WATER-SOLUBLE METALWORKING FLUIDS - The …

1 Registered trade markStevens Industrial Services (SIS) LtdHIGH PERFORMANCE FLUIDSWATER-SOLUBLEMETALWORKING FLUIDS general information bookletPrefaceUnfortunately, it is a fact of life that metal working FLUIDS are accorded a position of minor importance of these FLUIDS only occurs when there are problems: the productionprocess is suffering !Though, problems can be easily prevented if you know what you are this booklet we want to give you a little information about what a soluble metal working fluid actually is and how to realise a healthy, clean and trouble free production minimum of very important factor for trouble-free working is the correct choice of the parameters for a correct choice concerning FLUIDS are material, product.

2 Machine and the nature of the wide range of chlorine-free THE WORKS products can help you to make the sales team are ready to give you any assistance you hope that this booklet will help contribute to the optimisation of cutting fluid usage in your company. Contents1. Generalpage 12. Main purpose of cutting fluidspage 23. Structure of cutting fluidspage 3 4. Mai ntanance and control of cool ant spage 51. GeneralCutting FLUIDS are preparations/mixtures used in the cutting and forming METALWORKING industry for cooling, lubrication and swarf CUTTING FLUIDS :1.

3 Products , mostly based on ve geta ble o r m iner al oil, n on- water soluble such as:-- Tapping FLUIDS ;- Stamping and deep drawing Oil in water a mineral oil is introduced into water it will separate. To get a stableem uls ion we have to a dd a n em ulsifie r, so that wate r an d any other additives do not classifications of emulsion are: Synt het ic em ulsi on: co ntai ns 0% min. oil; Semi synthetic emulsion: contains up to 40% min. oil; Mineral oil based emulsion : more than 40% min. speed and p rice ( / m ) m ostly dictates the choice of the cutting fluid and given a choice of neat or WATER-SOLUBLE the choice will often be WATER-SOLUBLE e economics involve not only the purchase of coolant but also the costs of wastefluids and by machine stoppage because of fluid change.

4 Since the costs for waste disposaland machine stoppage become more important every year it is essential to keep thesecosts as low as factors to maintain the costs as low as possible are: Right choice of the coolant, other oils and accessories. Setting up an efficient control and maintenance right choice of the coolant must be made together with the supplier becauseonly they can judge if their coolant is suitable for your application. FLUIDS12. Main purpose of cutting fluidsDuring a metal cutting process temperatures of more than 1000 C will occur (seedrawing).

5 This heat transmission is 75% into the swarf, 18% into the tool tip and 7%into the is therefore very important to keep the heat development as low as possiblethrough lubrication and dissipation of the heat through tasks for cutting FLUIDS are: lubrication and coolinglubrication and :Can be done best by water because water has excellent heatexchange properties. Further, water is a thin fluid whichcan remove the swarf easilyLubricationLubrication: Mostly done with a mineral oil containing extreme pressure(EP) properties, to ke ep fr ict io n a s low a s possible leadingto less tool wear and prevention of swarf build-up and theopportunity for metals welding together.

6 2A cutt ing fl uid is necessarily very complex to be able to fulfill the many demands, such as: -Cooling;-Lubrication;-Universal application;-Long life;-Noise reduction;-Prevention of metal welding and swarf built up;-Reduction of dimensional instability;-No foaming;-No sticking;-No dangerous vapours;-Skin friendly;-Friendly for machine paint;-Rust protection;-Surface , increasingly, a cutting fluid must also be health and environment STRUCTURE OF CUTTING FLUIDSTo enable the FLUIDS to meet all these requirements, a large number of differentsubstances are required. An inventory of substances, which may be used in cuttingfluids, showed that there are a total of over 300 different individual y, cutting FLUIDS should (must) be free of many of the substances that were used as additives in the past, such as:1.

7 Chlorine;2. Nitrite;3. Di-ethanolamine;4. Aromatic hydrocarbons;1. When using chlorine-containing additives, harmful by-products occur atincreased temperatures. These are very poisonous and irritating for the skin.(chlorine-containing vapours can penetrate our body and give severe healthproblems).Further, the disposal of chlorine-containing waste is more expensive than no n-chlorine w aste. The se are e xce llent reasons to u se ch lorin e-free METALWORKING FLUIDS . Chlorine-containing FLUIDS were previously used because of there excellent EPproperties in the temperature range of 200 500 C.

8 And because chlorinecontributed to the stability of the coolants. 3 2. Nitrites had, in the past, a good record as anti rust inhibitors. 3. Nitrite however, forms nitrosamine, which is proven to cause cancer. The process for forming nitrosamine occurs more rapidly if there are amines inthe fluid , especially di-ethanol amine (= emulsifier and corrosion inhibitor).The use of nitrite-free coolants only is no guarantee that nitrosamine can notbe formed, because nitrite can get into the fluid over a period of time through: -Micro-organisms transforming nitrate in drinking water (used for diluting thecoolant) into nitrite;- Absorption of nitrogen oxide from the air (exhaust gases).

9 - Nitrite containing hardening salt, cleaners and/or corrosion , a coolant must not only be free of nitrite, but it also must be free of di-ethanolamine to prevent the forming of nitrosamine, which can cause should try to keep the nitrite content in the coolant below 50 ppm( determined by analytical test strips), because amine-containing substancescan always enter the fluid and nitrosamine can still be formed. 4. The use of basic oils with a high percentage of aromatic hydrocarbons (oftencheap) can for m, i f heated b elow 100 0 C , polycycli c aro ma tic hyd ro ca rbon s(PAH s).

10 These polycyclic aromatic hydrocarbons can cause it is important to use oils with an extreme low percentage of aromatichydrocarbons. This is possible by using modern, more expensive refinerytechniques. The Works products are completely chlorine free, nitrite free and di-ethanol aminefree. The mineral oils have an extremely low percentage of aromatic hydrocarbons(<< ) ! Environment- and health friendly metal working FLUIDS are costly and need good maintenance and 'house-keeping'44. MAINTANANCE AND CONTROL OF COOLANTSS oluble cutting FLUIDS typically consist of 95% water .