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附 錄
1 英文原文
THE GREEN DESIGN AND THE APPLICATION OF CUTTING FLUID
ABSTRACT
Cutting fluids are the important assist materials for machining. However; as applying cutting fluids as also brings about several environment problems. In order to realize green manufacturing, study on the green design and green application of the cutting fluids will be most effective way. The green design of fluids is design for the environment protection. It contains that the water-soluble cutting fluids will go instead of cutting oils, the vegetable oils and synthetic ester are substituted for mineral oil and the green additives are developed. The green application demands the cutting fluids doesn’t harm operator and the pollution of environment is the lowest in metal cutting. The concrete step is to strengthen the cutting fluids management and safeguard, to spread the concentrated cooling and lubricating systems, to use the protecting device and to adopt the sealing cutting. Moreover, the new technologies of disposing waster cutting fluids will be widely spreaded and developed.
1 INTRODUCTION
As developing industry leads to new material civilization it also brings about several environment problems. With the pollution more serious these problems of environment and natural resources have been generally realized. Consequently, many national governments have proclaimed a lot of mainstay of creating the wealth of the society; mechanical manufacturing industries are also the main source of the environment pollution. How to decrease or eliminate the manufacturing pollution becomes a new subject. Then, the green manufacturing is the important part of the sustained development strategy and is the modern manufacturing model of overall considering environment protection and natural resources utilization ratio. Seeking for the aim is that influence of products on environment pollution is the least and resource utilization ratio is the highest during the whole period from designing and manufacturing and using to scrapping of products.
It is considered that the machining will have occupying the mechanical working amount over ninety percent in the 21st century. Cutting fluids are the important assist materials for machining. Applying cutting fluid rationally can markedly improve the machining quality and productivity; reduce the tool wear and the machining costs. In consequence, the cutting fluids are widely applied in the machining. With man’s environment protection consciousness enhanced, reverse influence of applying cutting fluids was clearly recognized. The harm of cutting fluids is as follows: (1) endangering man’s health. In as mach as cutting fluids include chemical ingredient pernicious to man’s health, in applying the cutting fluids they made operators be harmed perhaps. Because of operators directly touching the cutting fluids, many kinds of skin disease may be caused to happen. Moreover, high temperature producing in the metal cutting fluid be heated, so that forming the vapor and the smell, may make operator’s respiratory tract and lung disease be infected. (2) Environment pollution. In metal cutting the leak and the spill over of the cutting fluids may pollute environment and affect safe production. To drain waste cutting fluids which were not disposed or didn’t achieve the drain standard, considerably pollutes lend, river and lake and seriously influence the growth of animal and plant, and ecological environment and ecological balance were destroyed. Then, the cutting fluids are environment pollution resources in the machining. The way of realizing green manufacturing is to adopt dry cut and to develop a new type cutting fluids good for environment. The dry cut doesn’t apply cutting fluids in the machining, but tools’ life is shortened, for the machining condition is bad the production costs is increased, the production efficiency is reduced and the surface quality machined worsened. Consequently, to develop green cutting fluid will benefit the machining and is an urgent task also. We hope the cutting fluid has the following properties: (1) Harmless for operators and environment. (2) Excellent cooling, lubrication, rust protection and cleaning ability. (3) The waste cutting fluid was disposed easily.
In the following the green design and the green application of the cutting fluid will be considered.
2 THE GREEN DESIGN OF THE CUTTING FLUIDS
The tradition design only considers the quality and cost so that it do harm to the operator and the environmental pollution and waste the resources, hampering the sustained development. The green design of the cutting fluid goes round the environment protection, and obeys following rules. (1) Nontoxic. This is most important. The green cutting fluid didn’t contain the additives pernicious to man’s health and to environment protection, and its ingredients were biologically dissociated and the waste fluid was easily disposed. (2) High function. The green cutting fluid possesses excellent cooling, lubrication and clean ability and it can satisfy the needs of modern machining. (3) Long life. The green cutting fluid can maintain excellent properties in the longer period of use, so that the efficacy of the cutting fluid can enough utilized and the drainage amount of waste fluid is reduced. (4) Good economy. In order that the green cutting fluid is widely applied to the machining the price of the green cutting fluid can be accepted. The task of the green design is as follows:
2.1 The water Soluble Cutting Fluids will Go Instead of the cutting Oils
The cutting oils comprise mineral oils, rust inhibitors, biocides and boundary lubricants. It’s advantages are excellent lubricating ability, good wettability of surfaces, good rust protection, however, it’s limitations are higher cost, poor cooling ability, smoke generation, fire hazards, messiness and possible health hazard. Furthermore, mineral oil resources are becoming less and less and humanity will face that petroleum resource was exhausted. The advantages of water-soluble cutting fluid are lower cost, good heat removal, higher speed capability, cleanliness and freedom from oil mist. Consequently, the substitution of the water-soluble cutting fluids for cutting oils can meet the demands of humanity health and environment-friendly. Synthetic fluids and semi-synthetic fluids ought to be greatly developed.
2.2 The Substitution of Vegetable Oils and Synthetic Ester for Mineral Oil
In cutting fluids the mineral oil is main component and play lubricant part, but it’s waste liquid biologically dissociated and make environment be pollution. Natural vegetable oils such as sunflower oil, rape oil, castor oil and Soya-bean oil etc. Have the advantages which are non-poison for humanity and environment, good biodegradation and reprocessing property, but the limitations are poor stability and high cost.
Table 1 Base oils biodegradation
Base oils
Biodegradation ratio
Mineral oils
0～40
Natural vegetable oils
90～100
Ester oils
90～100
Synthetic esters comprise polyatomic alcohol ester, binary and compound eater etc., and it’s advantages are non-poison, good high temperature property and oxidation resistance and lubricating ability, while it’s defects are high cost and poor hydrolysis stability. Then, the vegetable oils cooperate with synthetic esters is substituted for mineral oils, so that not only does the cutting fluid properties remain the same but the environment as well is not polluted.
2.3 Study on Green Additives
Cutting fluids comprise mineral oil, extreme pressure lubricants, oilness agents, rust inhibitors, surfactants and biocides etc and the properties depend mainly on the function. Then, the study on the additives is the key of the green design.
2.3.1 Limiting Additives of use as Follows:
?The rust inhibitors namely sodium nitrite, phenol, phosphate, chromate, etc;
?The surfactants rather difficult to biodegrade for example polyether surfactants;
?Extreme pressure agents such as sulphide and chlorinated.
2.3.2 The Development of New Additives
?Boric acid esters are new additives, the advantages are to do not harm to people and environment and it possess excellent anti-wear property, good rust protection, anticorrosion and sterilization, but it’s limitations is poor hydrolysis stability.
Borax is also a multifunctional additive to certain extent, and it’s application needs studying further.
?Such substances as molybdenates, citrates and borate etc are good rust inhibitors now. Study on their cooperating effect will greatly contribute to researching and producing new anti-rust complex compound.
?Copperish compounds that are formed from oleic, citric acid and stearic acid etc possess better sterilization. Boric acid esters are also good biocides, and combining with other germicide it may markedly raise fungicidal effectiveness.
3 THE GREEN APPLICATION OF CUTTING FLUIDS
The green application of cutting fluids are that the operators are not harmed and the pollution of the environment is the lowest and the amount of waste cutting fluids is decreased to a minimum in the course of applying cutting fluids. In order to realize the green applying of cutting fluids, the user must adopt the following measures.
3.1 Using Protecting Device and adopting the Closed cutting
In order to improve working conditions, the technical devices must be used, by which the cutting fluids doing harm to human health and environment can be reduced. The concrete steps are as follows: (1) operator must put on their boiler suit and face guard; (2) the devices for preventing the splash of cutting fluid are used; (3) the exhaust devices for purifying air are installed on the machine tools or in the workshop; (4) operator works on the machine tools of closed working area.
3.2 Spreading the Concentrated Cooling and Lubricating System
The modern concentrated cooling and lubricating system is a system in which many alone cooling and lubricating systems are combined into one. The advantages are prolonging service life of cutting fluids, realizing automatic control easily on the performance index of cutting fluid, producing lower waster fluid amount, maintaining and managing easily, carrying and treating chip easily.
3.3 Strengthening Daily Management
An effective channel of reducing the pollution of cutting fluid on environment is reducing the waste fluid amount of cutting fluid. The service life of the cutting fluids not only depends on primary quality of cutting fluids, but also is subjected to effect of the service conditions and maintenance method. Therefore, to strengthen daily management and maintenance of cutting fluids can restrain the growth of microbiology in cutting fluids, so that the service life of cutting fluid is prolonged and the waste fluid amount is reduced. The concrete measures are adopted as follows:
? Thoroughly clean sump, pipe work, machine and guards before the refilling;
? The water-based cutting fluids are made up using pure water;
? Keep the cutting fluid work under the fixed concentration and rational pH value conditions;
? Use the filters to remove timely chip and tramp oil;
? Regularly ass non-toxic bactericide in the cutting fluid;
? Timely circulate the cutting fluid when the machine tool is stopped long-term work;
3.4 Developing and Spreading the New Technologies of Disposing waste Fluids
Preventing the public hazard and environment pollution and ensuring the safety and health of the operator is causing extreme attention in the whole society. The waste cutting fluids are an important pollution source. At present, the physical, chemical and biodegradation methods are adopted.
In the water pollution control, monitoring the chemical oxygen demand (COD) and biological oxygen demand (BOD) is often regarded as main means. As water-based cutting fluids contain large number of organic matter, namely, organic ammonia, nonionic surface-active agents and polyatomic alcohol etc., active carbon adsorption and active mire may be adopted in order to reduce COD and BOD of the waste disposal. These methods are economic and effective. The recent research shows that the effete of combining active carbon with active mire is still better in disposing waste cutting fluids.
2 中文翻譯
切削液的綠色設(shè)計及應(yīng)用
摘要：切削液是機械加工中重要的協(xié)助材料。然而，切削液的使用也引起了多種環(huán)境問題。為了意識到綠色制造對綠色設(shè)計和切削液的綠色運用進行研究將是一種非常有效的方法。切削液的綠色設(shè)計是針對環(huán)保的設(shè)計。它包括水乳切削液將代替切削油、菜油和合成醋帶頭礦物油和綠色添加劑的發(fā)展。綠色適用性要求切削液不傷害操作者和在金屬切削中對環(huán)境最低。具體的方法是加強切削液的運用管理和預(yù)防措施，發(fā)展延伸集中冷卻和潤滑系統(tǒng)，利用保護裝置和采取密封切削。而且，處理廢棄的切削液的新技術(shù)將被廣泛傳播和發(fā)展。
1、序言
隨著不斷發(fā)展的工業(yè)導(dǎo)致新的材料文化，也帶來了多種環(huán)境問題。隨著污染變得更嚴重，這些環(huán)境和自然資源的問題已經(jīng)被普遍認識到。因此，很多全球性組織已經(jīng)頒布了許多法律和條規(guī)來防止環(huán)境污染和保護實驗人員的安全和健康。作為創(chuàng)造社會財富的支柱，機械制造業(yè)是環(huán)境污染的主要來源。如何減小或消除制造污染變成了一個新的課題。然而，綠色制造是可持續(xù)發(fā)展戰(zhàn)略的重要組成部分和綜合考慮環(huán)境保護和自然資料利用率的現(xiàn)代制造典范。追求的目標是產(chǎn)品對環(huán)境污染的影響最低和從產(chǎn)品的設(shè)計到制造到廢棄的整個過程中的資源利用率最高。
在21世紀，機械被認為將占據(jù)機械行業(yè)的90%之多。切削液是機械中最重要的輔助材料。合理地使用切削液可以顯著地提高機械的質(zhì)量和生產(chǎn)量，減少刀具的磨損和機械成本。因此，切削液被廣泛使用于機械中。隨著人們環(huán)境保護意識的提高，使用切削液的不利影響也被清楚的意識到，切削液的害處如下：（1）危害人類健康。大部分切削液當中含有對人類健康有害的化學成分，當使用切削液是有可能是操作者受到傷害。因為操作者直接接觸切削液，有可能引起多種皮膚疾病。而且，在金屬切割過程中產(chǎn)生的高溫是得切削液被加熱，從而形成的蒸汽和氣味，有可能是操作人員感染上呼吸和肺病。（2）環(huán)境污染。在金屬切削過程當中切削液的泄漏和溢出將污染環(huán)境和影響安全生產(chǎn)。排出那些未經(jīng)處理或者沒有達到排放標準的切削液，極大地污染了土地，河流和湖泊也嚴重影響了動植物的生長，生態(tài)環(huán)境和生態(tài)平衡也被破壞了。因此，在機器加工中，切削液是環(huán)境污染源。達到“綠色”制造的方法是采用干切削和發(fā)展一種對環(huán)境有益的新的切削液。干切割是在加工過程中不采用切削液，但是刀具壽命短，因為加工條件和生產(chǎn)成本增加，所以生產(chǎn)效率降低了，加工表面質(zhì)量也更差。因此，發(fā)展“綠色”切削液將有利于加工而且也是一項重要的課題。我們希望這種切削液具有下列特性：（1）對操作人員和環(huán)境沒有危害；（2）相當好的冷卻、潤滑、防銹和清潔功能；（3）廢棄切削液容易處理。
接下來將介紹切削液的綠色設(shè)計和綠色使用。
2、切削液的綠色設(shè)計
傳統(tǒng)的設(shè)計只是考慮切削液的數(shù)量和成本，所以它會危害操作人員的健康和污染環(huán)境和浪費資源，阻礙了持續(xù)的發(fā)展，切削液的“綠色”設(shè)計順從了環(huán)境保護，也遵守以下規(guī)則：（1）無毒。這是最重要的。這些綠色切削液不包含對人類健康和環(huán)境保護有危害的添加物，它的成份能自然離體，廢棄切削液也能容易被處理。（2）高效性。綠色切削液擁有優(yōu)質(zhì)的冷卻性。潤滑性和清潔功能，而且也能滿足現(xiàn)代機械的需求。（3）長壽命。綠色切削液在長時間的使用過程中能夠保持優(yōu)秀的性能，從而切削。（4）良好的經(jīng)濟性。因為這個，這些切削液被廣泛應(yīng)用于機械中，綠色切削液的價格也能被人們接受。綠色設(shè)計的重點在于：
2.1浮化切削液將取代切削油
切削油包括礦物油、防銹劑、殺生物劑和邊界潤滑劑。它的優(yōu)點是優(yōu)良的潤滑性，良好的表面濕性和良好的防生銹特性。然而，它的缺點是高成本、差的冷卻性、會產(chǎn)生煙霧、易起火、臟和可能的健康危害。更者，礦物油冷變得越來越少而且人類將面臨石油冷液的枯竭。乳化切削液的優(yōu)點是低成本、良好的熱傳遞、高速、干凈和不具有油霧。
因此，用乳化切削液代替切削油可以滿足人類健康和環(huán)境保護的需求。合成液和半合成液應(yīng)該被廣泛地發(fā)展。
2.2菜油和合成醋代替礦物油
在切削液中礦物油是主要成分和起著潤滑的作用，但是那些未被充分利用的液體自然離解從而使得環(huán)境被污染。那些自然菜油比如說向日葵油、葡萄油、蓖麻油和大豆油等等。它們具有對人類和環(huán)境無毒，良好的生物損耗和可在加工等優(yōu)點，但不足之處是穩(wěn)定性差和高成本。
表1 各種油的生物損耗
油
生物損耗率
礦物油
0 ~ 40
菜油
90 ~ 100
醋油
90 ~ 100
合成醋包含多原子醇醋、二元醋和復(fù)合醋等，它的優(yōu)點是無毒、良好的高溫性和抗氧化性和潤滑性，它的缺點是高成本和水解性差。從而，再合成醋配合而成的菜油代替礦物油，不但使切削液的性能保持不變，而且環(huán)境也同樣未被污染。
2.3關(guān)于綠色添加劑的研究
切削液又礦物油、邊界擠壓潤滑劑、油劑、生銹抑制、表面活劑和殺生物劑等組成，而且它的性能主要取決于這些成分的功能。所以，對這些添加劑的研究是綠色設(shè)計的關(guān)鍵。
2.3.1使用的少量添加劑如下：
?生銹抑制劑又可以叫做亞硝酸鈉、酚、磷酸鹽、鉻酸鹽等
?表面活劑相當難被生物離解。比如聚乙烯表面活劑
?邊界擠壓潤滑劑比如硫化物和氯化物
2.3.2新的綠色添加劑的發(fā)展
?硼酸醋是新的添加劑，它的優(yōu)點是對人類和環(huán)境無害，而且擁有相當好的防磨損性能，優(yōu)良的防銹能力，抗腐蝕性好和已滅菌，但是缺點是水解穩(wěn)定性差。
硼砂在一定程度上也是一種多功能添加劑，它的使用需要更深層的研究。
?像輝鉬礦，醋和硼腕等這些物質(zhì)現(xiàn)在是一種很好的生銹抑制劑，對它們的成分作用的研究將對研究作出很大貢獻和發(fā)明新的復(fù)雜的防銹復(fù)合物。
?由油酸、檸檬酸和硬脂酸等組成的含銅復(fù)合物，具有更好的殺菌能力。硼酸醋也是很好的殺生物劑，而且與其他殺菌劑配合可以顯著地提高殺菌劑的效率。
3.切削液的綠色使用
切削液的綠色使用是指在切削液的使用過程中，操作者不受傷害，對環(huán)境的污染最低和廢棄的切削液的數(shù)量減少到最小。為了達到切削液的綠色使用，使用者必須遵照以下方法。
3.1使用防護裝置和采用密封切削
為了改善工作條件，必須使用工程裝置，通過它可以使切削液對人類健康和環(huán)境的損害減小，具體的步驟如下：（1）操作者必須穿工作服和戴手套和面具；（2）使用防止切削液飛濺的裝置；（3）凈化空氣的排出裝置應(yīng)當被安裝在機床或工作房中；（4）操作人員應(yīng)當在密封機床上工作
3.2集中冷卻和潤滑系統(tǒng)的發(fā)展
現(xiàn)代集中冷卻和潤滑系統(tǒng)是有多個單獨的冷卻和潤滑系統(tǒng)組成的一個系統(tǒng)的才、系統(tǒng)。優(yōu)點是延長切削液的使用壽命，使切削液的顯示分度頭更易自動控制，創(chuàng)造更低的廢液排出量，更易保養(yǎng)和管理，更易帶走和出來切削液。
3.3加強日常管理
減小切削液對環(huán)境污染的一個有效渠道是減少廢棄切削液的數(shù)量。切削液的使用壽命不僅僅取決于切削液的各自質(zhì)量，而且也取決于使用環(huán)境和保養(yǎng)方法。因此，加強日常管理和切削液的保養(yǎng)能夠抑制切削液中微生物的生長，從而使得切削液的使用壽命延長和廢棄切削液數(shù)量是減少。具體的方法應(yīng)用如下：
?在重新添加切削液之前徹底地清洗曲柄箱、工作管、機器和防護裝置；
?切削液的水應(yīng)是純凈水；
?保證切削液工作在確定的濃度和適度的PH值條件下；
?在切削液中有規(guī)律的添加無毒殺菌劑；
?當機器刀具使用較長時間時應(yīng)定期換切削液；
3.4發(fā)展和延伸新的處理廢棄切削液的技術(shù)
防止公眾害處和環(huán)境污染和確保安全以及操作者的健康在整個社會越來越受到人們的關(guān)注。廢棄切削液是一個重要的污染源。目前，物理、化學和生物降解的方法都被采用了。
在水污染控制和檢測中，COD和BOD被認為是主要的方法。因為水性切削液包含大量的有機物，它們是有機氨、非離子表面活性劑和多原子乙醇等，因此，可以采用活性碳吸附以減少廢棄處理中的COD和BOD。這些方法既經(jīng)濟又有效。最近研究表面活性沼澤與那些枯竭的過時的活性碳結(jié)合在處理廢棄切削液方面仍非常有效。