Cooling Lubricant Composition for Machining Fiber-Reinforced Plastics
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Solution Overview
Problem
The machining of fiber-reinforced plastics and composite materials with metals poses challenges due to the reactivity of cooling lubricants with resin, leading to potential strength reduction and tool wear, especially when using specialized tools is not feasible.
Innovation Solution
A cooling lubricant composition including a sulfurized hydrocarbon, ethoxylated alkyl phosphate, maleic acid dibutyl ester polymer, and epoxidized ester, which is suitable for machining fiber-reinforced plastics and materials with metal inserts or layers without requiring specialized tools, providing lubrication and corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If cooling lubricant is used for machining fiber-reinforced plastics, then tool life and surface quality are improved, but resin strength may be reduced due to chemical reaction
Solution Approach 1:
The patent applies parameter changes by carefully selecting and controlling the chemical composition parameters of the cooling lubricant. Specifically, it uses sulfurized hydrocarbons with 4-30 carbon atoms and 1-5 sulfur atoms, ethoxylated/propoxylated alkyl phosphates with 12-30 carbon atoms, phosphoric acid esters with fatty alcohol polyglycol ethers, maleic acid dibutyl ester polymers with C10-20-1-alkenes, and epoxylated esters. These specific parameter ranges ensure effective cooling and lubrication while preventing harmful chemical reactions that would compromise resin strength.
Solution Approach 2:
The patent applies local quality by creating different functional zones within the cooling lubricant composition. The formulation provides localized cooling effects through water-based components, localized lubrication through sulfurized hydrocarbons and phosphates, and localized protection against chemical reactions through carefully selected ester and polymer components. This spatial-functional differentiation allows the lubricant to perform multiple functions simultaneously without compromising resin integrity.
2Duration of action of stationary object
If specialized tools are used for machining fiber-reinforced plastics, then tool wear is reduced, but device complexity and cost increase
Solution Approach 1:
The patent applies self-service by enabling standard tools to perform machining of fiber-reinforced plastics through the use of specially formulated cooling lubricant. The lubricant composition itself provides the protective and lubricating functions that would otherwise require specialized tool coatings or geometries. The sulfurized hydrocarbons and phosphoric acid esters create protective films on the tool surface during machining, allowing conventional tools to achieve extended tool life without modified designs.
3Temperature
If water is used for cooling, then cooling effect is achieved, but corrosion of tools and machines occurs
Solution Approach 1:
The patent applies composite materials principle by creating a composite cooling lubricant system that combines water-based cooling components with corrosion-inhibiting organic additives. The formulation integrates water (for cooling) with sulfurized hydrocarbons, phosphoric acid esters, and epoxylated esters (for corrosion protection). This composite composition delivers effective cooling while the organic components form protective films that prevent corrosion of tools and machine surfaces.
4Ease of manufacture
If dry machining is used, then no cooling lubricant is needed, but delamination and protruding fibers occur
Solution Approach 1:
The patent applies the intermediary principle by introducing the specially formulated cooling lubricant as a mediating substance between the tool and the fiber-reinforced plastic workpiece. This intermediary substance reduces direct mechanical interaction that causes delamination and protruding fibers. The lubricant film acts as a buffer that facilitates smooth material removal while preventing fiber pull-out and delamination, thereby improving surface quality without requiring complex encapsulation systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The cooling lubricant composition reduces tool wear, improves machining quality, and increases efficiency and productivity while ensuring the mechanical properties of fiber-reinforced plastics are not compromised, even when metals are present.
Implementation Method 1
a sulfurized hydrocarbon with 4 to 30 carbon atoms and 1 to 5 sulfur atoms and/or a sulfurized triglyceride with 10 to 20 carbon atoms in the fatty acid residue
Implementation Method 2
an ethoxylated and/or propoxylated alkyl phosphate with 12 to 30 carbon atoms in the alkyl residue, (c) a phosphoric acid ester with fatty alcohol polyglycol ether
Implementation Method 3
a maleic acid dibutyl ester polymerized with C 10-20-1-alkenes, and (e) an epoxylated ester
Implementation Method 4
The cooling and lubricating effect not only increases tool life but also improves the surface quality of the machined components
Implementation Method 5
Water could be used to cool the tools
Implementation Method 6
amino alcohol, corrosion inhibitor, emulsifier, defoamer, and biocide
Data Source
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AI summary
The invention relates to a cooling lubricant present in concentrate as an emulsion for the machining of fiber-reinforced plastics and also for the machining of material combinations of fiber-reinforced plastics and metals, as well as a cooling lubricant present in concentrate as a solution for the machining of fiber-reinforced plastics.