1、Designation: D 5619 00 (Reapproved 2005)An American National StandardStandard Test Method forComparing Metal Removal Fluids Using the Tapping TorqueTest Machine1This standard is issued under the fixed designation D 5619; the number immediately following the designation indicates the year oforiginal
2、adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.1. Scope1.1 This test method covers a laboratory technique toevaluate the relat
3、ive performance of metal removal fluids usinga non-matrix test protocol using the tapping torque testmachine.1.2 The values stated in SI units are to be regarded asstandard. Because the equipment used in this test method isavailable only in inch-pound units, SI units are omitted whenreferring to the
4、 equipment and the test pieces.1.3 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitatio
5、ns prior to use.2. Terminology2.1 Definitions of Terms Specific to This Standard:2.1.1 build-up edgea triangular deposit that forms adja-cent to the cutting edge on the face of the tool in a metalwork-ing operation.2.1.1.1 DiscussionThe high contact pressure between thecutting edge of the tap and th
6、e specimen material results in ahigh temperature. The high temperature, the wear debris, thehigh contact pressure, and some of the constituents of thecutting fluid combine at the cutting edge and form a triangulardeposit, referred to as a built-up edge (BUE). The BUE issustained by the chip curl as
7、it is passed over, and as the BUEgrows, it is abraded by the rubbing of the chip curl. Since theBUE is located exactly where the curl is generated, it contrib-utes to the size of the curl; the larger the BUE, the larger thediameter of the chip curl. A small chip curl will flow smoothlyup the flute o
8、f the tap and will not affect the torque. However,a large curl will drag and jam in the flute and will contribute tothe tapping torque.If a new tap is utilized, it is necessary to run several tests torun-in the tap. This process prepares the cutting edge to receivea characteristic BUE, depending on
9、which cutting fluid isutilized.If a cutting fluid is changed to another cutting fluid during a testsequence, it is necessary to discard the results from at least thefirst test of the new fluid since the previous BUE must beabraded or modified with the chemistry of the new fluid to formits own charac
10、teristic BUE.The ideal cutting fluid forms a small, stable BUE that assists inthe formation of a small curl.3. Summary of Test Method3.1 The torque required to tap a thread in a blank specimennut while lubricated with a metal removal fluid is measured andcompared with the torque required to tap a th
11、read in a blankspecimen nut while lubricated with a reference fluid. See Fig.1. The ratio of the average torque values of the reference oil tothe metal removal fluid tested, when using the same tap, isexpressed as the percent efficiency of the fluid. The efficiencyof two or more fluids can be compar
12、ed when the average torquevalues of the reference fluid on different taps are considered tobe statistically equivalent.4. Significance and Use4.1 The procedures described in this test method can beused to predict more accurately the lubricating properties of ametal removal fluid than previously avai
13、lable laboratory scaletests.4.2 This test method is designed to allow flexibility in theselection of test specimen metal composition, tap alloy orcoatings, and machining speeds.4.3 Comparison between various types of fluids can bemade, including cutting oils, soluble oils, semi-synthetics, orwater s
14、oluble synthetics.5. Apparatus5.1 Test Machine, the tapping torque test machine2asillustrated in Fig. 2 and Fig. 3.5.2 Plastic Squeeze Bottle, 100 mL or larger.5.3 GO/NO GO Wire Plug Gage2, 0.3360/0.3363 in.1This test method is under the jurisdiction of ASTM Committee D02 onPetroleum Products and Lu
15、bricants and is the direct responsibility of SubcommitteeD02.L0 on Industrial Lubricants.Current edition approved June 1, 2005. Published August 2005. Originallyapproved in 1994. Last previous edition approved in 2000 as D 561900.2This test method was conducted using apparatus and materials availabl
16、e fromFalex Corp., 1020 Airpark Dr., Sugar Grove, IL 60554.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.5.4 Drying Oven, controllable to 52 6 3C (125 6 5F).6. Reagents and Materials6.1 Cutting Nut Blanks, inside diameter of 0.3361
17、5 60.00015 in. material selected by the user of the test method.1215 steel alloy is recommended to be used for qualifying taps.6.2 Cutting Tap, 10 by 1.5 mm.6.3 Reference Fluid, a stable fluid that produces minimalbuildup edge on tap and yields repeatable test results.NOTE 1Any lubricant can be used
18、 as the reference fluid. However, itis recommended that the reference fluid not contain additives that willreact with metal, such as sulfur, chlorine, or phosphorus containing EPadditives, as these could react with the tap during the tap qualification andpotentially bias the results of the test flui
19、d. An ISO Grade 22 (90100SUS) mineral oil containing approximately 5 to 6 % lard has been foundto be an effective reference fluid.6.4 Solvent, safe, nonfilming, nonchlorinated.NOTE 2Each user should select solvents that can meet applicablesafety standards and still thoroughly clean the test parts. T
20、echnical gradeNaptha or Stoddard Solvent and reagent grade acetone have been foundsatisfactory.FIG. 1 Tapping Torque Curve (insets show position of tap in specimen blank)FIG. 2 Falex Tapping Torque Test MachineD 5619 00 (2005)27. Preparation of Samples7.1 For cutting oils and the reference fluid, tr
21、ansfer aminimum of 100 mL of the fluid to be tested to a clean plasticsqueeze bottle.7.2 For water soluble fluids, prepare a minimum of 100 mLof diluted fluid to be tested from the sample concentrate withwater (make a note of concentration and water quality; forexample, tap, deionized, hardness, etc
22、.) to the selected concen-tration and transfer to a plastic squeeze bottle.8. Preparation of Test Nut Blanks and Taps8.1 Clean taps and nut blanks in a sonic cleaner usingsolvent selected in 6.3 for at least 15 min. Oven dry at52 6 3C (125 6 5F). Store in a desiccator.NOTE 3The use of technical grad
23、e naphtha or Stoddard Solventfollowed by two rinses with reagent grade acetone and air drying has beenfound satisfactory.NOTE 4Taps should be checked carefully for nicks or any residualmetal preservative before they are used. If any nicks are detected, the tapshould be discarded. If residual metal p
24、reservative is evident, reclean as in8.1. A soft brush, such as a toothbrush, can be used to aid in removing anyresidue. A test tube brush may aid in removing metal preservatives fromwithin the test nut blanks.8.2 Before using nut blanks, the internal hole diametershould be checked with the GO/NO GO
25、 wire plug gage in 5.3.Discard any specimen nuts that are outside of this range.9. Preparation of Apparatus9.1 Zero the chart recorder according to the equipmentmanufacturers instructions.9.2 Zero the torque indicator on the test machine.NOTE 5When setting zeros (see 9.1 and 9.2), be sure to turn th
26、especimen turntable counterclockwise, away from the load cell, to removeany preload so that the meters can be zeroed properly.9.3 Calibrate the torque by placing the average torqueintegrator in the CALB or calibration position. Attach thecalibrator pulley to the lower plate of the test machineaccord
27、ing to the manufacturers directions. Attach cable byfeeding the end of the cable under the torque arm and securingit in the slotted pin under the specimen table at the 6 oclockposition. Calibrate the average torque meter by hanging aknown weight on the hook at the end of the cable. If the torquemete
28、r readout does not agree with the torque reading expectedwith the weight on the hook, adjust the span. Consult themanufacturers instruction manual for further details.9.4 Place average torque integrator to the average position.9.5 Set torque trigger point to 0.5 Nm.NOTE 6When using nut blanks of sof
29、ter materials such as aluminum,a lower torque trigger point of 0.2 Nm should be used.9.6 Select torque averaging initial and final values accord-ing to the equipment manufacturers instructions, depending onthe torque curve generated during test run and the desired areafor evaluation.NOTE 7Two hundre
30、d sixty and 560 revolutions times 60, or thatequivalent to 312 to 913 revolutions has been found to give effective dataover the full working range of the tap in the nut blank.10. Cutting Tap Qualification10.1 Set test machine to desired speed.NOTE 8Test cutting speed is dependent on nut blank materi
31、al. Consulta machinists handbook for recommended cutting speeds; 400 rpm isrecommended for 1215 steel.10.2 Select a new tap and install it in the test equipmentaccording to the equipment manufacturers instructions.10.3 Install a clean, unused nut blank on the table of the testmachine and secure to a
32、 torque of 25 in.-lb according to themanufacturers instructions.10.4 Lower pilot guide plug from center of nut blank to thesealing position. Fill nut blank and coat tap with reference fluidchosen in 6.4.NOTE 9A special tool is supplied with the test equipment to effect thecorrect distance. The seali
33、ng position allows for the entire nut blank cavityto be filled with the test fluid specimen.10.5 Start test run.10.6 Apply a continuous stream of reference fluid to tapthroughout the test run using a squeeze bottle in 5.2.10.7 After the test run is complete, record the averagetorque value.10.8 Remov
34、e the used nut blank and clean the tap usingsufficient solvents, selected in 6.3, and compressed air toremove test fluid, solvent, and metal chips. Leave tap on testmachine during this cleaning procedure.NOTE 10Rinse with solvent chosen in 6.3 or as listed in Note 3.10.9 Inspect tap for evidence of
35、built-up edge. If built upedge exists, discard tap and begin from 10.2 using a referencefluid that minimizes the formation of built-up edge. Build-upedge can cause variability in test results.10.10 Repeat 10.3 to 10.9 five times. Determine the arith-metic mean and standard deviation of the five torq
36、ue values. IfFIG. 3 Exploded View of Specimen AlignmentD 5619 00 (2005)3the standard deviation is within 62 % of the mean value, thetap is acceptable as a reference tap. Save this tap.10.11 Repeat 10.2 to 10.10 with a clean, new tap.10.12 Determine the arithmetic mean and standard devia-tion of the
37、torque values. If the standard deviation of the torquevalues is within6 2 % of the mean and the difference of themeans between this tap and the reference tap in 10.10 is within62 %, then this is an acceptable tap for use in testing;otherwise, discard this tap and repeat 10.11.NOTE 11The most efficie
38、nt procedure is to run several taps using thereference fluid and then to sort these into qualified groups. This will alsominimize the number of taps discarded.11. Procedure11.1 Install a clean, unused nut blank on the table of the testmachine and secure to a torque of 25 in.lb, according to themanuf
39、acturers instructions.11.2 Lower the pilot guide plug from the center of the nutblank to the sealing position. Fill the nut blank and coat the tapwith test fluid.11.3 Start the test run.11.4 Apply a continuous stream of test fluid to the tapthroughout the test run using a squeeze bottle in 5.2.11.5
40、After the test run is completed, record the averagetorque value.11.6 Remove the used nut blank and clean the tap as in 10.8.11.7 Inspect the tap for evidence of built-up edge. If built-upedge exists, note this in test results.11.8 Repeat 11.1-11.7 five times.12. Calculation12.1 Calculate the mean to
41、rque value for the five test runsfor the reference fluid.12.2 Calculate the mean torque value for the last three testruns for the test fluid, discarding the first two runs as there ispotential variability in results due to carryover effects from thepreviously run fluid.12.3 Calculate the percent eff
42、iciency of the test fluid asfollows:% Efficiency 5A/B!3100 (1)where:A = mean torque of the reference oil, andB = mean torque of the test fluid.12.4 Calculate the relative efficiency as follows:% relative efficiency 5efficiency of Fluid A/efficiency of Fluid B 3 100(2)13. Report13.1 Report the follow
43、ing information:13.1.1 The conditions used in the test: Tap type (for ex-ample, high speed steel, carbide, coated, etc.), nut blankmaterial, test speed, and fluid concentration and water hard-ness, when applicable.13.1.2 Record the average torque of the reference oil and theaverage torque of the tes
44、t fluid.13.1.3 Record the percent efficiency and percent relativeefficiency, noting any built-up edge.14. Precision and Bias14.1 Precision:14.1.1 The precision and bias of the measurements obtainedwith this test procedure will depend upon strict adherence tothe stated procedure.14.1.2 The consistenc
45、y of agreement in repeated tests on thesame test fluid will depend upon nut blank material type,homogeneity, and strict adherence to machining tolerances aslisted in 6.1; machine and material interaction; chemical orphysical reaction between cutting tap and specimen nut blank;test parameters selecte
46、d and close observation of the test by acompetent test machine operator.14.1.3 Materials used for the specimen nut blanks will havea major influence on the repeatability of test results. Generally,the variance in repeatability in this test method will parallel thefield condition of similar operation
47、s using the given material.Some materials tested can have a wide variance in test resultsbut also show a wide difference in comparative efficiencies. Onthe other hand, materials can show good repeatability but littledifferentiation in efficiencies. Therefore, the specimen nutblank material should be
48、 chosen to be representative of thematerial that will be in contact with the test fluids representingthe field condition.14.1.4 Selection of test rotational speed will influenceprecision of test data generated. Materials selected for use asspecimen nut blanks may require modification to the test spe
49、ed.Operating the equipment at test speeds that approximate thoserecommended for use in field applications will provide moreconsistent results. The operator should consult a machinistshandbook or another reference to obtain preferred cutting testspeeds.14.1.5 Table 1 gives data for three types of metalworkingfluids and three different metal cutting blanks, using a highspeed tool steel 10 by 1.5 mm cutting tap.14.2 Bias:14.2.1 Since there is no accepted reference material suitablefor determining the bias for the procedure in Test MethodD 5619 for measur
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