contaln
the u~ nti~ t agentsJ, blocid~ fo~m lnhlbitors, and
30 the li~.
_
.
': .
~883)
Typlc&l ~o~qnulatlon~ oi~ the composlt1one o~ thl~
inventlon w~ all within the follo~ring rsn~e~:
:Broad Pre~err~d
low vi~co~lty lnactive 15-84 22-48
or active Eulhlrized e3ter
o~ an ol~lnic ~tty acid
ro~ln ~cid ~oap 0-10 3_6
el;hox~rlat~d castor o~ 8-25 10-20
amlde Or diethar~ol a~in~ 8-25 10~20
and h ~tty acid
blocid~-:eunglcide 0_8 .1-5
c~orinated ~at or fa~ty 0-15 210
, ~cld e~ter
E~mine-type ru~t inhibitor 0-10 0-7
Na N02 0-5 0-3, 5
rO~m lnhibitor 0_3 0-2
:1 wat~r (~lstilled or o-60 ~30
'! deiorllzed~
In the ~ollowir2g exa~ which wlll i~urtheP
lllu~trate thl~ lnverltiQn, the ~unt8 o~ lngr~di.ent~ ~re
5 expr~s~d ln p~rta by w~ight unles~ oth~ lndlc~te~4
A cuttln~ oil corltalnlng inactl~ ur ~nd
chlorlne wa~l prepared u~ing the rollowing lnlsroGiont~:
- 4_
"' ' ' , , .
~89~ ~
Ingredient Parts
: low-viscosity aetive 20
sulfurized ester of an
olefinic fatty acid
low-viscosity synthetic27
fatty aeid ester
ethoxylated castor oil13
amide of diethanol amine 13
and coconut fatty acid
chlorinated synthetie 5
fatty acid ester
(28.30% Cl) blown to
300 SUS at 100F
Na NO2 1.5
water (deionized) 20.5 :~
'`
E_ample 2
A eutting oil was prepared using the following
ingredients:
.. .
Ingredient Parts
low-viseosity inaetive 39.65
sulfurized fat
ethoxylated castor oil 16
amide of diethanol amine 16
and coeonut aeid
morpholine bioeide-fungieide 0.15 .. .
ehlorinated methyl stearate 7.5
(20% Cl)
1 Na NO2 0.2
~ 30 water (deionized) 20.5
:
.
-- 5 -- .
8~L6 (4~83)
.,
Exampl 3
An actl~re~ ur cutt'Ln~s oil wa~ pr~r~d u~ing
the ~ollowlrlg ~ngredle~t~:
P~
hlghly stalfurlzed ~t~r 25. 91
Or an olerinlc rat~y acld
ro~in acld 4
t KOH 0.2
neutralized, e~teriri~d 13
e~hoxylated c~stor oil
.. eth~xylated ca~tor oil 4
amide o~ dlethanol hmin~ 13
and coconut acid
~orpholine-type 3~ 87
bioclde-funglcide
chlorlnated m~t~ t~r~e 7. 5
trlethanol ~mlne 7
Na NO2
.
wat~r (d~mineralized) 20~, 5
i
A pe~ um oil-b8~d cuttin~ o~l which i~ o~tsld~
th~ ~cop~ o~ th~ pre~ent inven~ior~ but lnclud~d ~or comp~ri~on
5 pu~po~ell wall prepared ~rom th~ ~ollowlng lngrl~dlemtll:
~ 6
:
,~
~38~g~ 883)
~~di~nt P~rt~
lOO~ec. n~phthenlc oll 81, 84
500-~ec. n~phthen~ oll 9. 09
eulfur " 9
sul~urized terpenæ l. 72
sulfurized l~rd oil, viRcous 4
chlorinated wax (65,~ Cl) 0.45
polyisobutylene 2
.~
.,. ~ .
,4nother p~trol~um oil-ba~ed cutting oll outslde
~he ~cop~ or this lnv~tion which could ~e ~ lrl~a to ~
wat~r-in-oil emul~ion other~ slmil~r to that d~cP~ib~d ln
l~le 1 w~ prepared ~rom the ~ollowing lngredi~nt~:
:'
~ P~
lO0-s~e. p~r~r~lnic 31. 44
neutral oll
hlghly ~ uriz~d ol~inic 9.65
r~tty acld ~st~r
~ulfur 0. 19
sul~urlz~d terpene 2. 70
chlorgnated p~ra~in 0.43
~odium petroleum sul~onat~ 15. 44
e~ul~lfier
etho~rlat~d c~tor oil 5079
ami~e of dl~thanol ~ e 9"65
and coconut acid
rosln acid 3
K~ 0 ,, ~7
N~ N02 1. 45
wo,t~r (deionized) l~, ?9
;~
- 7
,
, ' : , . . . .
883)
~08~9J~6
.~ ~le 6
The ~rlou~ cutting 0il8 described in the
;:; pr~cedin~ ~x~npl~ were evaluated on ~ te~t-cuttl~ D~c2~ine
~hlch was a 1 and 1~4-lnch.. 6-~lpindle ~ew Br~talrl Model 52
~utomatic screw machlne whlch ~ra~ u~d to manur~ctur~ ~n
5 ASl~M part ~rom l-lnch b~r ~tock. Th~ test con~itlona o~
machlne operation were ~d,~usted 30 ~L8 to caus~ tool ~allure
wlthin 0. 6- to 8-hour period (normal workin~ tim~ durlng on~
~hl~), Tool ~allure 18 cau~ed by the occurrulce o~ one or
~ore o~ three: (l) over~iz~ cut p~ c0,used by ~xc~sl~
; 10 tool wear3 (2) under~lze cut part c~used by wsld~illg of~ m t~l
onto the tool cutting edge, e.nd (3) finl~h ~ailure on the
p~rt. Thi~ 1~ exces~lve :I'OUghlle~811 on the ~urf~ce Or the part~,
.,
~'A`. ~or each cutt1ng oil, th~ tool r~d an~ spindle
peed o~ the nachine were adju~ted to give ~rom 6 to 8 hour~
15 of continuou~ operatlon b2fore tool fallure occurred. Th~
productlon rate wa8 than determlned. AdJu~tment~ were m~de
in r~ed and ~peed ~o a~ to giv~ the hi~she~t po~ibl~ r~te o~
- production o~ part~ wlthin the 6_ to 8~hour p~riod ~or a
gi~ren cutt1n~s oil. The productlon rate 1~ expr~ a ln p~l'td
20 per hour or, r~re pre~erably, in ~econd~ per p0.2~ und~r
maximw~ productlon conditions a~ ~Qscr1bed ~bove.
The cutting oil~ were found to hav~ th~ l~ollowing
m~xlmum cuttlng r~te3:
. .
,
. .
-- 8 _
,
,; ,
9~
Cutting Oil Seconds Per Part
Example l Less than 11.8, more than 8.8.
Example 2 Less than 11.8.
Example 3 Less than 11.8.
Example 4 More than 19.5.
Example 5 Less than 13.7, more than 1108. .
,,."
.
.. ~ ,- .
.~ ' ' '.
., .
.
.~,' .
. . .
. .
.
:. .
': :
... .
. . .
.. . .
,, ~
. .
;' .:
. ~ . .
~' ~
: _ g _
. '
~8139~6
SUPPLEMENTARY DISCLOSURE
In accordance with the teachings of the Principal
Disclosure, a water-in-oil emulsion is disclosed which is cap-
able of sustaining high production rates as a coolant and lub-
rica-ting agent in metal cutting. The combination of ethoxy-
lated castor oil and a fatty acid amide of diethanol amine forms
an efficient emulsifier system when used in conjunctio~ with an
oily material of a specific type. Conventional auxiliary
emulsifiers such as rosin acid salts and sodium petroleum sul-
:j,
fonate can be used as adjuncts. The oily material is preferably
made up of chemicals providing active species (i.e. S, Cl)
known to be effective lubricating agents in metal cutting.
Natural fats, such as refined lard oil, may also be used. The
preferred oily materials are -those of relatively low viscosity
(30-1000 SSU at 100F).
Now, and in accordance with the Supplementary Dis-
closure teachings a metal-working fluid is disclosed which has
a superior combination of properties with respect -to the known
fluids and which enables production capacities in metal-shaping
operation to be significantly enhanced compared with present
; production rates.
In order to obviate this difficultly, conventional
oil-in-water emulsions have been widely used as metal-working
fluids. The oil phase of such emulsions serves to lubricate
the working parts while the water phase serves to absorb the
`` heat generated by the working operation. Unfortunately,
conventional oil-in-water emulsions exhibi-t relatively poor
lubricity properties due to the external water phase. Poor
lubricity results in premature tool failure due to abrasive
; 30 degradation when the emulsions are used.
.
- SD-10 -
:;
` ~L"?138~1~
;..
. .
In addition to conventional oil-in-water emulsions,
conventional water-in-oil emulsions have also enjoyed some
use as metal-working fluids. Water-in-oil emulsions are
similar to oil-in-water emulsions in that each has an oil
phase for improving the lubricity of the bearing parts and an
aqueous phase for absorbing heat generated by the working
operation. However, conventional water-in-oil emulsions have -~
relatively high viscosities and therefore are unsuitable for
many different uses, for example for use in automatic machines
~10 in which the cutting fluid is pumped and filtered. Also, con-
, . .
ventional water-in-oil emulsions, like oil-in-water emulsions,
are disadvantageous in that they are relatively unstable.
Hence, they must be exactly compounded and their compositions ~ -
must be strictly maintained so that they remain in an emulsion
state.
A still further suggestion had been to employ an
oil-in-water micellar emulsion as a cutting fluid. As is
known, a micellar emulsion is an emulsion in which the particle
size of the emulsified particles is so small that the emulsion
~! 20 as a whole is thermodynamically stable. Such emulsions, however,
exhibit comparatively poor lubricity properties due to the
~: ~
external water phase and hence exhibit many of the disadvantages
discussed above in connection with conventional oil-in-water
, ,
emulsions.
It is thus an aspect of the present invention to
provide an improved metal-shaping process wherein the new
metal-working fluid of the present invention is employed to
lubricate and cool the parts being worked.
~ These and other aspect are accomplished in accordance
; 30 with the present invention wherein a water-in-oil micellar emul-
sion is employed in a metal-shaping operation as the metal-
working fluid.
~ .
- SD 11 -
.:, . . . . .
.: . . . . .
.,-; ~, , .
~()8891~
..
Because oil is the external phase of this type
emulsion, the lubricity properties of the emulsion as a
whole are very high and hence the production rate of the
metal-working operation is not slowed due to poor lubricity. ~-
Furthermore, the presence of the water keeps the temperature
of the tool, chip, workpiece and metal-working fluid at a
relatively low level since evaporation of the water in the
metal-working fluid will remove much of the generated heat.
As a result of this combination of properties, it has been
10 found that production rates in conventional metal-working
operations such as cutting can be increased on the average
of at least 40% and as much as 70% and more compared with
. conventional operating procedures using conventional metal-
working fluid. Furthermore, the relatively low viscosities
~ of water-in-oil micellar emulsions (if appropriately com-
: pounded) enables them to be pumped and filtered by conven-
tional pumps and filters, which allows them to be used in ::
conventional automatic cutting machines without alteration.
Furthermore, because micellar emulsions are thermodynamic-
2C ally stable, they are extremely easy to formulate and to
maintain and hence use of micellar emulsions in accordance
with the present invention is very convenient.
Thus, there is provided an improved metal-shaping
process in which at least two parts bear against one another
for shaping at least one of the parts, at least one of the
parts being shaped being formed from a metal, a metal-working
fluid being deposited on at least.one of the parts for lubri-
cating and cooling the parts during the metal-shaping operation,
the improvement in accordance with the present invention
wherein the metal-working fluid is a water~in-oil micellar
emulsion.
- SD 12 -
~: ' ' ,, "
8139~t~
In addition, there is further provided a novel metal
working fluid for use in the above process, especially in
connection with shaping ferrous metals, the metal-working fluid
comprising a water-in-oil micellar emulsion containing water,
emulsifier and an oil phase, the oil phase exhibiting ferrous
metals EP (extreme pressure) properties.
The present invention relates to all types of
metal-shaping operations in which the shape of a metal work-
piece is changed by means of a procedure in which the metal
work-piece and a metal-working tool bear against one another.
In accordance with the invention, the inventive metal-
shaping operation can be accomplished by means of chip
removal (e.g. cutting) or by deformation without chip removal -
(e.g. forgoing, cold heading). Examples of metal-shaping
operations included within the purview of the present in-
vention are cutting, grinding, rolling, drawing, blanking,
broaching, slotting, milling, threading, drilling, tapping,
forming, hobbing, reaming, spinning, forging, cold heading
~ and the like. Furthermore, the metal working tool used to
.~ .,' .
shape the work-piece can be made from a metal or a non-metal
such as a ceramic, cemented carbide and so forth. Also, all
` types of metal (e.g. iron, aluminum, magnesium, copper, etc.)
can be shaped in accordance with the procedure of the present
invention.
The metal-shaping operation is facilitated by con-
, tacting the surfaces of the parts which bear against one an-! other during the metal-shaping operation (hereinafter referred
.,
',7, - SD 13 -
., .
.. . .
.
~8l39~6
.,
to as "bearing surfaces") with a water-in-oil micellar emul-
sion. The manner in which the micellar emulsion is contact-
ed with the bearing surfaces of the parts being worked is
unimportant, and any technique can be used. For example,
the micellar emulsion can be directed at the bearing surfaces
by means of suitable nozzles or the like, or the micellar
emulsion can be manually deposited on the bearing surfaces
before or during engagement of these surfaces in any con-
ventional metal-working technique. In a particular embodi-
ment of the present invention, the inventive micellar emul-
sions are intended for use in automatic cutting machines
which automatically direct one or more streams of cutting
fluid at the bearing surfaces by means of a cutting fluid
handling system including means for directing a stream of
cutting fluid at the bearing surfaces, means for recovering
cutting fluid from contact with the bearing surfaces, means
for recycling the recovered cutting fluid for additional
contact with the bearing surfaces and optionally and pre-
ferably filter means for filtering the recycling cutting
' 20 fluid to remove chips and the like therefrom.
As the metal working fluid used in the inventive
process, any water-in-oil micellar emulsion in which the oil
phase exhibits lubricating properties can be employed.
Specific additives may be included to tailor the emulsion
to the demands of a particular metal. As is known, a water-
in-oil emulsion is an emulsion in which oil is the external
phase and water is the internal phase. As is further knownv
. ' .
:
- SD - 14 ~
. "
.
1~ 9~
a micellar emulsion is an emulsion in which the particle
siæe of the particles emulsified is so small that the emul-
sion as a whole is thermodynamically stable. Thus, the
metal-working fluids employed in the inventive process are
emulsions in which particles of water are suspended in an
external oil phase, the particles of water being so small
that the emulsion as a whole is thermodynamically stable.
Micellar emulsions have been known for some time.
Many publications and patents have issued regarding the
properties and composition of these materials. Sometimes
they are referred to in the art as microemulsions, soluble -
oils, swollen micelles and so forth. For a thorough dis- ;
cussion of these materials, see W. C. Tosch, "Technology of
Micellar Solutions", Paper No. SPE 1847-b, Society of
Petroleum Engineers of A. I. M. E., copyright 1967, American
Institute of Mining, Metallurgical and Petroleum Engineers,
Inc. Also note Prince, Emulsions and Emulsion Technology,
- ~
copyright 1974 by Marcell Dekker, Inc., pages 125-179.
The water-in-oil micellar fluids employed in the
present invention are characterized as being transparent or
translucent but not milky-white. As is well known the
change in appearance of an emulsion (be it oil-in-water or
water-in-oil) from a transparent liquid through a trans-
lucent liquid and to a milky-white opaque liquid (such as
milk) is due to an increase in the particle size of the
emulsified phase from a value at which substantially no
defraction of light occurs to a value at which substantial
defraction occurs. In accordance with the present inven-
tion, the micellar fluids employed have sufficiently small
emulsified particles so that they are either transparent or
translucent but not milky white.
' :
- SD 15 -
';
.
.. . . . ~ , .
~08~91~
Micellar emulsions in general are composed of three
- different components, an oil phase, a water phase and an
emulsifier. As the oil phase of the micellar emulsion
used in the present invention, any material known as an
"oil" (that is any of the numerous usually combustible
substances that are liquid or easily liquifiable at room
temperature by warming and are insoluble in water) can be
employed. The derivation of the oil is unimportant, and any
material, be it of animal, vegetable, mineral or synthetic
derivation, can be employed. Moreover, the composition of
the oil is also not critical, and materials of any composi-
tion can be employed. For example, oils composed predom-
inantly of hydrocarbons such as mineral oils and petroleum
- oils can be employed as can oils composed predominantly of
fatty acid esters (e.g. me~hyl esters and/or glycerides),
fats and so forth. Silicone oils can also be employed. Of
course, since the primary function of the oil phase of the
micellar fluids is to lubricate the bearing parts, the
materials selected to form the oil phase should exhibit
lubricity properties, i.e. the ma-terials should have the
capability of reducing friction between the bearing parts.
Also, it is well known that certain types of oils exhibit
superior lubricity properties for particular types of met-
als, and therefore the oil phase of a micellar water-in-oil
emulsion selected for processing a particular metal should
preferably be formulated with an oil exhibiting superior
lubricity properties for that metal.
The oil phase of the micellar emulsions used in
accordance with the present invention may also contain various
...
solids, such as waxes and the like, provided that the oil
phase as a whole is liquid under the conditions of compounding
` - SD 16 -
.: .: : : . : . .
, ~ . . ~ , . ~:
1~il8~6
and use (i.e. temperature and pressure) and further provided
that the oil phase exhibits lubricity properties. The oil
phase may also contain conventional solid additives which
remain in a solid form such as graphite, molybdenum disulfide,
- talc, etc.
It is also desirable in connection with working
ferrous metal work pieces to formulate the oil phase of the - '
micellar emulsions of the present invention so that they
have appropriate lubricity properties. In this regard, it ,
- 10 is well known to formulate cutting fluids intended for use ; ,
in working ferrous metal parts to have the property of EP ~'
(extreme pressure). The property of EP is a measure of the
ability of a lubricant to lubricate,bearing surfaces at the
. . .
'~ extremely high pressures encountered after the hydrodynamic
film of lubricant between the bearing surfaces has broken ,
`' down. In accordance with the present invention, the water-
in-oil micellar emulsions intended for use in the working of
ferrous metal parts are preferably compounded so as to have
extreme pressure properties.
Formulation of the water-in-oil micellar emulsions
of the present invention so as to have extreme pressure
characteristics in connection with working ferrous metal
parts can be accomplished in any conventional manner. Thus, '
, it is well known to employ chlorinated, sulfurized or sulfo- ~;
chlorinated organics such as hydrocarbon oils, fats, fatty
oils, fatty esters and so forth in the compounding of metal-
working fluids to impart ferrous-metal EP properties there-
to. In accordance with the present invention, one or more
of these materials can be employed as ingredients of the oil
phase of the inventive micellar fluids in order to impart
ferrous metal EP characteristics thereto.
' '
- SD 17 -
;:, . ,, . . . ~ . .
: ~ ~
~ ill99~L6
Similarly, it is also known to add elemental
sulfur to a cutting fluid as a ferrous metal EP additive,
and in accordance with the present invention elemental
sulfur can be added to the organic phase of the inventive
micellar emulsions for this purpose.
In addition, it is also known to incorporate
phosphorus into cutting fluids as a ferrous metal EP addi-
tive, and phosphorus can be employed in the inventive mi-
cellar emulsions as a ferrous metal EP additive. Incorpora-
tion of phosphorus into the oil phase of the inventive
micellar emulsions can be accomplished in any conventional
manner such as by employing phospho-chlorinated organic
materials (oils, fats and so forth) and/or phospho-sulfurized
organic materials (oils, fats and the like) as an organic
component of the oil phase or by adding various other
organic phosphate compounds, such as amine phosphates, to
the oil phase.
Certain fatty acids which are known to serve as EP
additives can also be directly added to the oil phase of the
inventive micellar emulsions.
In each of the foregoing instances in which a
sulfurized, chlorinated or phosphated organic is employed as
the source of the EP-active chemical, the sulfurized,
chlorinated or phosphorized organic can either be added to
other organics for constituting the oil phase of the emul-
sions or in the alternative can themselves constitute the
entire organic constitutent of the oil phase. Also, the
; dlfferent ferrous metal EP additives as described above can
; be employed singly or in mixtures.
- SD 18 -
.. . .
:l ~o~
The amount of EP additive contained in the oil
phase of the micellar emulsions employed in accordance with
the present invention for working ferrous metal work pieces
can vary between wide limits in accordance with conventional
practice. The minimal amount of EP additive is that which
is neseccary to cause an increase in the lubricity prop-
erties of the cutting oil under the conditions that the
hydrodynamic film from the cutting oil has been broken down.
The maximum amount of EP additive is 100%, that is the oil
phase can consist entirely of an oil which itself exhibits
EP characteristics. Since use of too much of the wrong kind
of EP additive can lead to excess degradation of the tool,
the kind and amount of EP additive, of course, must be
appropriately chosen.
When sulfur and/or chlorine is incorporated into
the oil phase of the invention micellar emulsions for use in
connection with working ferrous metal work pieces, it can be
,.
present either in active form or inactive form. Incorpora-
i~ tion of sulfur and/or chlorine into a cutting fluid for use
in connection with working ferrous metal work pieces in
active or inactive form is well known. ~ctive sulfur or
, .,
chlorine forms iron sulfide or chloride during the metal-
working operation thereby dirtying the bearing surfaces and
hence preventing welding of the bearing surfaces. This is
necessary when ductile ferrous metals are being processed.
Inactive sulfur and/or chlorine on the other hand does not
,!
form sulfides or chlorides at the temperature normally
encountered in metal-working operation and hence no dirtying -
of the bearing surface normally occurs. If extreme tempera-
tures are encountered, inactive sulfur and/or chlorine will
become active and dirty the bearing surfaces. Inactive
- SD 19 -
- ,
~: ' ' . ' ~
` ~88~
sulfur and/or chlorine-containing cutting fluids are em-
ployed when non-ductile steels are processed since welding
of the bearing surface is not a problem. In accordance with
the present invention, sulfur and/or chlorine can be in-
corporated into the oil phase of the micellar emulsions of
i the present invention either in active or inactive form.Specific examples of organic liquids found useful
as ingredients of the oil phase of the micellar emulsions
used in accordance with the present invention are lubricat-
ing oils preferably petroleum-derived with viscosities
between 20 and 500 Saybolt seconds at 100F, chlorinated
and/or sulfurized fatty acid esters such as sulfurized
methyl lardate, chlorinated methyl stearate, unsubstituted
fatty esters such as refined lard oil, various fatty acid
triglycerides (fats and oils) sulfurized hydrocarbons and
chlorinated paraffin.
As the emulsifier component of the micellar fluids
used in accordance with the present invention, any emulsi-
fier can be employed whether nonionic, anionic, cationic or ~-
amphoteric. In this regard, it is well known in the art of
` micellar emulsions that all emulsifiers are not effective in
forming micellar emulsions from all types of organic liquids.
On the contrary, only relatively few emulsifiers of the very
large group of known emulsifiers will be effective in forming
a micellar emulsion from a particular organic liquid. There-
; fore, it is necessary to select as the emulsifier or com-
bination of emulsifiers to be used in a particular embodiment
of the invention one which has the capability of forming a
micellar emulsion from the organic liquid selected. Other
than this, however, there is no limitation on the nature of
the emulsifier to be used in accordance with the present
nventlon .
- SD 20 -
. . , ~ - : . .
: . . . :
. . .
3916
Selection of an emulsifier to be used for forming
a micellar fluid from a particular organic liquid can be
accomplished very easily by trail and error. A unique
property of micellar emulsions is that they form thermo-
dynamically stable emulsions very easily. Very little
mixing is necessary to produce the emulsions. Micellar
emulsions are thus different from conventional emulsions
which normally require a great deal of mixing before an
emulsified state is reached. Therefore, in determining
whether or not a given emulsifier is suitable for forming a
micellar emulsion from a particular organic liquid, a simple
test in which the emulsifier, organic liquid and water are
placed in a common beaker and subjected to slight mixing can
be accomplished, formation of the micellar emulsion being
readily apparent from the slight mixing operation.
More specifically, a convenient way to determine
whether or not a particular emulsifier is effective in
forming a water-in-oil micellar emulsion from a particular
organic liquid is to carry out a water tolerance test in
accordance with the following procedure. The organic phase
of interest is placed in a beaker and the emulsifier to be
tested if soluble in the organic phase is dissolved therein.
If the emulsifier is not soluble in the organic phase, then
it is dissolved in water. The amount of the emulsifier
dissolved in the organic phase or water is about 15-25
percent, preferably about 20 percent, based on the total
weight of oil and emulsifier although the amount of emul-
sifier can vary significantly. Next, the organic phase is
slightly stirred and the water is slowly poured therein with
slight mixing to an amount of 5 to 7%. If this initially
added water forms an opaque milky white material with the
'''
- SD 21 -
.
. ~ .
~LV~89~6
organic phase, a micellar emulsion obviously has not formed
and the emulsifier can be rejected. If on the other hand
the composition obtained is either transparent or trans-
lucent, the emulsion is micellar. Normally, the composition
obtained when water is first added to the oil phase will
remain transparent, although it will be possible to observe
density lines in the composition which disappear as the
composition is mixed. As more and more water is added, the
composition will remain transparent for a time and then pass
through a haze point and become translucent. After becoming
translucent, the composition will remain translucent as more
water is added until it inverts to an oil-in-water emulsion.
In some situations, however, the composition will transform
into an opaque milky white emulsion immediately prior to
inversion. The water content at which the composition
transforms from transparent to translucent (and optionally
to opaque milky-white) and the water content at which the ~;
composition inverts to an oil-in-water emulsion depends upon
the composition of the oil phase. In accordance with the
present invention, the invention micellar emulsions should ;be able to tolerate at least about 12 percent, preferably at
least 20 percent and optimally at least 40 percent, water
before transforming into opaque milky white water-in-oil
emulsions or inverting into oil-in-water emulsions.
Examples of emulsifiers which have been found
useful in the formation of micellar emulsions in accordance
with the present invention include fatty acid diethanol
amides, ethoxylated fatty oils, such as ethoxylated castor
oil, ethoxylated alkyl and dialkyl phenols in which the
alkyl groups has from 6 to 22 preferably 8 to 12 carbon
- SD 22 -
.
,
~08~39~6
atoms, sodium petroleum sulfonate, sodium dioctyl sulfo-
succinate, synthetic sodium sulphonates, the isopropylamine
salt or dodecylbenzene sulfonic acid, "Amphoterge KS " (a
proprietary imidazoline derivate of Lonza, Inc.), oleic
oxazoline acetate and other organic acid salts, oleyl and
coco hydroxyethyl imadazolines and so forth. Oftentimes, it
will be necessary to employ these as well as other emul-
sifiers in combination in order to provide sufficient
emulsification capacity to form a micellar emulsion from the
oil phase of interest.
A particular emulsifier system which has been
found especially useful is the combination of ethoxylated
castor oil and a fatty acid amide of diethanol amine, as
described hereinbefore in the Principal Disclosure. Although
not specifically stated in the Principal Disclosure, the invert
emulsions described therein are water-in-oil micellar emul-
sions. Auxiliary conventional emulsifiers such as rosin
acid salts and sodium petroleum sulfonate can be used as
adjuncts to the emulsifier system based on the combination
of ethoxylated castor oil and a fatty acid amide of diethanol
amine, but such auxiliary conventional emulsifiers are not
essential. When this combination is employed as the emul-
sifier system, the oily materials forming the external phase
of the emulsion is preferably made up of chemicals providing
active species (S, Cl) known to be effective lubricating
agents in metal cutting (sulfurized esters, sulfurized lard
oil, chlorinated paraffins, etc.), as has been discussed
above. Natural fats, such as refined lard oil, also can be
used. Preferred are those oily materials of the foregoing
*Trademark
- SD 23 -
~ \
~08~91~;
types which are of relatively low viscosity (30-1000 SSU at
100F.). The oil phase in these emulsions can be composed
of non-petroleum oils as discussed in the parent application,
although petroleum oil can be added as discussed below.
Another emulsifier system which has been found to
be especially useful is the combination of sodium petroleum
sulfonate and nonylphenol ethoxylate. When this emulsifier
system is used, the ratio of sodium petroleum sulfonate to
nonylphenol ethoxylate is preferably between 25:1 to 1:3, more
preferably between 8:1 and 3:1. Also, the amount of ethyl-
ene and oxide with respect to the amount of nonylphenol in I ;
the nonylphenol ethoxylate is preferably between 4 and 20 on
a molar basis. In a particularly preferred embodiment of
the invention, it has been found desirable to use a mixture of
nonylphenol ethoxylates having different ethylene oxide/nonyl-
phenol ratios. For example, mixtures of "Ipegal C0-430"
(nonylphenol ethoxylated having 4 moles ethylene oxide per ~;~
mole of nonylphenol) and "Ipegal C0-850"** (nonylphenol ethoxy-
late having 20 moles of ethylene oxide per mole of nonylphenol)
have been found especially useful.
In addition to water, oil and an emulsifier, the
micellar emulsions used in accordance with the present
invention can also contain various additives to improve
their properties. For example, the emulsions can contain
biocides, fungicides, antioxidants, foam inhibitors, rust
inhibitors, anti-wear agents and so forth.
The relative proportions of the various ingred
ients in the micellar emulsions used in accordance with the
present invention are not critical. Any relative proportion
of ingredients can be employed so long as the composition as
* Trademark
**Trademark
- SD 24 -
89~
a whole is a water-in-oil micellar emulsion. In general,
the water content of a water-in-oil micellar emulsion for
use in a metal-working operation should range between
greater than zero to about 72 weight percent, preferably 7
to 60 weight percent, most preferably 12 to 21 weight per-
cent, while the emulsifier content should range between
about 8 to 70 weight percent, preferably 12 to 40 weight
percent, most preferably 22 to 32 weight percent, and the
oil phase should range between about 20 to 80 weight per-
cent, preferably 28 to 75 weight percent, most preferably 43
to 64 weight percent. It should, however, be appreciated
that the permissible relative proportions of the various
ingredients in a water-in-oil micellar emulsion vary depend-
ing upon the particular oil and emulsifier selected to
formulate the emulsion. Also, it should be appreciated that
the foregoing compositional ranges refer to the water-in-oil
micellar emulsions of the present invention when in an in-
use condition.
In this regard, since the water-in-oil emulsions
of the present invention are very easy to formulate, it is
convenient in accordance with another aspect of the present
invention to store and ship the compositions in a water-free
state. sefore the compositions are to be used, they can be
finally formulated by adding an appropriate amount of water
thereto to produce the micellar water-in-oil emulsions
discussed above. Thus, in another embodiment of the inven-
tion, water-in-oil micellar emulsion-forming compositions
are provided, these compositions comprising the same in-
gredients in the same relative proportions discussed above
except that water is absent from the composition.
- SD 25 -
9~6
In accordance with another feature of the present
invention, it has been found possible to produce metal-
working fluids having unusually high active sulfur contents
and simultaneously relatively low viscosities very simply
and economically. Conventional high active sulfur cutting
oils are normally straight oils and are formulated using
dissolved elemental sulfur to the solubility limit and high
active sulfurized organics (esters, hydrocarbon, oils, ~
etc.) to the active sulfur predetermined value. Normally, ~ -
the organics contain about 5-45~ active sulfur and the
organic phase is formulated to include fat to provide the
composition with the necessary lubricating characteristics.
Unfortunately, adding active sulfurized fat greatly in-
creases the viscosity of the cutting fluid and undesirably
high viscosities will be attained in the range of 1~2 to 2
percent active sulfur~ In addition, the color of the
finished product becomes undesirably dark. If low viscosity
blending stocks (base oils) are added to the fluids, flash
points become undesirably low. Active sulfur boosters such
as tertiary nonylpolysulfide and polysulfurized terpenes
"(Anglamol 31)"* can be added to increase the active sulfur
content without the attendant bad side effects, but these
materials are very expensive.
In accordance with this aspect of the present
invention, however, it has been discovered that cutting
fluids having a high active sulfur content (defined as
greater than 2% and preferably greater than 5~) and at the
same time a low viscosity can be produced at low cost by
using conventional high active sulfurized organics (i.e.
organics containing 5 to 45~ active sulfur and including
sufficient fat to provide the necessary lubricating char-
acteristics) in combination with a low viscosity base oil
*Trademark
-SD 26 -
stock as the oil phase and converting the fluid to a water-
in-oil micellar emulsion. Addition of water eliminates the
flash point problem associated with straight oils, thereby
permitting the use of low flash base stocks to decrease the
viscosity of the fluids while at the same time accommodating
large amounts of active sulfur. Elemental sulfur can also
be included in the organic phase up to the solubility limit.
In any event, it is possible in accordance with this aspect
of the present invention to provide cutting fluids having a
high concentration of active sulfur with low viscosities
very simply and inexpensively.
In accordance with this aspect of the invention,
any petroleum derived lubricating or base oil having a
viscosity of 20 to 500 seconds at 100F, preferably 25 to
100 seconds at 100F can be employed for viscosity-lowering
purposes. Examples of such hydrocarbon oils and "Factopure
T-30,"* which is a petroleum distillate having a specific
gravity of 60F of 0.778, SUS/100 = 30.5, pour point = -35F,
flash point = 175F and a Saybolt Color of 30; Mineral Seal
Oil, which is a petroleum distillate having a specific
gravity of 0.8265, SUS/100 = 42, flash point c 270F,
aniline point 190F and a pour point of 25F, and low
viscosity Naphthenic Mineral Oil, which is a petroleum
distillate having a viscosity of 60 SUS/100, specific gravity
= 0.8967, aniline point ~ 156.5, flash point = 315F. and
a pour point of less than -50F.
The amount of lubricating oil added to the oil
phase should be sufficient to provide an emulsion having a
viscosity of less than 300 Saybolt seconds at 100F, pre-
ferably less than 200 Saybolt seconds at 100F and optimally
about 100-150 Saybolt seconds at 100F. The relative amount
* Trademark
- SD 27 -
~8~
of lubxicating oil which must be added to arrive at these
viscosities depends upon the specific lubricating oil
selected as well as the composition of the remaining ingred-
ients in the oil phase. In general, however, the amount of
lubricating oil should be from greater than 0 to 70 percent
by weight, preferably 10 to 60 percent by weight, more
preferably 20 to 46 percent by weight, the percents being
based on the total weight of the composition, in order to -
realize the viscosity reducing effect. Also, the amount of ~-
high activated sulfurized organics in the emulsion should be
about 5 to 40%, preferably 10 to 35%, most preferably 12.5
to 22.5%, while the amount of emulsifier should be 8 to 70%
preferably 12 to 40%, most preferably 15 to 35%. Flnally,
the amount of water should be greater than zero to 90%,
preferably 7 to 68%, most preferably 15 to 35%.
As in the other embodiment of the present inven-
tion, the oil phase in this embodiment of the invention in
which a lubricating oil is included for viscosity control
purposes can also be composed of a wide variety of different
chemical components. For example, unsaturated fatty acid
esters, (methyl esters, triglycerides, etc.) organic phos
phate esters, phosphoramides and the like can also be in-
cluded in addition to the high active sulfur containing
organics and lubricating oils.
As the emulsifier to be used in the foregoing
embodiment of the invention in which a lubricating oil is
included in the oil phase of the emulsions for viscosity-
reducing purposes, any of the previously discussed emul-
sifiers can be used. The preferred non-ionic emulsifiers
are diethanolamides of fatty acids, ethyoxylated fatty oils,
ethoxylated alkyl and dialkyl phenols in which the alkyl
-SD 28 -
.
9~6
group have 8 to 12 carbon atoms. The preferred anionic
emulsifiers are sodium petroleum sulfonate, sodium dioctyl
sulfosuccinate, synthetic sodium sulphonates and isopropyl-
amine salt of dodecylbenzene sulfuric acid. The preferred
cationic emulsifiers are oleic oxazoline acetate and other
oleic oxazoline acid esters and oleo and coco hydroxyethyl
imidazolines. The preferred amphoteric emulsifiers include
"Amphoterge VS."*
Thus, the present invention provides metal-working
compositions for use in various types of metal shaping
operations, the compositions having formulations falling
within the limits set forth in the following Table I.
TABLE I
Amount, weight percent based on -
total weight of composition
Ingredient Broad Preferred Optimal
1. Oil phase exhibiting 20-80 28-75 43-64
lubricity properties
2. Emulsifier 8-70 12-40 22-32
3. Water >0-72 7-60 12-21
In a more specific embodiment, metal-working com-
positions for use in working ferrous metals are provided,
these compositions being formulated in accordance with the
foregoing Table I with the proviso that the oil phase of the
compositions exhlbits ferrous metal EP characteristics. In
this embodiment the oil phase preferably includes a satur-
ated or unsaturated hydrocarbon and/or fatty acid ester (oil
or fat) which contains chlorine or sulfur or both as well as
mixtures of these materials.
*Trademark
-- SD 29 -
1(~889~6
In another embodiment, the present invention pro~
vides high active sulfur metal-working compositions having
viscosities of less than 300 Saybolt seconds at 100~F and
compositions falling within the limi.ts set forth in the
following Table II.
''' ' '
TABLE II
Amount, weight percent based on
total weight of compositi.on
. ~
Ingredient Broad Preferred Optimal
. _ .... _ _ _
1. Petroleum derived lubricat- 0-70*10-60 20-40
ing oil with a viscosity
of 20-500, preferably
30-100, Saybolt seconds at
100F. .
2. High active sulfurized 5-40* 10-35 12.5-22.5
organics ~having about
5 to 45% active sulfur),
the organics including -
enough fat to provide
sufficient lubricating -
characteristics.
3. Water 0-727-68 12-28
4. Emulsifier 8-7012-40 15-35
* Ingredients 1 and 2 comprising at least 20 weight percent.
'' -
In still another embodiment, the present invention :-
provides specific metal-working compositions as described in
the parent application having typical formulations falling
within the ranges set forth in the following Table III.
- SD 30 - '
TABLE XII
Parts by Weight
Ingredient sroad Preferred
low-viscosity inactive or active 15-84 22-48
sulfurized ester of an olefinic
fatty acid
rosin acid soap 0-10 3~6
ethoxylated castor oil 8-25 10-20
amide of diethanol amine and a fatty 8-25 10-20
acid
biocide-fungicide 0-8 ,1-5
chlorinated fat or fatty acid ester 0-15 2-lQ -~ ;
amine-type rust inhibitor 0-10 0-7
NO2 0-5 0-3.5
foam inhibitor 0-3 0-2
water (preferably distilled or 0-60 8-30
deionized)
These compositions as indicated above make ideal
metal-working fluids for use in various types of metal-
working operations. Because oil is the external phase of a
water-in-oil micellar emulsion, the lubricity properties of
the emulsion as a whole are very high and hence the pro-
duction rate of a metal-shaping operation is not slowed due
to poor lubricity. Furthermore, the presence of the water
keeps the temperature of the cutting fluid at a relatively
low level since evaporation of the water in the cutting
f~uid will remove much of the generated heat. This combina-
tion of properties enables the micellar emulsions used in
the inventive process to greatly increase the production
capacity of a metal-shaping operation as compared to the
- SD 31 -
9~6
same operation in which straight oils or oil in-water emul-
sions are used as the metal-working fluids since in water
in-oil emulsions fluids water which has very poor lubricity
properties is the external phase while straiyht oils in-
herently have low heat transfer properties.
Furthermore, the relatively low viscosity of
water-in-oil micellar emulsions especially when formulated
to contain a viscosity-reducing lubricating oil as discussed
above allows them to be conveniently handled (e.g. pumped
and filtered) and thus allows them to be used in many
applications (such as in an automatic cutting machine)
wherein conventional water in oil emulsions with their high
viscosities cannot be employed. Furthermore, the stable
nature of the micellar emulsions used in the present inven-
tion further facilitates their use in that the de-emul-
sification problems associated with conventional emulsions
are completely avoided. Also, the task of keeping the
emulsions within proper concentration ranges by adding ;
makeup water as the emulsions are used, which is rather
difficult when using conventional water-in-oil emulsions due
to the vigorous mixing necessary to restore the lost water -
in such emulsions and the sensitivity of such emulsions to
compositional variations, is easy in accordance with the
present invention since micellar emulsions readily form with
little mixing at relatively wide concentrational ranges.
A still further advantage of the use of water-in-
oil type micellar emulsions in accordance with the present
invention is that these emulsions can be easily removed by
simple water washing since they readily invert to oil-in-
water emulsions. Furthermore, once the wash water becomes
contaminated with excess oil removal from the parts, the
- SD 32 -
1~8~
oil can be recovered by adding the wash water to the sumps
of other working machines as a source of water. Most
importantly, this avoids a disposal problem which could
otherwise result in environmental pollution. Further, if
too mu~h makeup water is added to these emulsions during use
causing them to invert to oil-in-water emulsions, great
damage will not be done since oil--in-water emulsions still
can serve as metal-working fluids, although they are not as
effective as those of the present invention. And, when the
excess water evaporates from these oil-in-water emulsions as
they are used, they will readily revert to the water-in-oil
micellar emulsions of the present invention due to the
thermodynamic stability of these emulsions. Moreover, if
the viscosity of the inverted high water emulsion should
be excessive and the water content cannot be reduced in
use, the fluid may be recovered by adding it to the sumps
of other working machines as a source of water.
Still another advantage of the use of water-in-oil
micellar emulsions in accordance with the present invention
is that the emulsions are fireproof even though they may
contain a significant amount of low flash point base oils.
This, of course, is a significant safety factor.
Still another advantage of the use of water-in-oil
micellar emulsions is that they exhibit outstanding tolerance
for hard water salts. For example, it has been found in
many instances that water-in-oil micellar emulsions of the
present invention can tolerate as much as 17,000 ppm hard
water salts without significant adverse effect on the
operating properties of the emulsions, although it was
notices that water-in-oil emulsions with this high salt
content would not form oil-in-water emulsions.
- SD 33 -
- \
A still further advantage of the use of water-in-
oil micellar emulsions arises when the working tool employed
is formed from a cemented carbide. In prior art metal-
working processes using a cemented carbide tool and an oil-
in-water metal-working fluid, at least a part of the cobalt
binder of the cemented carbide working tool is leached by
the metal-working fluid. In accordance with the present
invention, this leaching problem is avoided when water-in-
oil micellar emulsions are employed as the metal-working
fluid.
Finally, a significant advantage of the trans-
parent and almost transparent emulsions of the present
invention is that they allow visual inspection of the work
piece during the metal-shaping operation.
Additional water-in-oil micellar emulsion metal-
working fluids in accordance with the present invention were
produced. The compositions of these emulsions are set forth
in the following Table IV. In Table IV, designations "A" to
"E" refer to ingredients and have the following meanings:
Ingredient A - hydrocarbon petroleum oil having a viscosi-ty of
42 sec. at 100F
B - sulfurized methyl lardate having 10% total S, 0%
act~ive S, a viscosity of 79 sec. at 100F, acid #
of 0.8 and a saponification # of 165.
C - chlorinated methyl stearate having a viseosity of
23 centistokes at 100F and a ehlorine eontent of
20%.
D - ehlorinated paraffin having a viscosity of 85 see.
at 210F and 60% ehlorine.
E - 1 to 1 diethanol amide of eoeonut fatty aeid.
F - ethoxylated eastor oil.
G - sodium dioetyl sulfosueeinate.
H - sodium petroleum sulfonate having equivalent
weight of 440-470 and ash content of 15.5% as
Na2S04 .
- SD 34 -
.. . . .. .
.
I - nonyl ~henolethoxylate (4 moles ethvlene oxide ~er
mQle of nonyl phenol).
J - nonyl phenole~hoxylate ~20 moles ethylene oxide per
mole of nocyl phenol).
R - 1 to 1 diethanol amide of capric acid.
L - ~iocide/fu~gicide - mix~ure of co~plex amines"(Bioban
M - Na~02. (rust inhibitor)
*. *
N - defoa~ant("Hoda~ ~IG-89
*Trade~rErk
** Trademark
- SD 35 -
' ' ' .
C U~ o C' C C ., C .~ C
C ~ U~ o C C _ ~ C C
Ln o o ,~ ~ ~ U~ C C C
~D g g g g C U~ O
~;r I . . . . . . . . .
C~ o ~ C~ C C C ~
r~
o U~ C C o o o U~ C C
G -- U~ O O C O ~ ~`/ C
O C~ e~ U') U'l ~1 ~ C C U~
o U~ o o o o o U~ o o
O ~ ~ C C O O -- C~ C
O C ~ ~D O ~ t'- O ~ L~
~ ~ ~ --
.,
C ~: . . -
~ C 2
U~ ~ U~ C o O O~ C C
v _V ~ _~ ~ O U~ I L'`3 C ~ C --1 ~ ` ~C O C
3 ' E `5 ~`1 e~l
0~ ~ X
~ v 3
G ~ o ~ o o u) C C ' .
JJ C: o ~ O O C -- t`l C
O ~ O
I O C~ I ~ C C
E ~ W
~ E
_I
~o ~ U~ o o oo o 11~C C
U _I ~D O O OO O ~ ~ O
~ ~ COCO Ir~ 'C O U)
_l r~
r~ U~~ C C~ C C
G Cl~ r~ O O O O -- O :~
~
O O~ ~ X ~ U~ C C U~ ~
.' ,
U~o o~ C C
OO ~n ~ ~
O o,:,
--' C
_~ C 1~W C~ . ~ 2 ~ Z
8~ 3 :
~' ' .
'~ ~
- SD 36 -
:, . . .
. : , .
o ou~ o oo oo ~ ~ ~ o
o ~/ ~ o o o u~
C gu~ g 8 C ~ o U~ o
o U~ oo oU~
_ ~
o o c o o o u~ o n o
`J U~ C o o C o _ ` ~ ~ o
o~ o ~ 0 ~ ~ o o o U~
O O O O C o o no ~ o
o_ U~ ooCo ~CC
o C ~ ~ U~ _, ~ C o C U~
.5 ~ _, _
o o o o o o ~o U~ C
o ~ U~ o o o o ~l o C
o e~l ~o U) ~ ~ o o o U~
o U~ o o o o o U~ oU~ C
_1 O ~ In o o o o _I ~ o o
zrJ o ~o ~ ~ O _1 ~C O O U~
E
X o U~ O O O o O U~ OU~ C
~: C O ~ 0 C: O O ~ O C
O ~ ~i ~ ~ i OC OL~
'3 ~`I ~, _
_ o U~ o o o o o ~~ O O
O O C~ ~ O ~ t'l OO OU~
d` ~ ~ ~;
o U~ O o o o U~ oU~ C
o~ O ~1 rl O O O . ~ ~ O O
_~
O 1~ e~ ~ OO O ~
d`
.
8 8 g _, o uo. 8
o oo ~ i ~ C o C U~
o U~ o o o o ~ o U~ C
~o o ~ o o o _, ~ o C~
~ C U~ o o o U~
C~ . Ci
00
- SD 37 -
1~8~6
39~6
* t~ .
o o o o o o o o In O n o
o 1-- Ln o o o o o ~ In ~ o
.
O O O In ~ ~ -
~, ~, ~, .
~ ,, .
o o o o o o U~ o U~ o .-
NO ~1 Lr) O O O r-l O ~1 0 ,~:
~)
IS') O N ~ l O Ll') O 11
* ~ :
O o o o o o n o n o
O N ISl O O O r-l O ~1 0 r-l
~) Ir'~ O N t~ D O Ll'~ O L~
~,
4-1 '.
a) - -
O O O O O O O Lf) O 1~ 0
OO O Lt~O O O O ~I N ~1 0
~r~ O O ~ ~r ~ ~ ~ o o o
~' N r~
H .q t)
~1 .5: ~
m ~ ~
~o o o o o o o u~ o ~ o 4~ :s
E-~ ~5') o o -1 N ~1 0 0 U~
C~
N O r~ co ~I N O O O 11 ) ~) a
Ul N
a~
~: Q
O O O O O O O 11~) 0 1- 0
00 O O 11') 0 0 0 0 1--I N ~1 0 ~IJ ~.)
N O 00 N 111 LO ~i ~1 O O O Ll'l ~1 ~
~1 0 0
~1
~ O
,a) ,~,
O O O O O O O 11') 0 111 0 S-l r~l
O O 1~) 0 0 0 0 ~I N ~1 0 ~)
N O O N Ir, ;O ~1 ~r) O O O LS') r-l (I)
r~
;~
~ 1 0
O
~ ~ 0
,
a ~ Z ~ O
H ~C ~ *
* *
- SD 38 -
89~6
EXAMPLE 34
In order to determine the functional properties of
the micellar fluids used in accordance with the present
invention, a test procedure was conducted in accordance with
which the emulsion of Example 7 was compared to a commer-
cially available cutting fluid composed of a straight oil
containing inactive sulfur, chlorine and an amine phosphate.
In this comparison, both the emulsion of Example 7 and the
conventional cutting fluid were employed in separate test
runs to facilitate a specific metal-working operation. In
this test, an Acme Model FA-6 1 1/4" bar machine (which is
an automatic cutting machine equipped with an automatic
cutting fluid handling system for directing cutting fluid at
the part being machined) was employed to make 3/4" hydraulic
hose couplings from stock pieces comprising 3/4" cold drawn
hexagonal bars (12L14 leaded free machining steel). In the
metal-working operation, 65.0 weight percent of the metal of
each bar was removed, most of the metal-working being done
by drills.
The object of this comparison was to establish the
change in production capacity made possible by the use oE
Emulsion no. 7 as compared to the use of the conventional
cutting fluid based on the performance criteria that (1) the
surface roughness and dimensional variations in the parts
produced would be maintained within predetermined tolerances
and (2) the automatic cutting machine could be operated for
an entire 8 hour shift before shutdown to replace the cut-
ting tools. The production rate for each fluid was adjusted
to the maximum attainable without failing to meet the per-
formance criteria noted above.
- SD 39 -
: .
: - , , . :
. : ,
.
8916
Under these performance criteria, the machine was
operated for five consecutive days, two 8-hour shifts a day,
the machine being charged with the conventional cutting
fluid. With ~his cuttin~ fluid, it was found that the
maximum average production rate was 456 parts per hour, with
a nominal production rate 576 parts per hour.
After the foregoing reference runs, the conven-
tional cutting fluid was removed from the machine and the
emulsion of Example 7 was installed therein. With this
metal-working fluid, it was found that the maximum average
production rate was 778 parts per hour with a nominal pro-
duction rate of 831 parts per hour. Thus, it will be
appreciated that the maximum average production rate was
increased 70.6 percent by the use of a water-in-oil micellar
emulsion as the cutting fluid.
The emulsions of Examples 25 and 28 when tested in
a similar manner gave the same increase in production
capacity. Furthermore, it was also found that the life of
the tools`used in the machine was approximately doubled and
the surface characteristics of the finished parts improved
compared with the tool life and surface characteristics of
the reference test.
Although only a few embodiments of the present
invention-have been described above, it should be appreci-
ated that many modifications can be made without departing
from the spirit and scope of the invention. All such
modifications are intended to be included within the scope
of the present invention, which is to be limited only by
the following claims.
- SD 40 -
.
~ . , . ' ' . , . ., : ' '
. ' :. . , .. : : ~ .. . .
