Cutting Fluids - Understanding the Basics
Cutting fluids are special lubricants used to reduce friction and cool down the cutting tool/workpiece when machining. They also act as an intermediary between the surface of the tool and the workpiece, which enhances the chip removal process to form a better-quality product. As such, cutting fluids are of great significance to machining operations in manufacturing industries. This article aims to provide a brief overview of the basics of cutting fluids, including the types and applications, how to ensure safe use, and the challenges of using cutting fluids in the machining process.
Types of Cutting Fluids
Cutting fluids are mainly classified into four main groups: water-soluble fluids, neat cutting oils (NCOs), semi-synthetic fluids, and fully synthetic fluids. Water-soluble fluids are made of water and other components, such as emulsifiers, defoamers, and corrosion inhibitors. Neat cutting oils are composed of petroleum oils and offer superior lubrication than water-soluble fluids. Semi-synthetic fluids consist of a combination of neat cutting oils and water-soluble fluids. Fully synthetic fluids address the danger of bacteria contaminating water-soluble fluids and NCOs, and are formulated to eliminate the risk of biosecurity issues.
Applications of Cutting Fluids
Cutting fluids have various applications in machining operations. For example, they may be used to improve the machining accuracy of parts by reducing friction and heat. They can also be used to minimize the wear to the cutting tools and the workpieces, provide higher cutting speeds, improve surface finish and dimensional accuracy, reduce noise level and vibration, and reduce energy consumption. In addition, cutting fluids can also be used to reduce bacteria growth, prevent rust and corrosion, and extend the lifespan of cutting tools.
Ensuring Safe Use of Cutting Fluids
When using cutting fluids, it is important to take steps to ensure safe use of these materials. For one, cutting fluids should be kept away from food and food contact materials to prevent bacteria contamination. In addition, cutting fluids should be stored, handled and disposed of properly, and employers should provide safety training to employees to prevent accidents and injuries caused by the improper use of cutting fluids. It is also important to use cutting fluids that are specifically designed for the materials being machined, as certain cutting fluids can be corrosive or hazardous to certain materials.
Challenges of Using Cutting Fluids
Despite the advantageous features of cutting fluids, machining operations may also face certain challenges due to their use. For example, when used in large amounts, the machining environment may become increasingly contaminated by the cutting fluid, leading to several health and safety issues. In addition, cutting fluids can also cause some operational difficulties such as low productivity, fire hazards and cost concerns. Thus, it is important to choose and use cutting fluids wisely in order to ensure maximum productivity, profitability and safety.
Conclusion
Cutting fluids are important components of machining operations, as they provide a variety of benefits such as improving machining accuracy and extending the lifespan of cutting tools. However, it is important to understand the types, applications and safe use of cutting fluids, as well as the potential challenges that may arise due to their use. By considering all of these factors, machinists can effectively use cutting fluids while ensuring maximum productivity and safety in their machining operations.
