Rolling oils are need used for flat processing of Copper/Brass, to provide desired shape such as strip for flattening the rolled alloy. The rolling procedure involves continuous forward and backward extrusion of metal, which generates friction between the rolling surface and the strip.
The purpose of rolling lubricant such as Rolube 6001 is to lower the coefficient of friction, cooling and protection against corrosion.
6001 is engineered specifically for cold rolling Copper and Brass.
It easily forms an emulsion with water. It is designed to allow separation of tramp oil and metal fines with minimum staining of Copper and Brass surfaces.
During the annealing process 6001 has excellent burn off characteristics.
6001 is resistant to bacterial degradation and contains no phenols, PCBs, nitrites or heavy metal compounds.
6001 also functions as a drawing and stamping compound for Brass, Copper and Aluminum.
Stack Stain Test :
This is where we take 4 or 5 pieces of copper about 1″ x 3″. First they are cleaned in 1M HCl, rinsed in DI water, and wiped dry. The samples are immersed in a 5% emulsion is made of the oil to be tested for about 5 sec. The samples are shaken to remove excess coolant, stacked tightly together, and taped. They are placed in an oven at 125 deg. F for about 3 days. Then they are removed and allow to cool.
After they are unwrapped, the surfaces are examined for any staining. This test helps you produce stain free rolled metal.
OPERATING GUIDELINES :
Rolube 6001 is recommended for hot rolling aluminum and for hoot and cold rolling of copper brass, and other non-ferrous metal. It is used in 2-Hi and4-Hi breakdown mills, tandem mills, finishing operations, and tube mills. Depending on the amount of reduction and surface speeds, Rolube 6001 is used at between 0.5 to 8.0% in rolling operations; typical concentrations are: temper mill 0.5 to 3.0%, breakdown 3.0 to 5.0%, intermediate 5.0 to 8.05. For machining operations Rolube 6001 is used a concentration of 5.0%. For stamping and drawing Rolube is used at 5.0 to 50%.Hot rolling operation: 7 to 10%
Temperature: 70° F (21° C) – 130° F (54° C) maximum
Concentration: (% by volume with water)
Temper Roll: 0.5 – 3.0
Intermediate: 3.0 – 5.0
Breakdown: 5.0 – 8.0
Emulsion Preparation and Maintenance:
The use of pure, mineral-free(never softened) water to mix this product will improve sump life, reduce concentrate usage and carry off. Chemical emulsions like Rolube work best if they are mixed with room temperature water and by adding coolant concentrate to the water, NEVER THE REVERSE. Using premixed coolant concentrate as makeup will substantially improve performance and reduce usage. The specific makeup concentration should balance the water evaporation rate with the carryout rate. Adding makeup Rolube at 30-40% of the desired working concentration will generally maintain the proper concentration in the sump.)
Add Rolube to water with agitation. For best results water should have a pH of 6.9 to 7.5 and a total hardness of 100 to 275 ppm as calcium carbonate. The pH of the emulsion should be maintained between 8.5 and 9.5. Concentration of the emulsion is determined using a hand-held refractometer: the refract meter reading is the concentration. The best operating temperature is between 70° F (21° C) and 130° F (54° C). Although emulsions of Rolube 6001 are relatively unaffected by hard water for maximum use life, dematerialized water should be used for daily top-offs.
The water properties needed to form an emulsion with Rolube 6001 is pH of 6.9 – 7.6. Total hardness of water should be 100-275 ppm as CaCo3.
QUALITY CONTROL :
Mixes easily with minimal stirring. The pH of working bath will normally buffer off to 8.5 – 9.0 and will remain there. Concentration of the rolling emulsion should be maintained using a refractometer.
It will give you direct concentration reading.
Rolube 6001 concentrate should be stored in a clean, dry area away from extreme heat and open flames. Avoid freezing. If frozen, thaw in a warn area and mix before using. Keep drums closed when not in use.
Do not freeze. Mix prior to using if separation occurs. Keep drums closed when not in use.