The Selection of Cutting Fluids in Copper Processing Technology
In the surging wave of the booming modern manufacturing industry, metal processing cutting fluids, like unsung heroes, play an irreplaceable role. From the manufacturing of high - precision components in the aerospace field, to the production of engines and body frames in the automotive industry, and then to the processing of daily hardware appliances, metal processing cutting fluids are everywhere, deeply involved in and promoting the smooth progress of each manufacturing link.
I. Functional Interpretation and Characteristic Analysis of Metal Processing Cutting Fluids
(I) The Key Roles of Metal Processing Cutting Fluids
Metal processing cutting fluids are functional liquids specifically applied to the metal cutting processing technological process. During metal cutting, the intense friction between the cutting tool and the metal generates a large amount of heat, and at the same time, it leads to increased tool wear and a decline in the surface quality of the workpiece. The emergence of cutting fluids has effectively solved these problems. Through their unique formulations and properties, they intervene between the cutting tool and the workpiece, coordinate the relationship between the two, and ensure the smooth progress of the processing flow.
(II) The Key Characteristics of Metal Processing Cutting Fluids
1.The Action Mechanism of Excellent Lubricity in the Metal Cutting Process: At the moment of metal cutting, the cutting tool is in close contact with the metal workpiece, and the friction coefficient rises sharply. Cutting fluids are rich in lubricating components such as oily additives and extreme - pressure additives, which can form a thin and tough lubricating film on the surfaces of the cutting tool and the workpiece. This greatly reduces the friction resistance, making the cutting action of the tool smoother. This not only slows down the wear rate of the tool and extends its service life but also ensures high - precision processing of the workpiece surface, avoiding defects such as scratches and pull - marks that affect product quality, and making the processed metal surface smooth.
2.The Importance of Remarkable Cooling Efficiency for the Stability of Metal Processing Quality: During the metal processing process, especially in high - speed cutting, high - power grinding and other working conditions, heat accumulates rapidly. Cutting fluids have excellent heat - conduction capabilities and can quickly absorb and conduct a large amount of heat generated in the processing area. Through the circulation system, the cutting fluids continuously carry away the heat and maintain a suitable temperature in the processing environment. This prevents the cutting tool from annealing and softening due to overheating and losing its cutting ability. At the same time, it avoids problems such as workpiece deformation and changes in material properties due to high temperatures, providing a guarantee for stable processing quality.
3.The Significance of Strong Cleaning Function in Ensuring the Smooth Processing Flow: During cutting, metal debris scatters continuously in the processing area. If not cleaned in time, these debris will accumulate in every corner of the cutting tool, the workpiece, and the processing equipment, causing many problems. Cutting fluids have good fluidity and can carry the debris away from the processing site along the flow direction of the liquid. At the same time, some chemical components such as surfactants contained in the cutting fluids can enhance the emulsification and dispersion ability of the debris, making it easier to be removed. Thus, the cutting tool, the workpiece, and the equipment are always kept clean, avoiding secondary processing damage and equipment jamming failures caused by debris residue, and ensuring the efficient and orderly progress of the processing flow.
4.The Value of Reliable Anti - Corrosion and Rust - Prevention Characteristics in Extending the Service Life of Metal Workpieces: Metal workpieces are prone to be eroded by moisture, oxygen, and other corrosive substances in the surrounding environment during the processing process and subsequent storage stage. Components such as corrosion inhibitors and rust - preventives contained in the cutting fluids can form a protective film on the surface of the workpiece, isolating external erosion factors. Whether during processing or after processing is completed, this protective film can continuously play a role, ensuring that the appearance of the workpiece is not stained by rust and the material properties remain stable as before, effectively extending the service life of the workpiece and enhancing the overall value of the product.
II. Characteristic Analysis of Copper and Its Alloy Materials
(I) The Unique Characteristics of Copper and Its Alloy Materials
Copper and its alloy materials have the remarkable characteristics of relatively low strength and hardness, but extremely prominent plasticity and excellent ductility. In addition, their excellent thermal and electrical conductivity make them widely used in many fields. They provide key support for the precision electronic components of vehicles in the automotive electronics field, help aircraft deal with complex working conditions in the aerospace field, meet the fine needs of various smart devices in the smart home field, and ensure the efficient operation of machining in the machine - tool equipment field. It can be said that copper and its alloy materials are one of the metal materials with the widest application range in the non - ferrous metal family in our country.
(II) The Challenges Faced in the Copper Processing Process
Due to the overly excellent ductility, plasticity, and toughness of copper materials, the processing difficulty is instead increased during the processing process. In actual processing, the surface of the workpiece is prone to scratches and bumps, and the phenomenon of plastic adhesion occurs frequently, resulting in a decrease in grinding accuracy. At the same time, the active chemical properties of copper materials also bring problems. The workpieces after mechanical processing often turn black and change color rapidly. Therefore, when developing and producing cutting fluids suitable for copper processing, key properties such as lubrication, cooling, and anti - corrosion must be comprehensively considered.
III. Categories and Selection of Common Cutting Fluids in Copper Processing
(I) Categories of Common Cutting Fluids in the Copper Processing Field
Currently, in the field of copper material cutting processing, micro - emulsified cutting fluids and fully synthetic cutting fluids are highly favored. Micro - emulsified cutting fluids use refined mineral oil as the base oil and rely on high - lubricity extreme - pressure agents as the core lubricating components to ensure the smoothness and accuracy of the processing surface. Fully synthetic cutting fluids start from the dual needs of lubrication and cooling, select polymer polyethers and polyesters as the main lubricants, and are equipped with high - performance copper corrosion inhibitors, successfully solving the problem of easy oxidation and color change of copper when using fully synthetic cutting fluids.
(II) Selection of Cutting Fluids in Different Processing Scenarios
1.The Performance Requirements of Cutting Fluids in High - Speed Cutting and Drilling Scenarios: A large amount of heat is generated during high - speed cutting and drilling operations. If the cutting fluid cannot effectively dissipate this high heat in time, the cutting tool is easily wrapped by viscous materials, and built - up edges will multiply on the tool. This not only greatly shortens the service life of the cutting tool but also causes the workpiece to be worn and seriously impairs the processing surface accuracy. Therefore, in such working conditions, the cutting fluid must have excellent lubrication performance and strong cooling effects.
2.Analysis of the Performance Focus Points of Cutting Fluids in the Grinding Processing Scenario: The debris generated during grinding operations is extremely fine, and the heat released during the processing is extremely high. In this case, in addition to focusing on the lubrication and cooling performance of the cutting fluid, its sedimentation performance is also crucial. If the debris cannot settle smoothly with the cutting fluid but adheres to the cutting tool or the workpiece, the cutting accuracy will be seriously affected, and the smooth texture of the workpiece surface will disappear completely.
3.Analysis of the Use of Cutting Fluids in the Turning Operation Situation: When turning copper alloy materials, the cutting depth and feed rate are roughly the same as those of ordinary steel turning. Usually, no additional cutting fluid is required. However, it should be noted that when turning brass materials, using an emulsion with a concentration between 3% - 5% can meet the processing requirements and ensure the smooth completion of the processing task.
IV. Types of Lubricant Additives for Copper Processing
In the copper processing process, the rational selection of lubricant additives is of great significance. Different types of additives play their unique roles and work together to ensure the processing effect.
1.Oily Additives: Oily additives are usually composed of animal and vegetable oils, higher fatty acids, higher fatty alcohols, and their esters. They have polar groups in their molecules and can firmly adsorb on the metal surface to form a physical adsorption film. In low - load, low - speed cutting or grinding and other working conditions in copper processing, oily additives can effectively reduce the friction coefficient, reduce the direct contact between the cutting tool and the workpiece, thus playing a good lubricating role, preventing defects such as scratches and pull - marks on the workpiece surface, and improving the surface quality of the processing.
2.Extreme - Pressure Additives: Extreme - pressure additives mainly include organic compounds containing sulfur, phosphorus, and chlorine. When copper processing encounters extreme working conditions such as high - load, high - speed, or high - temperature, the adsorption film formed by ordinary oily additives will be damaged due to high temperature and high pressure. At this time, extreme - pressure additives play a key role. They can chemically react with the metal surface to generate a chemical reaction film with a lower shear strength. This film can still maintain good lubrication performance under high - temperature and high - pressure conditions, effectively preventing phenomena such as sintering and seizure caused by the direct contact of metals between the cutting tool and the workpiece, and greatly improving the lubrication effect of the cutting fluid under harsh conditions.
3.Antioxidants: During the copper processing process, the lubricating oil will oxidize and deteriorate due to factors such as contact with air, high temperature, and metal, resulting in a decline in performance. Antioxidants can inhibit the oxidation process of the lubricating oil and extend its service life. Common antioxidants include phenolic and amine compounds. They can capture the free radicals generated during the oxidation process of the lubricating oil, interrupt the oxidation chain reaction, maintain the stability of the lubricating oil, and ensure that its lubrication, cooling, and other properties remain effective without being affected by oxidation.
4.Copper Corrosion Inhibitors: Given that the chemical properties of copper are relatively active and it is easy to be oxidized and corroded during the processing process. Copper corrosion inhibitors can form a dense protective film on the surface of copper, preventing corrosive substances such as oxygen and moisture from contacting copper, thereby preventing problems such as color change and corrosion of copper workpieces during the processing and subsequent storage processes. For example, benzotriazole (BTA) and its derivatives have good corrosion - inhibition effects on copper and are common types of corrosion inhibitors used in copper processing lubricating oils.
Metal processing cutting fluids, with their excellent properties in lubrication, cooling, cleaning, anti - corrosion, and rust - prevention, have become an indispensable part of the metal processing technology chain. In the copper processing process, scientifically and reasonably selecting cutting fluids according to different processing scenarios and requirements is of great significance for improving processing efficiency, ensuring processing quality, and reducing production costs. With the continuous development of the manufacturing industry, research on the performance and application of cutting fluids will also continue to deepen, providing strong support for promoting the modern manufacturing industry to a new level of higher precision and higher efficiency.
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