Replacement of Chlorinated Paraffins in Metalworking Fluids 5th international Conference on Metal Removal Fluids Thomas Rossrucker, Wilhelm Rehbein, Michael Koenig
Trends and Requirements in Metalworking Processes Trend
Effect
Increased Productivity
Higher material removal rates require higher machining speeds
Reduced Oil Consumption
Longer oil-change intervals require better oxidation stability and less volatility, less oil drag out with chips or work pieces
Reduced Process Steps (e.g. forming instead of cutting)
Fewer machines, less waste and waste disposal. Tougher processes require high additive performance
Improved Occupational Health and Safety
Reduced formation of oil mist, no toxicologically problematic substances, base oils with low aromatic content
Total Cost Management
Consideration of the whole process chain from purchasing to disposal
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Replacement of Chlorinated Paraffins in Metalworking Fluids
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ADSORPTION
Adsorption / Reaction of Extreme Pressure Additives
H H Cl
H
S
S S R
H Cl
H Cl H
Cl
O
O O O O
S S S S S O
Sulfurized Triglyceride
REACTION
Cl-Paraffin
- Fe - Cl - Fe - Cl - Fe - Cl -
3
R S
R S S
S S S S S Fe Fe Fe Fe Fe
Polysulfide
S
S
Fe - S - Fe - S - Fe -
Replacement of Chlorinated Paraffins in Metalworking Fluids
Sulfur Carriers as Replacements for Chlorinated Paraffins Multifunctional: Lubricity Extreme pressure / cold welding Prevent welding Improve Oxidation stability
Influenced by: Polarity and degree of polymerization Sulfur Content and polarity Sulfur content Inactive sulfur
Mixed lubrication partial surface-surface-contact Lubricity, AW/EP work well and protect Boundary lubrication Boundary friction direct surface-surface-contact Urgent need for strong EP/AW
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Replacement of Chlorinated Paraffins in Metalworking Fluids
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Laboratory Tests
Frequently used Laboratory Tests Type
EP
AW
FB Weld
Four Ball Wear -load +time
6
Lubricity EP/AW AW /Lub (EP) Pin & V
Brugger
FZG
+load -time
MW simulation Microtap cut
form
Chlorinated Paraffins
+-
+
-
+++
+
-
-
+
Sulfurized-Triglyceride (inactive)
++
++
-
++
+
+
+
++
Sulfurized-Triglyceride (active)
+++
-
++
+
++
-
++
++
Polysulfide
+
--
+
-
+++
--
+
-
P-Ester
-
+++
--
--
--
++ +
+-
-
Replacement of Chlorinated Paraffins in Metalworking Fluids
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Thread cutting results (Microtap) cutting - alloy V4A (AISI 316) 300
300
300 Average value 261
255
Maximum value
258
250 224 193
200
Torque [Nm)
166 152
150
7
50
0
0
tool fracture
Parameters: Thread cutting Tool: 4 mm Alloy: V 4 A Speed: 800 rpm Depth: 6 mm
109
tool fracture
100
158 145
0
Replacement of Chlorinated Paraffins in Metalworking Fluids
Sulfurized Products - Synergists Well known Synergists Chlorinated Paraffins
Overbased Sulfonates
S Y N E R G I E
Overbased Salicylates and other Dispersants
Polymer Esters
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Replacement of Chlorinated Paraffins in Metalworking Fluids
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Synergism Polysulfide with Polymer Esters Base oil: ISO VG 46 (paraffinic)
6000
1
5500
5000 0,8 4000
0,73 0,6
0,65 0,5 8
3000 0,53 2000
0,42
0,39
0,4
0,44
0,2
1000
0
0
Polymer Ester Polysulfide
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Four ball wear scar [mm]
Four ball weld load [N]
1,2
DIN 51350 p.3 (1500 rpm / 60 min)
DIN 51350 p.2 (1500 rpm / 1 min)
7000
4,5% 4,0% 0,5% 1,0%
3,5% 1,5%
3,0 % 2,0%
2,5% 2,5%
2,0% 3,0%
1,5% 3,5%
Replacement of Chlorinated Paraffins in Metalworking Fluids
Field Tests
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Chlorinated Paraffins, Influence of Cutting Speed (Temperature) 4 R S S
H H Cl
15% CLP
3.5
S SR
H
H
Cl
H Cl H Cl
O
O O O O
SS S SS
3
O
Sulfurized Triglyceride
Polysulfide
REACTION
Cl-Paraffin
S S S S S Fe Fe Fe Fe Fe
S
S Fe - S - Fe - S - Fe - S - Fe
- Fe - Cl - Fe - Cl - Fe - Cl - Fe - Cl -
tool life [m]
ADSORPTION
RS S
2.5 2 1.5 1 0.5 0 28
35 44 cutting speed [m/min]
Opposed milling
Temperature
Tool HS 10-4-3-10 (1.3207), TiNcoated, re-ground, 65HRC
11
55
α = 11° °γ = 0° λ=5
Workpiece
Conditions
42CrMo4V (AISI 4140) Rm = 1040 N/mm²
ae = 4mm df = 100 mm Vc = 28 – 55 m/min
FZ = 0.31 mm hCU = 120 µm
Replacement of Chlorinated Paraffins in Metalworking Fluids
Sulfur Carriers / Influence of Activity on Force and Wear
R S S H H Cl
crater wear
480
50
460
45
S S R
H
H
Cl
H Cl H
Cl
O O O O
O
Sulfurized Triglyceride
S S S S S
S Polysulfide
REACTION
Cl-Paraffin
O
40
S Fe - S - Fe - S Fe - S - Fe
Spec. cutting force [N/mm]
440 S S S S S Fe F e F e F e F e - Fe - Cl - Fe - Cl - Fe - Cl - Fe Cl -
35
420
30 400 25 380 20 360
15
340
10
320
Opposed milling
5
300
0
S-Ester (inactive) S-Ester (medium S-Ester / Olefin active) (medium active)
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crater wear [µm]
ADSORPTION
specific cutting force R S S
Polysulfide (active)
Replacement of Chlorinated Paraffins in Metalworking Fluids
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Influence of Phosphorus containing Additives on Tool Life 15% Cl-paraffin (50% Cl)
5% sulfurized special EP
5% sulfurized special EP + 1% AW
7 6
tool life [m]
5
Opposed milling
4 3 2 1 0 28
Tool HS 10-4-3-10 (1.3207), TiN-coated, re-ground, 65HRC
13
α = 11° °γ = 0° λ=5
35 44 cutting speed [m/min]
Workpiece
Conditions
42CrMo4V (1.7225) Rm = 1040 N/mm²
ae = 4mm df = 100 mm Vc = 28 – 55 m/min
55
FZ = 0.31 mm hCU = 120 µm
Replacement of Chlorinated Paraffins in Metalworking Fluids
Field Test: Groove Broaching
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Groove Broaching / Test Oils
Composition
RC 6
10% Polysulfide (40% S) 10% conventional S-TG*)
RC 11
10% Polysulfide (40% S) 10% conventional S-TG 2% C8-ZnDTP 41% Chlorinated Paraffin 7.0% Polysulfide (40% S)
RC 12 RC 14 RC 15 RC 16
12.0% S-Ester/Olefin (26% S) 5% Polysulfide (40% Sulfur) 12.0% S-Ester/Olefin (26% S) 4% Polysulfide (40% Sulfur) 2% C8-ZnDTP 12.0% S-Ester/Oelfin (26% S) 4% Polysulfide (40% S) 2% ashless DTP
V40 cSt
S (%)
Cl (5)
4ball weld load @ 1min. 1500rpm
4ball wear scar @ 1h 30kg
21.0
5.0
0
600 kg
0.98 mm
21.1
5.5
0
600 kg
0.93 mm
20.5
2.9 %
18.5
750 kg
0.72 mm
20.8
5.1
0
650 kg
0.85 mm
21.0
5.2
0
600 kg
0.80 mm
20.5
5.2
0
600 kg
0.73 mm
*) TG = Triglyceride
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Replacement of Chlorinated Paraffins in Metalworking Fluids
Groove Broaching / Formation of Angular Wear RC 6
RC 11
RC 12
RC 14
RC 15
RC 16
50 Cutting speed : Tool: depth of cut :
45
angular wear [10-2 mm]
40
24m/min HSS, TiN-coated 80µm
35 30 25 20 15 10 5 0 0
16
1000
2000
3000 no. of machined parts
4000
5000
6000
Replacement of Chlorinated Paraffins in Metalworking Fluids
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Press-In Test
Press-In Test / Procedure 30,100mm
Oversized bolt Ball bearing steel Material: 100Cr6 Rz = 1µm
Fmax = 300 kN (approx. 67000lbs)
Feff.
30,000mm
Die Heat treatable steel Mat.: 20MoCrS4 Rz = 1
65,0mm
18
Resulting radial stress 180 Mpa (approx. 26100psi)
Replacement of Chlorinated Paraffins in Metalworking Fluids
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Press-In Test / Characteristic Wear Marks
SC-1
19
SC-4
Replacement of Chlorinated Paraffins in Metalworking Fluids
Press-In Test / Sulfur Carriers SC-1
SC-3
Sulufrized Additives 15% Sulfur
140
SC-1
Sulfurized Oelfin/Ester Mix.
SC-2
Mix of Polysulfide and synthetic Ester
SC-3
Sulfurized Lard Oil
SC-4
Special sulfurized Olefin / Triglyceride, high Temperature Sulfur Release
120
normal force [kN]
SC-2
160
100
80
SC-4
ISO VG 220
CLP (C14-C17)
60
40
20
0 0
20
5
10
15
20 punch travel [mm]
25
30
35
40
Replacement of Chlorinated Paraffins in Metalworking Fluids
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Press-In Test / CLP Replacement
40% sulfurized polymer
20% sulfurized polymer + 3% AW 40% Cl-paraffin (50% Cl)
20% sulfurized ester +3% AW
160
140 Fmax = 300 kN
normal force [kN]
Feff.
120
100
80
60
40
20
0 0
21
5
10
15
20 25 punch travel [mm]
30
35
40
45
Replacement of Chlorinated Paraffins in Metalworking Fluids
Summary
Modern metalworking processes require advanced lubricant technology. The performance of chlorinated paraffins decreases with increasing machining speed or temperature due to chemical decomposition. An easy 1:1 substitution like x% chlorine = y% sulfur or phosphorous is impossible in the majority of cases due to the multi-functional properties of the CLPs. By combining suitable lubricant additives it is possible to adjust the characteristics of metalworking fluids to the specific demands of the processes and to even exceed the performance of chlorinated paraffins containing cutting and forming lubricants.
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Replacement of Chlorinated Paraffins in Metalworking Fluids
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