U.S. patent application number 12/302307 was filed with the patent office on 2009-09-24 for lubricants for use in processing of metallic material and methods for processing the metallic material using the lubricants.
This patent application is currently assigned to TOYOTA BOSHOKU KABUSHIKI KAISHA. Invention is credited to Teruo Fukaya, Mami Kato.
Application Number | 20090239774 12/302307 |
Document ID | / |
Family ID | 38512461 |
Filed Date | 2009-09-24 |
United States Patent
Application |
20090239774 |
Kind Code |
A1 |
Kato; Mami ; et al. |
September 24, 2009 |
LUBRICANTS FOR USE IN PROCESSING OF METALLIC MATERIAL AND METHODS
FOR PROCESSING THE METALLIC MATERIAL USING THE LUBRICANTS
Abstract
A nonchlorine lubricant for use in processing of a metallic
material includes a lubricant base. The lubricant base includes at
least one member selected from the group consisting of the
vegetable oils and the neopentylated polyol esters. The lubricant
may further include an additive added to the lubricant base. The
additive comprises a sulfuric extreme pressure agent, an organozinc
compound and a calcium ingredient. Preferably, the additive is
added to the lubricant base such that sulfur content, zinc content
and calcium content in the lubricant are respectively 5.0-50 wt %,
0.2-10 wt % and 0.01-10 wt % of total weight of the lubricant.
Inventors: |
Kato; Mami; ( Aichi, JP)
; Fukaya; Teruo; ( Aichi, JP) |
Correspondence
Address: |
GREENBLUM & BERNSTEIN, P.L.C.
1950 ROLAND CLARKE PLACE
RESTON
VA
20191
US
|
Assignee: |
TOYOTA BOSHOKU KABUSHIKI
KAISHA
Aichi-ken
JP
|
Family ID: |
38512461 |
Appl. No.: |
12/302307 |
Filed: |
June 15, 2007 |
PCT Filed: |
June 15, 2007 |
PCT NO: |
PCT/JP2007/062559 |
371 Date: |
November 25, 2008 |
Current U.S.
Class: |
508/370 ;
508/400 |
Current CPC
Class: |
C10M 2223/045 20130101;
C10M 2207/2835 20130101; C10M 2219/024 20130101; C10M 2219/08
20130101; C10N 2040/24 20130101; C10N 2030/02 20130101; C10N
2010/04 20130101; C10M 169/04 20130101; C10M 2219/046 20130101;
C10M 2207/401 20130101 |
Class at
Publication: |
508/370 ;
508/400 |
International
Class: |
C10M 137/10 20060101
C10M137/10; C10M 159/20 20060101 C10M159/20 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 16, 2006 |
JP |
2006-167344 |
Claims
1-8. (canceled)
9. A nonchlorine lubricant for use in processing of a metallic
material, comprising: a lubricant base, and an additive added to
the lubricant base, wherein the lubricant base comprises at least
one member selected from the group consisting of vegetable oils and
neopentylated polyol esters, wherein content of the vegetable oils
and/or the neopentylated polyol esters in the lubricant is 40-80 wt
% of total weight of the lubricant, wherein the additive comprises
a sulfuric extreme pressure agent, an organozinc compound and a
calcium ingredient, wherein the additive is added to the lubricant
base such that sulfur content, zinc content and calcium content in
the lubricant are respectively 5.0-50 wt %, 0.2-10 wt % and 0.01-10
wt % of total weight of the lubricant, and wherein the calcium
ingredient comprises highly-basic calcium sulfonates having base
value of 300 mgKOH/g or more.
10. The nonchlorine lubricant as defined in claim 9, wherein the
processing of a metallic material comprises shearing of the
metallic material.
11. The nonchlorine lubricant as defined in claim 9, wherein the
organozinc compound comprises at least one member selected from the
group consisting of zinc dialkyldithiophosphate and zinc
dialkyldithiocarbamic acid.
12. A method for processing a metallic material using a processing
tool, comprising the steps of: feeding a nonchlorine lubricant
between the metallic material and the processing tool, wherein the
lubricant comprises a lubricant base and an additive added to the
lubricant base, wherein the lubricant base comprises at least one
member selected from the group consisting of vegetable oils and
neopentylated polyol esters, wherein content of the vegetable oils
and/or the neopentylated polyol esters in the lubricant is 40-80 wt
% of total weight of the lubricant, wherein the additive comprises
a sulfuric extreme pressure agent, an organozinc compound and a
calcium ingredient, wherein the additive is added to the lubricant
base such that sulfur content, zinc content and calcium content in
the lubricant are respectively 5.0-50 wt %, 0.2-10 wt % and 0.01-10
wt % of total weight of the lubricant, and wherein the calcium
ingredient comprises highly-basic calcium sulfonates having base
value of 300 mgKOH/g or more.
13. The method as defined in claim 12, wherein the processing of a
metallic material comprises shearing of the metallic material.
14. The method as defined in claim 12, wherein the organozinc
compound comprises at least one member selected from the group
consisting of zinc dialkyldithiophosphate and zinc
dialkyldithiocarbamic acid.
Description
TECHNICAL FIELD
[0001] The present invention relates to lubricants for use in
processing (e.g., press working) of a metallic material (which is
also referred to as metal processing). Further, the present
invention relates to methods for processing the metallic material
using the lubricants.
BACKGROUND ART
[0002] Examples of known metal processing technique for
manufacturing a product (e.g., a car part) may include press
working (e.g., press forming, shearing (blanking, die cutting, half
die cutting and punching)), bending, burring, drawing and rolling,
each of which can be performed by means of a processing tool (e.g.,
a mold). For example, in shearing (one of press working), a
metallic material (a processed material) may preferably be stamped
out with a mold (i.e., a punch and die assembly), thereby producing
a formed article. The formed article thus produced is relatively
finely finished. Therefore, the formed article produced by shearing
does not substantially require additional processing such as
cutting, grinding, or other such processing. In particular, in fine
shearing, for example, in fine blanking (FB), the formed article is
more finely finished than the formed article produced by normal
shearing. Thus, the formed article produced by FB can be used as an
end product without additional processing. This may lead to a
reduced number of manufacturing processes of the product. For these
reasons, in recent years, fine shearing as typified by FB has been
broadly used in a metal processing field for manufacturing car
parts or other such parts.
[0003] In processing of the metallic material, lubricants are
generally applied between the metallic material and the processing
tool, e.g., the mold (the punch and die assembly), in order to
reduce frictional heat generated therebetween or to prevent
formation of "burr" or "shear drop" on a processed surface (e.g., a
shear surface) of the metallic material. The lubricants thus
applied may effectively prevent the processing tool (the mold) from
wearing by the frictional heat. In addition, the lubricants may
effectively increase processing accuracy of the metallic material.
Generally, shearing may generate a large shear stress between the
metallic material and the mold (the punch and die assembly). In
particular, fine shearing may generate a shear stress greater than
the normal shearing. Therefore, the lubricants for use in shearing
and fine shearing require excellent lubricity and seize
resistance.
[0004] Conventionally, in metal processing, chlorine lubricants
have been broadly used. The chlorine lubricants can provide good
lubricity and seize resistance. However, chlorine ingredients
contained in the chlorine lubricants can be easily decomposed to
produce undesirable decomposition products during processing or
with time. The decomposition products thus produced may rust the
metallic material and the processing tool (the mold). Further, the
chlorine ingredients may produce harmful or toxic substances when
they are incinerated. Also, the chlorine ingredients may corrode or
damage incinerators. In order to solve these problems, there is a
need to develop improved or nonchlorine lubricants that can provide
substantially the same lubricity and seize resistance as the
chlorine lubricants.
[0005] Up to now some nonchlorine lubricants for use in metal
processing have been developed. For example, Japanese Laid-open
Patent Publication Number 2002-155293 teaches a nonchlorine
lubricative composition for use in metal processing, which
composition includes a lubricant base (mineral oils or synthetic
oils) and an additive (a sulfuric extreme pressure agent,
organozinc compounds and imide compounds) added to the lubricant
base. Japanese Patent Number 2,641,203 teaches a nonchlorine
lubricative composition for use in metal processing, which
composition includes a lubricant base (mineral oils or other such
oils) and an additive (a sulfuric extreme pressure agent and
highly-basic metal sulfonates) added to the lubricant base Further,
Japanese Laid-open Patent Publication Number 8-20790 teaches a
nonchlorine lubricative composition for use in metal processing,
which composition includes a lubricant base (mineral oils or
synthetic oils) and an additive (a sulfuric extreme pressure agent
(e.g., olefin polysulfides), highly-basic metal sulfonates and
organozinc compounds) added to the lubricant base.
[0006] However, the known nonchlorine lubricative compositions
generally contain mineral oils as the lubricant base. Therefore,
such lubricative compositions may produce a bad smell caused by the
mineral oils during processing. This may lead to deterioration of
working condition. In addition, the mineral oils generally have
high kinetic viscosity. The high kinetic viscosity of the mineral
oils may lead to clogging of filters of a metal processing machine.
Also, due to the high kinetic viscosity of the mineral oils, the
lubricative compositions may have reduced self-removability.
Therefore, the lubricative compositions cannot be easily removed or
washed out from a formed article. Further, the lubricative
composition taught by Publication Number '293 does not have
sufficient lubricity and seize resistance. Therefore, such a
lubricative composition is not suitable for press working, in
particular, fine shearing. In other words, if this lubricative
composition is used in shearing, the mold (the punch and die
assembly) can be rapidly worn out because of inferior lubricity of
the lubricative composition. Naturally, shearing speed cannot be
increased. This may lead to reduced productivity. Similarly, the
lubricative compositions taught by patent Number '203 and
Publication Number '790 do not have sufficient lubricity and seize
resistance. Therefore, these lubricative compositions are also not
suitable for press working such as fine shearing.
DISCLOSURE OF INVENTION
[0007] It is, accordingly, one object of the present invention to
provide an improved nonchlorine lubricant for use in processing of
a metallic material.
[0008] In one embodiment of the present invention, a nonchlorine
lubricant is taught for use in processing of a metallic material.
The lubricant includes a lubricant base. The lubricant base
includes at least one member selected from the group consisting of
the vegetable oils and the neopentylated polyol esters.
[0009] According to the present lubricant, the lubricant does not
produce a bad smell because the lubricant does not contain mineral
oils. Therefore, the lubricant does not deteriorate working
condition. Furthermore, the lubricant may be friendly for the
environment. In addition, the lubricant is less subject to
solidifying because the lubricant does not contain animal oils.
[0010] The lubricant may further include an additive added to the
lubricant base. The additive may include a sulfuric extreme
pressure agent, an organozinc compound and a calcium ingredient.
Preferably, the additive is added to the lubricant base such that
sulfur content, zinc content and calcium content in the lubricant
are respectively 5.0-50 wt %, 0.2-10 wt % and 0.01-10 wt % of total
weight of the lubricant.
[0011] The lubricant thus formulated may have substantially the
same lubricity and seize resistance as the conventional chlorine
lubricants.
[0012] Further, in another embodiment of the present invention, a
method is taught for processing a metallic material using a
processing tool. The method includes the steps of feeding the
nonchlorine lubricant that is described above between the metallic
material and the processing tool.
[0013] According to the present method, frictional heat generated
between the metallic material and the processing tool can be
effectively reduced, so that the processing tool can be prevented
from wearing. As a result, the processing tool may have a long
service life. Further, formation of "burr" or "shear drop" on a
processed surface (e.g., a shear surface) of the metallic material
can be prevented.
[0014] Other objects, features and advantages of the present
invention will be readily understood after reading the following
detailed description together with the claims.
BEST MODE FOR CARRYING OUT THE INVENTION
[0015] In the following, a detailed representative embodiment of
the present invention will be described.
[0016] A lubricant for use in processing of a metallic material may
include vegetable oils and/or neopentylated polyol esters as a
lubricant base. Preferably, the lubricant may include a
(nonchlorine) additive added to the lubricant base. The additive
may be a sulfuric extreme pressure agent (Ingredient A), an
organozine compound (Ingredient B) and a calcium ingredient
(ingredient C). The lubricant may have substantially the same
lubricity and seize resistance as known chlorine lubricants by
appropriately controlling or determining the sulfur content, the
zinc content and the calcium content contained therein. As will be
recognized, the lubricant contains neither mineral oils nor
chlorine ingredients. Therefore, the lubricant does not deteriorate
working condition. Also, the lubricant does not produce harmful or
toxic substances if it is incinerated. In addition, the vegetable
oils contained in the lubricant are less subject to solidification
than the other oils (e.g., animal oils). As a result, the lubricant
may have increased self-removability. Further, according to the
lubricant, filters of a metal processing machine may preferably be
prevented from clogging.
[0017] First, the lubricant base of the lubricant will be
described. In this embodiment, the lubricant base may be at least
one member selected from the group consisting of the vegetable oils
and neopentylated polyol esters. In other words, the vegetable oils
and the neopentylated polyol esters can be used in either a pure
form or in a combined form. In addition, when the vegetable oils
and the neopentylated polyol esters are used in the combined form,
they can be mixed in various combinations, i.e., combinations of
one or more vegetable oils and one or more neopentylated polyol
esters, combinations of two or more vegetable oils only, or
combinations of two or more neopentylated polyol esters only. The
vegetable oils and the neopentylated polyol esters may preferably
include all vegetable oils and neopentylated polyol esters that are
known per se for use in a composition for processing a metallic
material. In other words, the vegetable oils and the neopentylated
polyol esters are not limited to special vegetable oils and special
neopentylated polyol esters. However, it is preferable that the
vegetable oils and the neopentylated polyol esters may have kinetic
viscosity of 1 mm.sup.2/s to 1000 mm.sup.2/s at 40.degree. C., more
preferably 5 mm.sup.2/s to 100 mm.sup.2/s at 40.degree. C.
[0018] Examples of the vegetable oils are linseed oil, safflower
oil, soy been oil, sesame oil, corn oil, canola oil, cotton seed
oil, olive oil, rice bran oil, coconut oil, palm oil, palm kernel
oil and hydrogenated products thereof. Generally, it is preferable
that the vegetable oils mainly contain fatty acids (more preferably
linear fatty acids) having a carbon number of 8-22. Further, in
view of the fact that the vegetable oils are usually used for
foods, the vegetable oils do not generally produce a bad smell.
[0019] Examples of the neopentylated polyol esters are
neopentylglycol, trimethylolpropane, pentaerythritol and
dipentaerythritol. These exemplified compounds may have excellent
heat resistance and lubricity, high ignition points and low
volatility. However, trimethylolpropane and pentaerythritol are
more preferable in view of heat resistance, volatility and
lubricity. Generally, it is preferable that the neopentylated
polyol esters contain alkyl groups having a carbon number of
7-22.
[0020] In the present invention, content of the vegetable oils
and/or the neopentylated polyol esters in the lubricant is 40-80 wt
% (not less than 40 wt % and not greater than 80 wt %) of total
weight of the lubricant, preferably 50-70 wt %, and more preferably
55-65 wt %. In such a range of content of the vegetable oils and/or
the neopentylated polyol esters, the lubricant may have sufficient
lubricating performance and have substantial effects of the
additive. In the content of 55-65 wt %, the lubricating performance
and the effects of the additive are maximized. If the content of
the vegetable oils and/or the neopentylated polyol esters in the
formulated lubricant is less than 30 wt % of total weight of the
lubricant, the lubricant may have insufficient lubricating
performance. On the contrary, even if the content of the vegetable
oils and/or the neopentylated polyol esters in, the formulated
lubricant is greater than 80 wt % of total weight of the lubricant,
the lubricant may only have limited performance and effects. In
addition, if the content of the vegetable oils and/or the
neopentylated polyol esters is excessively increased (e.g., greater
than 80 wt %), content of the additive is inversely extremely
reduced, so that the lubricant cannot have substantial effects of
the additive.
[0021] Next, the additive of the lubricant, i.e., the sulfuric
extreme pressure agent (Ingredient A), the organozinc compound
(Ingredient B) and the calcium ingredient (Ingredient C) will be
described.
[0022] In this embodiment, the sulfuric extreme pressure agent
(Ingredient A) may preferably include various types of sulfuric
compounds that can provide extreme pressure property. In other
words, the sulfuric extreme pressure agent is not limited to
special sulfuric compounds. Examples of the sulfuric extreme
pressure agent are sulfurized fats, sulfurized fatty acids,
sulfuric esters, sulfurized olefins, polysulfides, thiocarbamates
and sulfurized mineral oils. The exemplified compounds for the
sulfuric extreme pressure agent can be used in either a pure form
or in a combined form.
[0023] Further, the sulfurized fats may preferably be made by
reacting sulfur with various types of fats (e.g., lard oils, whale
oils, vegetable oils and fish oils). The sulfurized fats may
include a sulfurized lard, a sulfurized canola oil, a sulfurized
caster oil and a sulfurized soy been oil.
[0024] In addition, the sulfurized fatty acids may include a
sulfide of oleic acid. Also, the sulfuric esters may include a
sulfide of methyl oleate and a sulfide of octyl rice bran fatty
acid. The sulfurized olefins may preferably be produced by reacting
C.sub.2-C.sub.15 olefins or their multimers (e.g., dimers, trimers
or tetramers) with a sulfurizing agent such as sulfur and sulfur
chloride.
[0025] Examples of the polysulfides are dibenzylpolysulfides,
di-tert-nonylpolysulfides, didodecylpolysulfides,
di-tert-butylpolysulfides, dioctylpolysulfides,
diphenylpolysulfides and dicyclohexylpolysulfides.
[0026] Examples of the thiocarbamates are zinc thiocarbamates,
dilaurylthiodipropionates and distearylthiodipropionates.
[0027] The sulfurized mineral oils may preferably be produced by
dissolving elementary sulfur into mineral oils. The mineral oils
for use in preparation of the sulfurized mineral oils may be, for
example, but are not limited to, many kinds of oils that can be
produced in a general petroleum refinery process.
[0028] The organozine compound (ingredient B) may include zinc
dialkyldithiophosphate (which will be referred to ZnDTP
hereinafter) and zinc dialkyldithiocarbamic acid (which will be
referred to ZnDTC hereinafter). Alkyl groups contained in ZnDTP and
ZnDTC may be identical with or different from each other. That is,
in ZnDTP, two alkyl groups bonding to a phosphorus atom via an
oxygen atom may be identical with or different from each other.
Similarly, in ZnDTC, two alkyl groups bonding to a nitrogen atom
may be identical with or different from each other. The alkyl
groups contained in ZnDTP and ZnDTC may preferably be alkyl groups
having a carbon number of three or more. Further, these alkyl
groups can be replaced by aryl groups. In addition, the
above-described compounds for the organozinc compound can be used
in either a pure form or in a combined form.
[0029] Moreover, the calcium ingredient (Ingredient C) may include,
but are not limited to, calcium sulfonates, calcium salicylates and
calcium phenates. However, the calcium sulfonates are preferred in
terms of kinetic viscosity and price. More preferred are basic
calcium sulfonates. Further more preferred are highly-basic calcium
sulfonates having base value of 300 mgKOH/g or more. In addition,
the above-described compounds for the calcium ingredient can be
used in either a pure form or in a combined form.
[0030] As described above, the lubricant of the present invention
may preferably be formulated by adding the additive (Ingredient A,
Ingredient B and Ingredient C) to the lubricant base (i.e., the
vegetable oils and/or the neopentylated polyol esters). In the
present invention, the lubricant may be formulated such that sulfur
content in the formulated lubricant is preferably 5.0-50 wt % (not
less than 5.0 wt % and not greater than 50 wt %) of total weight of
the lubricant, more preferably 6.0-30 wt %. If the sulfur content
in the formulated lubricant is less than 5.0 wt % of total weight
of the lubricant, the lubricant may have insufficient seize
resistance and lubricity. On the contrary, if the sulfur content in
the formulated lubricant is greater than 50 wt % of total weight of
the lubricant, the lubricant may only have limited performance and
effects.
[0031] Further, the lubricant may be formulated such that zinc
content in the lubricant is preferably 0.2-10 wt % (not less than
0.2 wt % and not greater than 10 wt %) of total weight of the
lubricant, more preferably 0.3-5.0 wt %. If the zinc content in the
formulated lubricant is less than 0.2 wt % of total weight of the
lubricant, the lubricant may have insufficient seize resistance and
lubricity. Conversely, even if the zinc content in the formulated
lubricant is greater than 10 wt % of total weight of the lubricant,
the lubricant may only have limited effects.
[0032] Further, the lubricant may be formulated such that calcium
content in the lubricant is preferably 0.01-10 wt % (not less than
0.01 wt % and not greater than 10 wt %) of total weight of the
lubricant, more preferably 0.5-5.0 wt %. If the calcium content in
the formulated lubricant is less than 0.01 wt % of total weight of
the lubricant, the lubricant may have insufficient seize resistance
and lubricity. On the contrary, if the calcium content in the
formulated lubricant is greater than 10 wt % of total weight of the
lubricant, the lubricant may only have limited effects.
[0033] As described above, the additive for use in the preparation
of the lubricant essentially consists of the sulfuric extreme
pressure agent (Ingredient A), the organozinc compound (Ingredient
B) and the calcium ingredient (Ingredient C). However, various
types of known additional agents can be added to the lubricant
without obscuring the object of the invention in order to increase
or stabilize basic properties of the lubricant, if necessary. The
known additional agents may include a viscosity modifying agent, a
rust inhibitive agent, an antioxidizing agent, a corrosion
prevention agent, a coloring agent, an antifoaming agent and a
fragrant material.
[0034] The viscosity modifying agent may preferably include all
viscosity modifying agents that are known per se for use in a
composition for processing a metallic material. In other words, the
viscosity modifying agent is not limited to special viscosity
modifying agents. However, the viscosity modifying agent may
preferably be added so that the lubricant may have kinetic
viscosity of 1 mm.sup.2/s to 1000 mm.sup.2/s at 40.degree. C., more
preferably 5 mm.sup.2/s to 100 mm.sup.2/s at 40.degree. C.
[0035] The rust inhibitive agent is not limited to special
compounds. Examples of the rust inhibitive agent are calcium-based
rust inhibitive agent, barium-based rust inhibitive agent and
wax-based rust inhibitive agent. Examples of the antioxidizing
agent are amine series compounds and phenolic compounds. Examples
of the corrosion prevention agent, are benzotriazols, tolyltriazols
and mercaptobenzothiazoles. Further, the coloring agent may be
various types of dyes and pigments.
[0036] The lubricant of the present invention may have beneficial
effects in various processing of the metallic material such as
press working (e.g., press forming, shearing (blanking, die
cutting, half die cutting and punching)), bending, burring, drawing
and rolling, each of which can be performed by means of a special
processing tool. In particular, the lubricant may have beneficial
effects in shearing (in particular, fine shearing as typified by
fine blanking (FB)).
[0037] Also, the lubricant of the present invention does not
contain chlorine components. Therefore, the lubricant may have rust
inhibiting performance greater than the conventional lubricants.
That is, the lubricant may effectively prevent a processing tool
(or a mold) and the processed metallic material from rusting. In
addition, the lubricant may effectively increase processing
accuracy of the metallic material when it is fed between the
metallic material and the processing tool (the mold). Moreover, the
lubricant can be use for processing various types of metallic
materials, e.g., stainless steel, alloy steels, carbon steels and
aluminum alloys. However, the lubricant may provide particularly
beneficial effects when applied to the alloy steels and the carbon
steels.
[0038] A representative method for processing the metallic material
using the lubricant will now be described.
[0039] As described above, the lubricant is formulated by adding
the additive (i.e., Ingredient A, Ingredient B and Ingredient C) to
the lubricant base. Subsequently, the formulated lubricant is
applied between the metallic material and the processing tool (the
mold) in order to lubricate therebetween when the metallic material
is processed. Thus, the metallic material can be smoothly processed
(e.g., sheared) with a high degree of processing accuracy.
[0040] Generally, the lubricant may be applied to the metallic
material by means of, for example, but are not limited to, a roller
and a sprayer. The lubricant thus applied may effectively increase
processing accuracy of the metallic material. In addition, the
lubricant that is applied between the metallic material and the
processing tool (the mold) may effectively protect the processing
tool from rusting and damaging, thereby providing a prolonged
working life of the processing tool.
[0041] The examples of the lubricant of the present invention will
now be described. Further, the following examples are illustrative
and should not be construed as limitations of the invention.
[0042] In the following description, the content of each ingredient
was expressed as a weight part. In addition, the sulfur content (%)
was expressed as a weight percent of sulfur atom to the total
weight of each lubricant. Similarly, the zinc content (%) was
expressed as a weight percent of zinc atom to the total weight of
each lubricant. Further, the calcium content (%) was expressed as a
weight percent of calcium atom to the total weight of each
lubricant.
[0043] In a first test, seven example lubricants (Examples 1-7;
nonchlorine lubricants) and one control lubricant (Control 1;
chlorine lubricant) were prepared by utilizing substances listed
below as the lubricant base and the additive. Compositions of the
seven types of example lubricants (Examples 1-7) and the control
lubricant (Control 1) are shown in Table 1.
[0044] (1) The lubricant base (which will be referred to as "LB")
[0045] LB1: canola oil [0046] LB2: palm oil [0047] LB3: safflower
oil [0048] LB4: trimethylolpropane (C.sub.12) [0049] LB5:
trimethylolpropane (C.sub.18) [0050] LB6: pentaerythritol
(C.sub.12) [0051] LB7: pentaerythritol (C.sub.18)
[0052] (2) The additive [0053] a) The sulfuric extreme pressure
agent (Ingredient A) [0054] a1: polysulfides (32 wt % sulfur
content) [0055] a2: sulfrized fats (15 wt % sulfur content) [0056]
b) The organozinc compound (Ingredient B) [0057] b1: ZnDTP (9 wt %
zinc content; 16 wt % sulfur content) [0058] c) The calcium
ingredient (Ingredient C) [0059] c1: calcium sulfonates (15 wt %
calcium content) [0060] d) Other additives (Ingredient D) [0061]
d1: chlorinated paraffins (50 wt % chlorine content)
[0062] With regard to the lubricants of Examples 1-7 and Control 1,
a lubrication performance evaluation test was performed. In order
to perform the lubrication performance evaluation test, work pieces
having the lubricants were respectively processed (sheared or
punched), so as to produce formed articles (test pieces).
[0063] Preparation of the formed articles was carried out under
following conditions.
[0064] Processing Machine
[0065] Link-motion pressing machine (AIDA) having two punches and
dies [0066] Work piece feed: 23.5 mm [0067] Material of the punch
1: SKD11 [0068] Material of the punch 2: SKD11+TiN coating [0069]
Material of the dies: SKD11
[0070] Work Pieces
[0071] SPH 440 [0072] Width: 70 mm [0073] Thickness 4.6 mm
[0074] Application of the Lubricants [0075] The lubricants of
Examples 1-7 and Control 1 were uniformly fed to the surfaces of
the work pieces by a resin roll coater.
[0076] Processing [0077] The work pieces having the lubricants were
respectively subjected to processing (shearing or punching) by the
punches 1 and 2, thereby producing the formed articles (test
pieces) that have a pair of punched holes each having a size of 10
mm (length).times.12 mm (width).times.4.6 mm (depth). The two
punches 1 and 2 were arranged such that the two punched holes were
simultaneously formed. Further, with regard to each of the work
pieces, a pressing load required for processing was measured.
[0078] After processing, the punches 1 and 2 were visually observed
for the surface appearance thereof, so as to determine occurrence
of defects, including wear, seizing, damage and stripping of TiN
coating. From the appearance, the punches 1 and 2 were evaluated
based on the following reference levels:
[0079] A: Superior (No defects)
[0080] B: Fine or Good (Substantially no defects)
[0081] C: Poor (Minor defects)
[0082] D: Inferior (Significant defects)
[0083] In addition, the formed articles thus formed were visually
observed for the sheared surface appearance of the punched holes
(i.e., processing accuracy of the formed articles), so as to
determine occurrence of defects, including burr and shear drop.
From the observed appearance, the sheared surface appearance of the
punched holes were evaluated based on the following reference
levels:
[0084] A: Superior (No defects)
[0085] B: Fine or Good (Substantially no defects)
[0086] C: Poor Minor defects)
[0087] D: Inferior (Significant defects)
[0088] Results are shown in Table 1.
TABLE-US-00001 TABLE 1 Examples Control 1 2 3 4 5 6 7 1 LB1 60 LB2
60 LB3 60 LB4 60 LB5 60 LB6 60 LB7 60 a1 10 10 10 10 10 10 10 a2 10
10 10 10 10 10 10 b1 10 10 10 10 10 10 10 c1 10 10 10 10 10 10 10
d1 70 Sulfur 6.3 6.3 6.3 6.3 6.3 6.3 6.3 -- Content (%) Zinc 0.9
0.9 0.9 0.9 0.9 0.9 0.9 -- Content (%) Calcium 1.5 1.5 1.5 1.5 1.5
1.5 1.5 -- Content (%) Chlorine -- -- -- -- -- -- -- 35 Content (%)
Pressing 93 93 98 93 92 98 97 97 Load (ton) Appearance A A A A A A
A A of Punches Appearance A A B B A B A A of Punched Holes
[0089] As shown in Table 1, with regard to Examples 1-7 and Control
1, the punches 1 and 2 may have superior surface appearance. This
means that the lubricants of Examples 1-7 and Control 1 may prevent
the punches 1 and 2 from wearing during processing. Also, with
regard to Examples 1-7 and Control 1, the punched holes of the
formed articles may have superior sheared surface appearance. This
means that the lubricants of Examples 1-7 and Control 1 may form
the punched holes free from burr and shear drop. These results
demonstrate that the lubricants of Examples 1-7 may have excellent
seize resistance and lubricity that are same as or similar to the
(chlorine) lubricant of Control 1.
[0090] Further, it is demonstrated that the lubricants of Examples
1, 2, 5 and 7 may have greater performance than the chlorine
lubricant of Control I in that, according to these lubricant, the
work pieces can be processed (punched) under a lesser pressing load
(92-93 ton). In addition, it is demonstrated that the vegetable
oils (Examples 1-3) may have substantially the same performance as
the neopentylated polyol (Examples 4-7). Further, as will be
apparent from comparing Examples 4 and 5 (or Examples 6 and 7), the
neopentylated polyol esters having a larger carbon number may have
a greater performance than the neopentylated polyol esters having a
smaller carbon number. Moreover, as will be apparent from comparing
Examples 1-3, the lubricant base substances LB1 and LB2 (canola oil
and palm oil) may have a performance slightly greater than the
lubricant base substance LB3 (safflower oil). Similarly, as will be
apparent from comparing Examples 4-7, the lubricant base substances
LB4 and LB5 (trimethylolpropane) may have a performance slightly
greater than the lubricant base substances LB6 and LB7
(pentaerythritol).
[0091] In a second test, two example lubricants (Examples 8 and 9;
nonchlorine lubricants) were prepared by utilizing the above listed
substances as the lubricant base and the additive. Compositions of
the two types of lubricants (Examples 8 and 9) are shown in Table
2. In Example 8, a combination of the lubricant base substances LB1
and LB4 are used as the lubricant base. As will be recognized, the
lubricant base substances LB1 and LB4 are respectively have a
relatively excellent performance as demonstrated in the first test.
To the contrary, in Example 9, a combination of the lubricant base
substances LB3 and LB6 are used as the lubricant base. As will be
recognized, the lubricant base substances LB3 and LB6 are
respectively have a relatively inferior performance as demonstrated
in the first test.
[0092] With regard to the lubricants of Examples 8 and 9, a
lubrication performance evaluation test was performed in the same
manner as the first test. Results are shown in Table 2.
TABLE-US-00002 TABLE 2 Examples 8 9 LB 1 30 LB2 LB3 30 LB4 30 LB5
LB6 30 LB7 a1 10 10 a2 10 10 b1 10 10 c1 10 10 d1 Sulfur Content
(%) 6.3 6.3 Zinc Content (%) 0.9 0.9 Calcium Content (%) 1.5 1.5
Chlorine Content (%) -- -- Pressing Load (ton) 93 98 Appearance of
A A Punches Appearance of A B Punched Holes
[0093] Table 2 demonstrates that the lubricants of Examples 8 and 9
may have good seize resistance and lubricity similar to Examples
1-7. Further, as will be apparent from Tables 1 and 2, the
combination of the lubricant base substances LB1 and LB4 may have
substantially the same performance as the lubricant base substance
LB1 or LB4 in the pure form. Similarly, the combination of the
lubricant base substances LB3 and LB6 may have substantially the
same performance as the lubricant base substance LB3 or LB6 in the
pure form.
[0094] In a third test, six example lubricants (Examples 10-15)
were prepared by utilizing the above listed substances as the
lubricant base and the additive. Compositions of the six types of
lubricants (Examples 10-15) are shown in Table 3. In these
examples, only the lubricant base substance LB1 having a relatively
excellent performance as demonstrated in the first test is used as
the lubricant base. Also, only the additive substances a1 and a2
(Ingredient A) are used as the additive. The additive substances a1
and a2 are respectively added so that the formulated lubricants may
have various sulfur content.
[0095] With regard to the lubricants of Examples 10-15, a
lubrication performance evaluation test was performed in the same
manner as the first test. Results are shown in Table 3.
TABLE-US-00003 TABLE 3 Examples 10 11 12 13 14 15 LB1 70 80 90 70
80 90 a1 30 20 10 15 10 5 a2 15 10 5 Sulfur Content (%) 9.6 6.4 3.2
7.1 4.7 2.1 Zinc Content (%) -- -- -- -- -- -- Calcium Content (%)
-- -- -- -- -- -- Pressing Load (ton) 93 98 106 94 100 110
Appearance of B B D B C D Punches Appearance of B C D B C D Punched
Holes
[0096] As shown in Table 3, according to the lubricants of Examples
10 and 13 having a greater sulfur content, the punches 1 and 2 may
have excellent surface appearance. Also, the punched holes of the
formed articles may have excellent sheared surface appearance. To
the contrary, according to the lubricants of Examples 12 and 15
having a lesser sulfur content, the punches 1 and 2 may have
inferior surface appearance. Also, the punched holes of the formed
articles may have inferior sheared surface appearance. These
results means that the lubricants having a greater sulfur content
may generally have greater seize resistance and lubricity than the
lubricants having a lesser sulfur content. Further, by comparing
Example 11 with Example 14, it is presumed that an appropriate
sulfur content may preferably be about 5.0% or more, more
preferably be about 6.0% or more.
[0097] In a fourth test, three example lubricants (Examples 16-18)
were prepared by utilizing the above listed substances as the
lubricant base and the additive. Compositions of the three types of
lubricants (Examples 16-18) are shown in Table 4. In these
examples, only the lubricant base substance LB1 is used as the
lubricant base. However, all of the additive substances a1, a2, b1
and c1 (Ingredients A-C) are used as the additive. The additive
substances b1 is added so that the formulated lubricants may have
various zinc content.
[0098] With regard to the lubricants of Examples 16-18, a
lubrication performance evaluation test was performed in the same
manner as the first test. Results are shown in Table 4.
TABLE-US-00004 TABLE 4 Examples 16 17 18 LB 1 74 72 70 a1 10 10 10
a2 10 10 10 b1 1 3 5 c1 5 5 5 Sulfur Content (%) 4.9 5.2 5.5 Zinc
Content (%) 0.1 0.3 0.5 Calcium Content (%) 0.75 0.75 0.75 Pressing
Load (ton) 101 97 96 Appearance of C B A Punches Appearance of C B
A Punched Holes
[0099] As will be apparent from Table 3, the lubricants having a
greater zinc content may generally have greater seize resistance
and lubricity than the lubricants having a lesser zinc content.
Further, by comparing Example 16 with Example 17, it is presumed
that an appropriate zinc content may preferably be about 0.2% or
more, more preferably be about 0.3% or more.
[0100] In a fifth test, four example lubricants (Examples 19-22)
were prepared by utilizing the above listed substances as the
lubricant base and the additive. Compositions of the four types of
lubricants (Examples 19-22) are shown in Table 5. In these
examples, only the lubricant base substance LB1 is used as the
lubricant base. However, all of the additive substances a1, a2, b1
and c1 (Ingredients A-C) are used as the additive. The additive
substances c1 is added so that the formulated lubricants may have
various calcium content.
[0101] With regard to the lubricants of Examples 19-22, a
lubrication performance evaluation test was performed in the same
manner as the first test. Results are shown in Table 5.
TABLE-US-00005 TABLE 5 Examples 19 20 21 22 LB 1 69.5 69 67 65 a1
10 10 10 10 a2 10 10 10 10 b1 10 10 10 10 c1 0.5 1 3 5 Sulfur
Content (%) 6.3 6.3 6.3 6.3 Zinc Content (%) 0.9 0.9 0.9 0.9
Calcium Content (%) 0.1 0.2 0.5 0.75 Pressing Load (ton) 97 97 95
95 Appearance of B B B A Punches Appearance of C C B A Punched
Holes
[0102] As will be apparent from Table 5, the lubricants having a
greater calcium content may generally have greater seize resistance
and lubricity than the lubricants having a lesser calcium content.
Further, from these results shown in Table 5, it is presumed that
an appropriate calcium content may preferably be about 0.01% or
more, more preferably be about 0.5% or more.
[0103] In a sixth test, four control lubricants (Controls 2-5) were
prepared by utilizing the above listed substances. Compositions of
the four types of control lubricants (Controls 2-5) are shown in
Table 6. As will be apparent form Table 6, in these controls, the
lubricant base is not used. That is, the controls are formulated
from only the additive substances a1, a2, b1 or c1.
[0104] With regard to the control lubricants of Controls 2-5, a
lubrication performance evaluation test was performed in the same
manner as the first test. Results are shown in Table 6.
TABLE-US-00006 TABLE 6 Controls 2 3 4 5 LB 1 -- -- -- -- a1 100 a2
100 b1 100 c1 100 Sulfur Content (%) 32 15 16 Zinc Content (%) 9
Calcium Content (%) 15 Pressing Load (ton) 108 100 102 110
Appearance of D C C D Punches Appearance of C C C C Punched
Holes
[0105] As will be apparent from Table 6, the control lubricants
containing no lubricant base may have inferior seize resistance and
lubricity.
[0106] The results of the first to sixth tests demonstrate that the
lubricant of the present invention may have excellent performance
(e.g., excellent seize resistance and lubricity) that are same as
or similar to the conventional chlorine lubricant when they are
used for processing (in particular, shearing) of the metallic
material. This means that the present lubricant may be suitable for
processing (in particular, shearing) of the metallic material. The
lubricant may preferably contain both of the lubricant base and the
additive at a desired ratio. The lubricant base may be the
vegetable oils and/or the neopentylated polyol esters. The additive
may be the sulfuric extreme pressure agent (Ingredient A), the
organozinc compound (Ingredient B) and the calcium ingredient
(Ingredient C). The sulfur content in the lubricant may preferably
be 5.0-50% of total weight of the lubricant. The zinc content in
the lubricant may preferably be 0.2-10% of total weight of the
lubricant. The calcium content in the lubricant may preferably be
0.01-10% of total weight of the lubricant.
[0107] A representative embodiment of the present invention has
been described in detail. This detailed description is merely
intended to teach a person of skill in the art further details for
practicing preferred aspects of the present teachings and is not
intended to limit the scope of the invention. Only the claims
define the scope of the claimed invention. Therefore, combinations
of features and steps disclosed in the foregoing detail
description, may not be necessary to practice the invention in the
broadest sense, and are instead taught merely to particularly
describe detailed representative examples of the invention.
Moreover, the various features taught in this specification may be
combined in ways that are not specifically enumerated in order to
obtain additional useful embodiments of the present teachings.
* * * * *