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Afton Chemical STLE 2017
The document discusses the importance of friction control and coolant separability in slideway lubricants used in metalworking operations, emphasizing the need for formulations that maintain both properties. It details methods for measuring these parameters and presents findings from various tests on slideway oils and their compatibility with metalworking fluids. Key conclusions highlight that optimized formulations can effectively balance friction reduction and coolant life preservation.
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Afton Chemical STLE 2017
- 1. AftonChemical.com Friction control andcoolant separability of slideway lubricants Marc Ingram, Paul Norris, Ralph Lumby, Carl Williams, Gabriel Clarke Afton Chemical Ltd, Bracknell, UK Presented at STLE 2017
- 2. AftonChemical.com Contents Introduction to SlidewayOils Friction control Coolant separability Methods Afton slideway rig SKC Coolant separability test Discussion Formulating for good friction and coolant separability 2017 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation.
- 3. AftonChemical.com Introduction Hydrodynamic slideways areused on a variety of machine tools commonly found in metalworking operations 2017 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation.
- 4. AftonChemical.com Slideway Fundamentals Slideways areused to ensure the accurate positioning and movement of a tool relative to a work piece The speed that the tool platform is translated along its axis must be predictable Any inconstancies in its movement will be translated into errors in the manufactured part 2017 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation.
- 5. AftonChemical.com Friction Control Adding afriction modifier reduces or eliminates stick- slip, but can also reduce how quickly the slideway oil separates from the MWF in the sump… 2017 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. 0 0.05 0.1 0.15 0.2 0.25 0.3 0 50 100 150 200 Frictioncoefficient Sampling time (s) 1 mm/min 0 0.05 0.1 0.15 0.2 0.25 0.3 0 50 100 150 200FrictionCoefficient Sample Time (s)
- 6. AftonChemical.com Coolant Separability 2017 ©Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. t = 0 mins t = 4 mins t = 8 mins t = 12 mins t = 16 mins t = 20 mins
- 7. AftonChemical.com Coolant Separability Slideway oilscan contaminate the coolant during normal machine operation Slideway oil and MWF are “emulsified” in the high pressure nozzle of the machine The slideway oils must be compatible with a range of coolants Problems that can arise include: Color change Change of the physical state of the MWF Polluting the machine interior Loss of cutting performance Oil burning during cutting 2017 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation.
- 8. AftonChemical.com Introduction Summary Friction control Machining Accuracy • Low friction • Stick-Slip avoidance Metalworking fluid compatibility Fast separation • Reduced impact on metalworking fluid • No reduction of coolant life 2017 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. t = 20 mins
- 9. AftonChemical.com Two Methods Friction measurements Coolantseparability 2017 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation.
- 10. AftonChemical.com Afton Slideway Rig FrictionMeasurements Test Method 2017 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation.
- 11. AftonChemical.com Tribological Conditions Sliding surfaces Flat on flat contact Typical conditions are mild Speed – 20 to 200 mm/min (for cutting steel) Surface pressure – 10 - 50 MPa Temperature – ambient Mostly steel-steel or cast iron Low friction materials are also sometimes used • Epoxy resins with graphite • PTFE strips 2017 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation.
- 12. AftonChemical.com Afton Slideway Rig Fullscale instrumented slideway Surface grinder machine 2017 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation.
- 13. AftonChemical.com 2017 © AftonChemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Afton Slideway Test Rig
- 14. AftonChemical.com 2017 © AftonChemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Afton Slideway Rig Curve
- 15. AftonChemical.com 2017 © AftonChemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Cleaning Procedure Surfaces are thoroughly cleaned with Setral 0900-0020 and naphtha between test runs
- 16. AftonChemical.com Fundamental Understanding ofFriction Control By manipulating the boundary film thickness and shear strength we can modify the shape of this curve 2017 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.01 0.1 1 10 100 1000 10000 CoefficentofFriction Sliding Speed mm/min Boundary Mixed Hydrodynamic Slideway
- 17. AftonChemical.com SKC Method Coolant Separability 2017© Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation.
- 18. AftonChemical.com SKC Gleittechnik GmbHMethod Behaviour of de-emulsification of bedway oils and coolants-lubricants 12 different coolants, each mixed with slideway oil Agitated with a vortex mixer and inverting the tube Performance is rated after 1 hour, 1 day and 1 week 2017 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation.
- 19. AftonChemical.com 2017 © AftonChemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Rating System o = oil z = intermediate mixture e = emulsion
- 20. AftonChemical.com 2017 © AftonChemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Example Results SKC Results MWF 1 3.1.1 MWF 2 1.1.1 MWF 3 1.1.1 MWF 4 1.1.1 MWF 5 1.1.1 MWF 6 1.1.1 MWF 7 1.1.1 MWF 8 1.1.1 MWF 9 2.1.1 MWF 10 2.1.1 MWF 11 1.1.1 MWF 12 1.1.1 1 hour mean 1.33 24 hour mean 1.00 1 hour 1 day 1 week
- 21. AftonChemical.com Friction vs CoolantSeparability 2017 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation.
- 22. AftonChemical.com Formulation Approach Take arepresentative slideway formulation Gradually replace one friction modifier with another Evaluate how the changing ratio of the two friction modifiers affect friction and coolant separability 2017 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Phosphonate with 1 alkyl chainPhosphite with 2 alkyl chains
- 23. AftonChemical.com 2017 © AftonChemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Friction Modifiers 0 0.05 0.1 0.15 0.2 0.25 1 2 3 4 5 Treatrate(%) Formulation Number Friction modifier replacement Phosphonate - 1 alkyl chain Phosphite - 2 alkyl chains
- 24. AftonChemical.com 2017 © AftonChemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Effect on Friction 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.001 0.01 0.1 1 10 100 1000 10000 FrictionCoefficient Sliding Speed (mm/min) Darmstadt Dynamic Friction - Steel/GCI 1 2 3 4 5 Increasing concentration of the phosphonate with 1 alkyl chain
- 25. AftonChemical.com 2017 © AftonChemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Effect on Coolant Separability Formulation 1 2 3 4 5 Phosphonate – 1 alkyl chain 0 0.0250 0.0500 0.0750 0.1000 Phosphite – 2 alkyl chains 0.2120 0.1590 0.1060 0.0530 0 SKC Results 1 2 3 4 5 MWF 1 3.1.1 3.1.1 1.1.1 1.1.1 1.1.1 MWF 2 1.1.1 1.1.1 1.1.1 1.1.1 1.1.1 MWF 3 1.1.1 1.1.1 1.1.1 1.1.1 1.1.1 MWF 4 1.1.1 1.1.1 1.1.1 1.1.1 1.1.1 MWF 5 1.1.1 1.1.1 1.1.1 1.1.1 2.1.1 MWF 6 1.1.1 1.1.1 1.1.1 1.1.1 1.1.1 MWF 7 1.1.1 1.1.1 1.1.1 1.1.1 1.1.1 MWF 8 1.1.1 1.1.1 1.1.1 1.1.1 1.1.1 MWF 9 1.1.1 2.1.1 2.1.1 5.1.1 5.2.1 MWF 10 1.1.1 2.1.1 2.1.1 4.1.1 4.2.1 MWF 11 1.1.1 1.1.1 1.1.1 1.1.1 1.1.1 MWF 12 1.1.1 1.1.1 1.1.1 1.1.1 1.1.1 1 hour mean 1.17 1.33 1.17 1.58 1.67 24 hour mean 1.00 1.00 1.00 1.00 1.67 Increasing concentration of the phosphonate with1alkyl chain
- 26. AftonChemical.com 2017 © AftonChemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Friction vs Coolant Separability 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0 1 2 3 4 5 6 MeanSKCrating FrictionCoefficient(at10mm/min) Formulation number Friction data 1hour mean 24 hour mean Increasing concentration of the phosphonate with 1alkyl chain
- 27. AftonChemical.com 2017 © AftonChemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Conclusions Friction control and coolant compatibility are important in slideway applications Good performance in both can be achieved with special formulations Slideway oil resevoir on a typical machine tool