TECHNICAL RESOURCE GUIDE | METALWORKING FLUIDS FUNCTIONS OF METALWORKING FLUIDS: WATER-SOLUBLE OILS: Water-Soluble Oils are macro or micro emulsions containing more than 60%-85% mineral oil dispersed in water. Milky, and opaque in color due to stable dispersion of oil droplets in water, their functions are lubrication, cooling, and improved chip evacuation. Advantages: Water-Soluble Oils are recommended for moderate and heavy-duty machining operations where a large amount of metal is rapidly being removed (milling or turning). Ideal for use where lubricity is important but the excellent cooling properties of water are also required. Disadvantages: Corrosion and fungi and bacteria development in machines and workpieces if coolant is not properly maintained, some coolants leave sticky residues in machine SYNTHETIC FLUIDS: Synthetic fluids mostly contain water, chemical lubricants and rust inhibitors instead of petroleum or mineral oils. Their consistency gives them strong fluidity, making them an effective choice for pressure applications across flat and open work areas as well as when splatters and discharges are prominent. Resulting particles and metal debris have an easier time becoming trapped in oils, so synthetic blends also offer a smaller eco footprint and health risk while breathing in industrial environments. Advantages: Synthetics can be blended to offer higher heat dissipation while producing less byproduct and foaming during use, which makes them the preferred option in high heat and high velocity operations such as grinding and turning. Synthetics also tend to be more stable, which allows them to mix better with water. Disadvantages: Because synthetics mix well with most materials, it can cause incompatibility with machining oils and create quick contamination during use. When heated or mixed they can also foam and mist, causing sump oil and messy residue to form on machines. Proper monitoring is required to prevent unwanted mixing or other problems. SEMI-SYNTHETICS: Semi-synthetics can contain up to 30% in petroleum oils, making them a strong blend of oils, water, and chemical concentrates such as corrosion inhibitors, fuel biocides and surfactants (wetting agents). They provide a balance between the strong lubricity of oils and the more malleable options from synthetics, with performance and prices that typically fall between the two as well. Advantages: The oil and synthetic chemical blends offer compatibility with a large number of machining applications and materials. Semi-synthetic coolants give you the option of pinpointing what your operations need with a more balanced range of wetting, cooling and cleaning properties. They are typically easier to maintain with a longer service life, and do not have the potential health hazards of soluble oils. Moreover, synthetic blends typically have improved residue and mist production, and can offer better waste containment, smells and less bacterial growth. Disadvantages: While semi-synthetics offer a more balanced coolant experience, they are not completely exempt from foaming, misting or leaving residue. Different chemical compositions can also cause surface-based skin reactions such as dermatitis, and mixing and accidental contact with pure oils, other synthetic blends, and even water with differing pH balances can also cause unexpected contamination. STRAIGHT CUTTING OILS: Straight cutting oils form a smaller grouping of mainly non-emulsifiable fluids that contain lubrication additives like vegetable oils and fats. These are generally more popular in applications that require increased lubrication along with effective heat transferring, such as tapping or drilling, and their primary function is lubrication with a bit of cooling. Advantages: They provide extremely fluid lubricity, increased rust protection and are generally easy to maintain when compared to synthetics and other blends. Oils still offer more fluid heat transferring, which is increasingly important in applications that require heavy coverage and flow during use, such as in deep-hole tapping. In spray applications, oils can also offer better control to the operator. Disadvantages: The problems with oils come from their less than stellar ability to disperse or dissipate during high temperature use, making them a risk for both fire and smoke production. Additionally, they will likely mist, more than other options, and leave a film-like residue on your tools and workpieces. And their lubricity, while excellent, may only be fully optimized in lower speed cutting and machining operations due to the factors listed above.
Phone: 1.800.221.0270 | Fax: 1.800.722.0703 | Web: www.travers.com | Email: [email protected] INTRODUCTION: Coolants provide machining applications with extremely important heat dissipation, lubrication, and also rust and rancidity protection. In many cases, they are the lifeline of your operations, and keep your heavy- duty tools and workpieces powered through extended usage. Finding the right coolants for your shop, your machining needs, and also your budget, can be just as important as have the right tools for the job.
With the exception of dry machining, most metalworking operations require the use of cutting fluids. These coolants are designed specifically as cutting tool lubricants, for rust prevention, and also for maintaining safe machining temperatures and work environments. In addition, they can also help evacuate chips and prolong tool life. The simplest way to break down coolant types is to divide them into straight oils and water-miscible fluids. However, the truth is that many types of ingredients, synthetic blends and industrial options exist to satisfy a wide variety of applications.
For starters pure oil, or petroleum, contains no water and provides the powerful lubrication needed for heavy-duty operations. However, its poor cooling properties can make it dangerous when machining with high temperatures. By comparison, water can be nearly 2.5 times better at maintaining safer temperatures, but is also a much less effective lubricant that also causes rusting. That is why many shops look to synthetic compounds for a more balanced solution that features durable lubrication, corrosion protection and also effective cooling properties.
Today, water-miscible cutting fluids make up nearly 80% of machining coolants. While that may seem an overwhelming majority, water-miscible actually describes an extremely wide variety of fluids. It includes synthetic and semi-synthetic lubricants as well as soluble oils.
Travers Tool's expert technical advisors can also assist you with proper metalworking fluid selection and more at 800.234.9985 or at [email protected]
TROUBLESHOOTING: Use the quick reference guide below to help pinpoint the cause of your issue and find potential ways to resolve it. Travers Tool's expert technical advisors can assist you with proper metalworking fluid selection, troubleshooting, and more at800.234.9985 or at [email protected]
EXCESSIVE RUSTING OF SHORT HEAVY OR STICKY FOAMING: PARTS: SUMP LIFE: RESIDUES: • Check the concentration: • The coolant mix is too lean: • The concentration is too low: • The coolant concentration is A mix that is too rich can contribute Check the concentration with a Check concentration with a too rich: Check the concentration to foaming. Check concentration with refractometer and adjust if refractometer and adjust if with a refractometer and adjust as a refractometer and adjust. necessary. necessary. necessary. • Mechanical problems: • The pH is too low: • The tramp oil is sealing surface • Excessive tramp oils Check for a leak on the intake side Check pH with paper or a meter to of sump: contamination: or around the shaft seals of a coolant ensure its above 7.5. If rust occurs, Take steps to reduce or remove Tramp oils can build up and coat pump, which would result in air being add 2% concentrate to sump and floating tramp oils to prevent the machine surfaces. Take steps to drawn into the fluid, creating foam. check the concentration again. rapid growth of anaerobic bacteria. reduce or remove floating tramp oils.
Phone: 1.800.221.0270 | Fax: 1.800.722.0703 | Web: www.travers.com | Email: [email protected] OPTIMAL USE OF METALWORKING FLUIDS IN TAPPING APPLICATIONS Optimal use of coolants & lubricants throughout tapping operations allows for increased production, longer tool life, more accurate threads, and more efficient chip removal.
Straight Cutting Oil Usage: Used for most general purpose tapping applications. For non-ferrous and non-metallic materials, a coolant or a cutting fluid (light oil or soluble oil) is most often recommended. Tapping, especially with thread-forming taps, requires more lubrication than cooling. A coolant or cutting fluid might lack the lubrication necessary to obtain optimal tool life and part finish. Avoid use of a heavy viscosity oils that can cause the chips to cling to the tap and increase the chance of breakage.
Application Of Selected Coolant/Lubricant: It is important to apply the coolant or lubricant with adequate pressure to ensure even coverage and protection. To ensure uniform and more balanced distribution, use more than one nozzle around the tap. The nozzles should be located as close to the workpiece as possible, angled close to the axis of the tool, and pointed directly into the hole in order to remove chips away from the flutes. For horizontal tapping, where the tap is stationary and the workpiece is rotating, use of two nozzles allows two streams of lubricant, one on each side of the tap. The coolant or lubricant should be applied during the forward motion of the tap into the workpiece and aimed at the hole being created to allow it to flush the chips clear of the application. When possible, force the lubricant into the hole under pressure to increase its effectiveness at clearing chips away from the tap.
SELECTION GUIDE Rustlick™ is the ITW Pro Brands specialty metalworking fluid and sump maintenance line. All fluids, anti-foaming agents, rust penetrants, non- conductive lubes and more, provide industry-leading protection that extends tool and coolant life. The majority of Rustlick drum mixer products, chlorine- free premium products and sprays are proudly manufactured in the USA.
Phone: 1.800.221.0270 | Fax: 1.800.722.0703 | Web: www.travers.com | Email: [email protected] ITW PROFESSIONAL BRAND SELECTION GUIDE ITW Professional Brands offers a wide variety of heavy duty metalworking fluids designed to help optimize your process based on the type of material being machined and/or the application. These long sump life, advanced bio-resistance formulations are at the forefront of innovative, technical advancements. They last 2X longer in hard water environments and because they can run at low concentrations, cost is reduced as well. Combine with technical support, and you’ll be on track to optimizing your application and productivity. See the chart below for help choosing an appropriate metalworking fluid.
Phone: 1.800.221.0270 | Fax: 1.800.722.0703 | Web: www.travers.com | Email: [email protected] SELECTION GUIDE ValCOOL industrial cleaners, cutting fluids, lubricants and coolants are engineered to provide heavy duty performance in even the harshest environments. With a wide variety of synthetic, semi-synthetic and water soluble options, ValCool has the ideal fluid for your difficult-to-machine materials and most challenging applications. For assistance with ValCool product selection or to see if you qualify for a free trial offer, call 800.234.9985 or email [email protected]
Phone: 1.800.221.0270 | Fax: 1.800.722.0703 | Web: www.travers.com | Email: [email protected]