to using soluble metal manufacturing fluids - Q8Oils

1 Engineers guideto using soluble metal manufacturing fluidsMetal WorkingFluids Guidepage twocontentsIntroductionTerminologyWhat are soluble oils?StorageMixingMaintenanceHandling precautionsTreatment of infectionsDisposalSystem cleaning proceduresSafety, health & environmentTrouble shooting guidePage WorkingFluids Guidepage threeintroductionThis guide is intended to provide users withinformation and advice on how to managewater miscible and neat metal working fluids atevery stage from cradle to grave . It aims to givea broad understanding of cutting fluids , wiredrawing and rolling emulsion management ratherthan attempting to cover every smallest detail.

2 Itconcentrates on giving practical advice to userson how to get the best from their systems andhow to avoid the mistakes which can be causedduring the system design and product guide also covers the essentials ofmaintenance and the monitoring of emulsions aswell as giving you advice on what to do whenthings go wrong. You will also find recommendedprocedures for the safe waste disposal of watermiscible metal working fluid at the end of itsuseful you have any questions regarding any point inthis guide, then please contact your local WorkingFluids Guidepage fourterminologyThis guide to metal working fluids is written tobe understood by everyone involved in theuse, maintenance and management of neat andsoluble metalworking fluids , wire drawing androlling emulsions.

3 For those people with limitedknowledge of these products and industryterminology, the following definitions may behelpful:EmulsifierAdditive used to bond water and oil molecules together by polar detergent additive to maintain system InhibitorChemical additive to keep metal surfaces bright and Pressure AdditiveCommonly known as EP, provides a chemical, friction reducing additive for killing WorkingFluids Guidepage fiveterminologyFungicideChemical additive for killing fungal / BiostabilityThe control of bacterial mixed evenly in water at the correct particle OilAny leaking or lost oil (slide way, hydraulic or gearbox)

4 Present in a metal working measurement of acidity and instrument for checking the concentration or dilution of a metal working fluid by light measurement of a solutions ability to conduct SlideA test that contains nutrient surfaces to develop and measure bacteria, fungi and yeast infection in metal working WorkingFluids Guidepage sixMetalworkingThe most important functions of a metalworking fluid are to reduce the friction between the partbeing cut and the machine tool, to extend the life of the tool,cooling and to transport the chips and swarf away from thecutting zone. Drawing EmulsionThe most important functions of a drawing emulsion are to lubricate between the metal and the metal and capstan, to extend the life of the die, protectthe capstan.

5 Cool surfaces and to keep the drawing machineclean by carrying fines to the filtration EmulsionThe most important functions of a rollingemulsion are to cool the metal and work rolls whilst providing the required lubrication to the roll bite to enable thereductions required also to protect the work rolls and mill surfaces from more you understand about soluble oils the better ableyou will be to manage them effectively and appreciate whyprecautions should be taken and procedures oil in water (milky type)Mineral oil which is finely dispersed into water by use of water miscible metal working fluid canbe any of 3 basic types:1 Semi synthetic or micro emulsions (semi-transparent)Mineral oil and synthetic components very finely dispersed into or chemical solutions (transparent)A true solution of water and water mixable are emulsions and fluids formetal working , drawing and rolling?

6 metal WorkingFluids Guidepage sevenemulsifiersEmulsifier AdditivesThese enable water and oil to interact by polar interactionTypical oil in water emulsion in schematic formatTail is attracted to oilHead is attracted to waterwater phaseoil droplet1 micronemulsifierThis type of emulsion is formed when concentrate is addedto water & mixed correctly. Typically the smaller the oildroplet the more translucent the emulsion appearanceand generally more WorkingFluids Guidepage eightemulsifiersTypical water in oil (invert emulsion)This is the type of emulsion formed when water isadded to oil rather than following the recommendedprocedure. Note how water droplets are inside the oildroplet yet the water is still the continuous phasesurrounding the oil.

7 The final emulsion particle size ismuch larger and takes on a vastly differentappearance and behaviour it will not perform thesame as an oil in water dropletemulsifierswater phaseoil droplet1 WorkingFluids Guidepage ninesoluble metal working fluids typically containneat metal working fluids typically contain Mineral and/or synthetic oil (1-80%) Emulsifiers Surfactants Corrosion Inhibitors Lubricity additives Extreme Pressure additives (EP) Bactericides Biocide Fungicide pH buffers Antifoams metal ProtectivesAny one component can run out before theother causing an imbalance. Mineral and/or synthetic oil Corrosion Inhibitors Lubricity additives Extreme Pressure additives (EP) Anti-oxidising agent/anti-oxidant Antifoam Anti mist WorkingFluids Guidepage tenthe importance ofdroplet sizeWater miscible metal working fluids workmore effectively when droplet sizes fallwithin the range to microns.

8 The diagramshows the relative sizes of solution type and oilemulsion type fluid at one end of the scale,compared to an emulsion infected with microorganisms and tramp oil. This illustrates the needfor regular monitoring and SizesSolution TypeMicron SizeTramp OilMicro WorkingFluids Guidepage elevenstorage of metal working fluidsNeatmetal working fluids should be stored in anenvironment where there is no contact with wateror any other contaminant. When drums arestored outside they should be placed horizontallyto avoid water or contaminant seeping into concentrates contain asmall percentage of water, this is because certainadditives are only soluble in water.

9 As a result ofthe product containing water the concentrateneeds to be protected against freezing otherwisethe freeze / thaw cycle will separate thecomponent parts and cause problems. If theambient temperature drops below 0 C, theconcentrate should be stirred and heated-up priorto use. A quick test with 95 ml water and 5 mlconcentrate in a glass can show you if theproduct is still miscible in water and gives a water miscible concentrates should also beprotected against excessive heat, direct sunlightand should be stored WorkingFluids Guidepage twelvestorage of metal working fluidsRecommendationsAs a rule of thumb Q8 Oils recommend that youalways store soluble oil concentrate and neatmetal working fluids indoors at a temperatureabove freezing.

10 It is essential to protect concentrates: from frost from water contamination from any other potential contaminant from heat or direct sunlightAlways store barrels on their sidewith bung holes at the horizontalposition as shown. This will maximise storage life by avoidingwater tanks should be inspected regularly forcontamination. If the emulsions are stored intanks we advise you to perform bacteriological examinations every 6 months. If any bacteriological activity is observed, thetank and any connected equipment should be disinfected with a WorkingFluids Guidepage thirteenThe mixing process can affect the long term stability of a metal working fluid emulsion Always add concentrate to water to avoid instability Never add water to concentrate, as this can cause gels and lumps Refer to Q8 Technical Data sheets for manual mixing instructionsIt is recommended that you use a soluble oilmixer or dosing unitThe Dosatron type is a waterpressure powered model, whichstops when demand is zero.