Function and Selection of Metal Processing Fluids
Metalworking fluids (MWFs) play an essential role in almost every machining and manufacturing process in the metalworking industry. From different grades of oil, to water-based coolants and synthetics, these fluids are designed to cool, lubricate and prevent fatigue in metals, and aid in chip removal. Depending on the alloy grade, the best fluid should be selected and regularly changed and monitored to ensure optimal performance and ensure the fluids effective life cycle.
Definition
Metalworking fluids are a combination of physical and chemical additives designed to remove heat and chips, extend tool life, and prevent surface corrosion. They include a variety of different fluids such as water-mix and oil-based fluids, depending on the process and application. Metalworking fluids are specially formulated to meet the requirements of particular operations. They are engineered to function within a specific range of conditions, such as temperature and chemical composition.
Benefits
Metalworking fluids provide significant benefits to the process, including improved chip removal, better surface finish, improved lubricity, and increased cutting tool life. The cooling ability of the fluid helps dissipate heat generated from the cutting process, which helps reduce tool wear, flanks, and burnishing. The lubricity characteristics of the fluid help reduce friction between the part and the tooling, allowing for a smoother surface finish. The fluid helps reduce the build-up of chips and debris, which can lead to clogging of tooling, and reduced surface finish quality.
Selection Criteria
When selecting the best type of mechanical cutting fluid for a specific application, it’s important to consider a number of factors, including the type of alloy, the machining operation, the surface finish quality, the type of coolant system, and the environment.
Alloy: Different alloys and grades of steel require different cutting fluids for optimal performance. Fluids that are designed for machining carbon-based alloys may not be suitable for machining stainless steel, for example.
Machining Operation: The type of machining operation being performed as well as the cutting speeds and feed rates need to be considered when selecting a cutting fluid.
Surface Finish Quality: The surface finish required on the end product is a factor when selecting cutting fluids. Higher grade fluids can provide improved surface finish and reduced wear on the cutting tool.
Coolant System: The type of coolant system you are using is a critical factor when selecting a cutting fluid. Different types of systems require different types of fluids, such as soluble oil-based or non-soluble fluid-based solutions.
Environment: The environment in which the machining is being performed also plays a role in fluid selection. Vapor-emitting cutting oils are typically used in enclosed or shrouded systems, while water-based or synthetics are typically used in open systems.
Conclusion
In conclusion, metalworking fluids play an important role in the metalworking industry. From the selection of different grades of oil and water-based coolants to synthetics, metalworking fluids are designed to both cool and lubricate metalworking operations, as well as to aid in chip removal. It is important to select the best metalworking fluid for the application based on the alloy being machined, the machining operation, the surface finish quality, the type of coolant system, and the environment in which it is being used. Regular maintenance and monitoring of the metalworking fluids is necessary to ensure optimal performance and safety, and that the metalworking fluids have an effective life cycle.
