摘 要

金属切削液作为金属加工中的重要配套材料，在加工金属时不可或缺。由于加工要求越来越高，切削速度和切削温度越来越高，许多金属切削液性能不足以满足切削要求，高性能的金属切削液日益被人们重视。微乳切削液是一种比较先进的金属切削液，由于其具有良好的润滑性、冷却性、稳定性和清洗性等性能。使得微乳切削液逐渐被广泛应用到金属加工中。二十一世纪以来，环保型切削液围绕“无毒害、低污染、长寿命、高性能”主题开展研究。

本文研究了年产5000t一种金属加工用的环保型微乳切削液的生产车间设计，该微乳切削液以矿物油、极压润滑剂、乳化剂、助乳化剂、油性剂、和防锈剂等为原料，混合加热搅拌，制备出一个稳定的分散体系。确定该微乳切削液的反应配比为：蒸馏水：500SN基础油：二乙醇胺硼酸酯：妥尔油脂肪酸：石油磺酸钠：OP-10：吐温80：1-辛醇：乙醇=23：12：23：8：5：9：10：6：3。

其生产流程简单介绍为将原料分为两相，一相为油相，油相中向500SN基础油中逐一加入妥尔油脂肪酸、石油磺酸钠和苯并三氮唑搅拌混合均匀得到油相；另一相为水相，水相以乙醇溶解OP-10HE 吐温80，然后再加入水、1-辛醇、和二乙醇胺硼酸酯搅拌混合均匀得到水相。然后将油相和水相送入搅拌釜中混合乳化制得微乳切削液原液。

其次是车间设计，通过物料衡算和能量衡算计算主体设备的尺寸，再根据工艺要求对各种辅助设备进行选型。然后布置设备，车间布置分为两层，一层为预混系统、泵房和包装系统，二层为各原料的储罐。

关键词：微乳切削液；金属加工；乳化剂；助乳化剂；微乳化；油相；水相。

Abstract

With the development of economy, the metal processing industry has developed accordingly. As an important supporting material in metal processing, metal cutting fluid is indispensable in metal processing.Because machining requirements are higher and higher, cutting speed and cutting temperature are higher and higher, the performance of many metal cutting fluids is not enough to meet the cutting requirements.Microemulsion cutting fluid has been widely used in metal cutting.Microemulsion cutting fluid is a kind of advanced metal cutting fluid, because of its good lubrication, cooling, stability and cleaning properties.Microemulsion cutting fluid has been widely used in metal machining.Since the 21st century, environmental friendly cutting fluids have been studied on the theme of "non-toxic, low pollution, long life and high performance".

In this paper, the workshop design of an environment-friendly microemulsion cutting fluid with an annual output of 5000t for metal processing is studied. The microemulsion cutting fluid is made of mineral oil, extreme pressure lubricant, emulsifier, emulsifier, oil-based agent and anti-rust agent, etc., by mixing heating and stirring, a stable dispersion system is prepared.The reaction ratio of the microemulsion cutting fluid was determined as follows: distilled water: 500SN base oil: diethanolamine borate: Tol oil fatty acid: sodium petroleum sulfonate: OP-10: Twain 80:1-octanol: ethanol = 23:12:23:5:9:10:6:3.

The production process is simply described as follows: the raw materials are divided into two phases. One phase is the oil phase. In the oil phase, toll oil fatty acid, sodium petroleum sulfonate and benzotriazole are added into the 500SN base oil one by one to get the oil phase.The other phase was aqueous, which dissolved op-10he Tween 80 with ethanol, then added water, 1-octanol, and diethanolamine borate to stir and mix to get aqueous phase.Then the oil phase and the water phase are mixed and emulsified in the agitator to get the microemulsion cutting fluid.

The second is the workshop design, through the material balance and energy balance calculation of the size of the main equipment, and then according to the process requirements for the selection of various auxiliary equipment.The workshop is divided into two floors: the first floor is for premix system, pump room and packaging system, and the second floor is for storage tanks of each raw material.

Key words:Microemulsion cutting fluid;Metal working;Emulsifier;Auxiliary emulsifier；Micro emulsion;oil phase;water phase.

目录

第1章 绪论 1

1.1 简介 1

1.2 金属的切削过程 1

1.3 切削液发展历史 1

1.4 切削液的分类 2

1.5 微乳化技术及应用 2

1.5.1 什么是微乳液 2

1.5.2 微乳液的形成机理 2

1.6 切削液的作用机理 2

1.6.1 冷却机理 3

1.6.2 润滑机理 3

1.6.3 清洗机理 3

1.6.4 防锈机理 3

1.7 工艺配方 3

第2章 生产工艺流程 5

2.1原料及设备 5

2.1.1原料 5

2.1.2主要仪器及设备 6

2.2 生产工艺操作 6

2.3 工艺流程简图 6

第3章 物料衡算及能量衡算 6

3.1 衡算依据 6

3.2 年产量及天产量计算 7

3.3 物料衡算 7

3.4 热量衡算 10

3.4.1总的热量衡算 10

3.4.2油相的热量衡算 11

3.4.3水相的热量衡算 11

第4章 搅拌釜的设计 12

4.1 搅拌釜的几何尺寸 12

4.2 夹套的结构与尺寸设计 13

4.3 壁厚的计算 14

4.3.1 搅拌釜壁厚的计算 14

4.3.2 夹套厚度计算 14

4.4 水压试验应力校核 15

4.5 搅拌釜相关数据 15

4.5.1 釜体的主体部分 15

4.5.2 支座的选型 16

第5章 搅拌器的设计 16

5.1 搅拌器类型 16

5.2 传动装置及搅拌轴 17

5.2.1 传动装置 17

5.2.2 搅拌轴 17

5.3 轴封装置 18

5.4 其他附件 18

5.4.1 凸缘法兰 18

5.4.2 安装底座 18

5.4.3 机架 18

5.4.4视镜 18

第6章 生产安全及“三废”治理方案的制定 18

6.1生产安全制度 18

6.2三废处理 19

6.2.1“三废”处理原则 19

6.2.2三废处理与综合利用 19

第7章 车间布置 20

7.1车间布置方案 20

第8章 工程技术经济评价 20

8.1投资估算 20

8.1.1设备 20

8.1.2建厂 20

8.1.3人工 20

8.1.4检修与维修 21

8.1.5原料 21

8.1.5总投资估算 21

8.2经济效益 22

结论 22

参考文献 22

致 谢 23

附录A设备装配图 23

附录B工艺流程图 23

附录C1车间布置图 23

附录C2车间布置图 23