Metal Cutting Fluids Why do we need them?

1. Metal Cutting Fluids Why do we need them? • Cooling • Lubrication Also provides:- • Swarf Flushing • Corrosion Protection

2. Metalworking Fluids Basic Principles of Metal CuttingFluids ; What they are & how to use them correctly

3. What are neat cutting oils? The performance of a neat cutting oil is influenced by 3 factors:- • Viscosity • Additives • Levels of additives

4. Viscosity Viscosity (at specific temperature) Measured in centistokes (cSt @ 40c) Range from 5 to 40 cSt Water = 1cSt Hydraulic = 32cSt

5. Effects of viscosity Cooling & Swarf Flushing Lubricity Viscosity Viscosity

6. Lubricity additives • Base Mineral Oils Highly refined oils of high, medium or low viscosity • Esters Natural fats Vegetable oils Synthetic esters

7. Lubricity additives • Anti-wear additives Typically phosphorous compounds or ZDDP • E.P. (extreme pressure ) additives Chlorinated paraffins Sulphur Usually sulphurised esters or polysulphides

8. Neat Oils vsSoluble Coolants Cooling Lubrication Neat Oils Soluble Coolants

9. What are coolants? Lubricity Additives Add to water Emulsifiers & detergents Metalworking coolant or emulsion HOCUT ? Corrosion Inhibitors Bio- Protection

10. Oil in water emulsion

11. Coolant jargon • Conventional soluble oil • Semi-synthetic • Synthetic • Extreme pressure • Biostable

12. Factors affecting Coolant life • Micro-Organisms • Tramp oil • Water Quality • System Design • People

13. Micro-Organisms( typically bacteria / fungi) • Results in:- • Bad smells • Coolant separation • Corrosion • Increased disposal costs

14. Common Types Of Micro -Organisms • Aerobic bacteria -live in the presence of airAnaerobic bacteria -live in the absence of air(bad eggs) • Yeasts/ Moulds /Fungi -visible organism (rubber-like)

15. Tramp Oil • Oil from positive lubrication & leaks • Often resulting in:- • Bacteria attack • Coolant separation • Smoke and fume • High disposal cost

16. Water Quality • The presence of inorganic • salts in coolant make up • water will affect:- • Coolant stability • Foaming

17. Water Quality Ideal Water Hardness = 100-200ppm. Chloride zero Sulphate zero Low salts High salts Soap formation Coolant instability Corrosion Bacterial attack Excessive foaming Water hardness expressed as ppm. (parts per million ) as calcium carbonate.

18. Coolant mixing • Always add oil to water(use a • mixing valve if possible) • Always mix coolant before • adding to the coolant sump

19. Monitoring & control Always maintain concentration between specified limits.

20. Monitoring & control • Possible. skin irritation • Expensive (product waste) • Foaming If concentration becomes too high.

21. Monitoring & control • Bacterial attack • Corrosion • Increased disposal • Expensive If concentration becomes too low.

22. Monitoring and control • How is concentration measured? • Refractometer --- on-site • Titration --- on-site / lab. • Instrumentation --- lab.

23. Fluid Concentration Chart

24. How is Condition Measured? pH readings 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 acidic neutral alkaline soluble oils favours bacterial growth good corrosion protection acceptable to skin

25. IP 125 Steel swarf on a cast iron plate. (overnight test) IP 287 Cast iron swarf on a filter paper. (2 hour test ) Monitoring corrosion protection

26. Soluble Oil Trials Machine Cleaning Antisep Biocidal Cleaner (A.B.C.) kills bacteria & dissolves dirt to ensure the new coolant has a good start. • 2-4% A.B.C. circulated with coolant for 24/48 hours • Empty & rinse • Refill with pre-mixed coolant at correct conc.

27. Health and safety Skincare • Handling concentrates • Concentration control • Hygiene • Proper use of skin creams • Good housekeeping • HSE guide to metalworking

28. Environmental & H&S Issues There is an increasing demand for products that are ‘FREE’- from e.g.:- • Nitrite-free • Chlorine-free • PCA -free • Phenol-free • DEA-free

29. Environmental &H&S Issues • Nitrite Can react with amines to form ‘nitrosamines’ (carcinogenic). • DEA -diethanolamine Can react with nitrogen from the air to form ‘nitrosamines. Nitrite/DEA in fluids is a health and safety issue, not environmental

30. Environmental & H&S Issues • Chlorine Disposal by burning can form dioxin, a carcinogen Special incinerators needed for safe disposal Disposal cost is very high in Europe Chlorine is an environmental issue, not health and safety

31. FLUIDCARE SERVICESHealth risks and MWF mists • HSE are demanding that metalworking fluids users should clearly demonstrate that they take every practicable step to control fluids, improve their condition and reduce exposure. • We recognise that the new guidance on health risks especially regarding asthma and respiratory diseases will pose problems for users. We offer a package of services aimed at helping customers identify the risks and effective measures of prevention and control. • Risk assessment • Fluids testing and bio-audits • Exposure monitoring • Atmosphere control • New Scandmist air filtration products are also available to remove both mist and bacteria from machine enclosures. Click on the download to learn more about the issues and to see Houghton products and services. • Visit www.hse.gov.uk/metalworking for further information. More…………… Preventing respiratory diseases and metalworking fluids ScandMist air filtration equipment