Preparation of Cutting Fluid for Wire Cutting
Wire cutting is an important technique among the various types of machining operations. During wire cutting of the workpiece, some excessive heat and metal debris are produced and thus coolant or cutting fluid is necessary to improve the cutting performance, prevent the wearing of cutting tool and reduce the jagged cutting surface of the workpiece. Generally speaking, water-based cutting fluids are commonly used for wire cutting. However, specific cutting fluid is required for different cutting conditions. This article aims to discuss the process of cutting fluid preparation for wire cutting.
The composition of wire cutting fluid mainly includes several parts: anti-rust agent, wetting agent, defoamer, dispersant and biocide. The anti-rust will form protective film on the surface of the workpiece to prevent anti-corrosion and anti-rust. The wetting agent is added to reduce surface tension and increase surface absorption. The defoamer is used to reduce the generation of foam caused by cutting fluid during the processing, while the dispersant mainly works to keep the suspending state of various components in the cutting fluid, and can also separate the particles and inhibit their regrouping. At last, the biocide is added to inhibit the bacteria, fungi and other microorganisms in the cutting fluid.
The cutting fluid is generally prepared by two or three steps. Firstly, all of the components which must be added into the cutting fluid should be weighed according to the proportion of the recipe. After that, the water is added and the overall solution should be stirred evenly by a machine to ensure homogeneity. Secondly, put the solution into a heating tank and slowly heat it to the appropriate temperature (usually around 75-80℃). Keep the solution at this temperature for about 30 to 45 minutes for defoam and disperse. Finally, the solution should be cooled to a proper temperature for use.
Wire cutting is high-precision work, improper preparation of cutting fluid can affect the machining quality of the workpiece. After the cutting fluid is prepared, the appearance and physical and chemical properties of the cutting fluid should be inspected. If there is any problem, the proportion of the components in the recipe should be adjusted accordingly or the cooling process should be repeated.
In conclusion, preparation of cutting fluid for wire cutting is necessary in order to improve the machining performance and reduce the wear of cutting tools. During the preparation process, the components in the recipe should be weighed and stirred evenly, then heated and cooled to the appropriate temperature. Lastly, the appearance and physical and chemical property of the cutting fluid should be tested.
