Metalworking Fluid

Abstract

A metalworking fluid is disclosed. The fluid comprises an oleaginous component, an aqueous component, and a surfactant dispersed in the aqueous component. The metalworking fluid is substantially free from defoamers or anti-foam compounds.

1 . Metalworking fluid comprising an emulsion of:
 An oleaginous component;   An aqueous component; and   A surfactant;   wherein either the oleaginous component or the aqueous component forms micelles with the surfactant, and wherein the metalworking fluid does not contain insoluble defoamers or anti-foam compounds to compensate for foaming.   
     
     
         2 . Metalworking fluid as claimed in  claim 1 , wherein substantially all of the surfactant is bound within micelles of the oleaginous or the aqueous component, such that there is substantially no unbound surfactant present in the fluid. 
     
     
         3 . Metalworking fluid as claimed in  claim 1  or  2 , wherein in use, the emulsion is diluted or undiluted. 
     
     
         4 . Metalworking fluid as claimed in  claim 1  or  2 , wherein the metalworking fluid is an additive. 
     
     
         5 . Metalworking fluid as claimed in any of  claims 1  to  4 , wherein the micelle is a normal-phase micelle, and the oleaginous component forms the centre of the micelle. 
     
     
         6 . Metalworking fluid as claimed in  claim 5 , wherein the surface comprises at least one surfactant monomer layer. 
     
     
         7 . Metalworking fluid as claimed in any of  claims 1  to  6 , wherein the structure of the surfactant dictates the structure of the micelle. 
     
     
         8 . Metalworking fluid as claimed in  claim 7 , wherein the micelle is generally spherical in structure. 
     
     
         9 . Metalworking fluid as claimed in any preceding claim, wherein the oleaginous component comprises a lubricating composition. 
     
     
         10 . Metalworking fluid as claimed in  claim 9 , wherein the lubricating composition is a Group I, II, II, IV or V base oil. 
     
     
         11 . Metalworking fluid as claimed in  claim 9 , wherein the lubricating composition comprises a blend of components, at least one of which has lubricating properties. 
     
     
         12 . Metalworking fluid as claimed in any preceding claim, wherein the surfactant is an ionic surfactant, a non-ionic surfactant or a mixture thereof. 
     
     
         13 . Metalworking fluid as claimed in any of  claims 1  to  4 , wherein the micelle is an inverse-phase micelle, and at least some of the aqueous component forms the centre of the micelle. 
     
     
         14 . Metalworking fluid as claimed in any preceding claim, comprising:
 10 to 50 wt % of lubricating composition;   3.0 to 8.0 wt % of surfactant;   5.0 to 10 wt % corrosion inhibitor;   0 to 1.0 wt % yellow metal;   0 to 8.0 wt % esters; and   Water to balance.   
     
     
         15 . Metalworking fluid as claimed in  claim 9 , wherein the lubricating composition is a mineral oil having a kinematic viscosity at 40° C. of greater than or equal to 20 cst. 
     
     
         16 . Metalworking fluid as claimed in  claim 1 ,  2 ,  3  or  4 , wherein the average micelle diameter follows a Gaussian distribution having a mean μ, and wherein the standard deviation σ is less than or equal to 0.2μ. 
     
     
         17 . Metalworking fluid as claimed in  claim 16 , wherein the mean average micelle diameter is ≤0.3 μm. 
     
     
         18 . Metalworking fluid as claimed in any preceding claim, wherein the metalworking fluid is used in a destructive metalworking process. 
     
     
         19 . Metalworking fluid as claimed in any of  claims 1  to  17 , wherein the metalworking fluid is used in a deformation metalworking process. 
     
     
         20 . Method of making the micelles of lubricant and surfactant in the metalworking fluid as claimed in any of  claims 1  to  19 , comprising:
 Mixing a first fluid comprising an aqueous solution of a surfactant; 
 Obtaining a second fluid comprising a lubricating composition; 
 Mixing the first and second fluids under a shear force to produce an intermediate fluid; 
 and 
 Recovering a fluid comprising micelles of the lubricant and the surfactant. 
 
     
     
         21 . Method as claimed in  claim 20 , wherein the step of mixing the first and second fluids comprises stirring at a rotational speed in the range of 1200 to 1600 rpm. 
     
     
         22 . Method as claimed in  claim 21 , wherein the first and second fluids are mixed to form an intermediate fluid and, further comprising the step of:
 Adding a third fluid to the intermediate fluid under a lamellar flow.   
     
     
         23 . Method as claimed in  claim 22 , where the intermediate fluid has a higher viscosity than either the first or the second fluid. 
     
     
         24 . Use of a fluid containing no defoamers or anti-foam compounds as a metalworking fluid or an additive for a metalworking fluid. 
     
     
         25 . A method of forming a metalworking fluid, comprising:
 Forming a first fluid comprising a surfactant;   Forming a second fluid comprising an oleaginous compound;   Mixing the first fluid and the second fluid under a shear force to produce an intermediate fluid; and   Mixing an aqueous fluid and the intermediate fluid under laminar flow to create an metalworking fluid.   
     
     
         26 . A metalworking fluid as claimed in any of  claims 1  to  19  made using the method according to  claim 25 . 
     
     
         27 . A metalworking fluid made using the method of  claim 25 .