Metal-working

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What is a Cutting Fluid?
• A cutting fluid is an oil or oil-in-water emulsion used in the process of
metal removal

• Cutting fluids can be classified as

– Neat
– Soluble
– Synthetic

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Function of Neat Oil
Remove Swarf
Good antifoam
properties
Improve Surface Finish

protect against
wear Improve tool life

protect against
provide cooling corrosion

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Function of Soluble Oil
Good antifoam
properties Improve Surface finish
Remove swarf
protect against
wear
Lubricate

Bacterial resistance protect against

corrosion
provide cooling
Emulsion Stability

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Soluble versus Neat
• Soluble
9 High speed operations
9 Where a large amount of
heat is produced
9 For grinding
9 Where cost is an issue
9 Health and safety issues
9 Light to reasonably heavy
duty applications
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• Neat
9 Heavy duty applications where
high levels of lubrication are
required.
9 Improve sump life
9 Improve surface finish
9 Improve tool life
9 Light to heavy duty applications
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Advantages/Disadvantages of using
soluble oil
• Advantages
– Cost effective (use diluted)
– Excellent for cooling
– Clear appearance making it
easier to use for precision
operations
– Can use one product for
various applications.
• Disadvantages
– Prone to bacterial attack
– Can’t be used for extremely difficult
operations
– Needs to be regularly topped-up with
water due to evaporation
– Needs to be mixed with water (time)
– Needs regular monitoring
– Greater chance of skin irritation

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Soluble Oil Componentry
• Activity
– Design a soluble oil and specify why each component should be
added.
– You need to have components which give the product each of the
properties a soluble oil requires.

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Soluble Oil Componentry
• Mineral Oil
• Emulsifiers
• Antifoam
• Biocide / Fungicide
• Corrosion Inhibitor
• EP Additives
• Deodorant
• Couplers

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When to use Soluble Oils
– For large systems (price)
– Where high cooling rates are required
– Low stock removal
– Where fire may be an issue
– Operator acceptance

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What is an emulsion?
• A stable suspension of one liquid within another liquid.
• For soluble oils, oil droplets are suspended in a water phase.
• Soluble cutting fluids which produce an emulsion with relatively
large oil droplets (2-4 microns) will produce a milky emulsion.
– Larger droplets provide good lubrication properties and can
carry EP additives effectively.
• Soluble cutting fluids which produce an emulsion with relatively
small oil droplets (0.5-1.5 microns) produce clear emulsions.
– Smaller droplets allow for more effective cooling.

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Making an emulsion
• Always add oil to water with agitation.

• Adding water to oil will result in an invert emulsion

– This is when the oil is trapped inside the water droplet, leading to an
unstable emulsion.

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Types of Metals

• Metals are classified as ferrous or non-ferrous

– Ferrous metals contain iron. Eg; cast iron, carbon steels, free-
machining steels and stainless steel
– Non-ferrous metals do not contain iron. Eg; aluminium, copper,
brass and bronze

• Metals can be further classified as alloyed or non-alloyed

– Alloyed metals contain a mixture of two or more metallic elements,
to change the metal’s properties.

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Carbon Steels
• Carbon
– Used at 0.12-0.60%
– Increasing carbon increases the strength and hardness but
reduces the machinability.
• Silicon
– Used at 0.1-0.4%
– Increases the tensile strength and corrosion resistance but
reduces machinability.
• Manganese
– Used at 0.5-1.3%
– Increases tensile strength but reduces machinability.

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Alloy Steels

• Alloys are used to: -

– Improve wear
– Provide additional corrosion resistance
– Increase hardness and tensile strength

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Alloy Elements
• Chromium
–Used at up to 4%
–Reduces corrosion but also reduces workability
• Molybdenum
–Used at up to 0.7%
–Provides resistance to cutting and wearing but reduces workability.
• Nickel
–Used at up to 3%
–Increases material toughness and strength but reduces workability.

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Stainless Steel
• Characterised by high concentrations of chromium and nickel.
• Resistant to corrosion.
• Machinability is significantly worse than ferrous metals.
• 18/8 Stainless = 18% chromium and 8% nickel

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Aluminium
• Used mainly for its lightness and corrosion resistance.
• Silicon used to increase hardness and resistance to abrasion, but
reduces machinability.
• Has a tendency to stick during the cutting process.
• Lubricants high in oil and fat are best for machining aluminium.

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Copper
• Copper
– Fairly pure (approx 0.7% impurities)
– Very difficult to machine.
– Produces long continuous chips which interfere with the cutting
process.
– Active sulphur should not be used as it will cause staining.

• Brass
– A copper alloy which contains zinc.
– Fairly easy to machine.
– Active sulphur should not be used as it will cause staining.

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Machinability
• This describes the ease or difficulty of machining a particular metal.

– A ‘machinability rating’ is given to metals, to describe this.

– The larger the machinability rating, the easier the material is to
machine.
– The machinabilty rating is determined by a standard set of
machining conditions as well as industry experience.

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Machinability Ratings

Cast iron 50-80

Carbon Steels 40-70
Stainless Steel 25-45
Aluminium 300-1500
Copper 60-70
Brass 200-600

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Brinnell Hardness
Brinell values are determined by pressing a 10mm tungsten carbide
ball in to the test metal surface using a 3000kg load, for 15 seconds.
The circular imprint is measured and converted to a hardness
measure.
Results are reported as;

HBW 3000 / 10 =256

where
H= Hardness 3000= Test load
B= Brinell 10= Diameter of test ball
W= Tungsten Ball 256= Hardness rating

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Rockwell Hardness
• Rockwell Hardness is a more common form of reporting metal
hardness
• Values are determined by pressing a 1mm steel or conically ground
indenter into the test metal surface under loads of up to 120kg. The
impression is measured microscopically and converted to a hardness
measure.
• Hardness is reported as;
• HRC 45

Where;
H= Hardness 45= Hardness rating
R= Rockwell
C= Diameter of test ball

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MWO - Nomenclature
• Honilo • Sintolin
–Honing, Neat –Clear, semi synthetic, Soluble

• Ilocut • Syntilo
–Cutting, Neat –Clear, full synthetic, Soluble

• Clearedge • Iloquench
–Clear, EP soluble oils • Quenching, Neat

• Safetycool • Iloform
–Economical grade –Forming

• Superedge • Ilogring
–Heavy duty soluble oils –Grinding, neat

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Tests used for soluble oils
• Concentration
– Acid Split
– Refractometer
• pH
• Bacteria
• Tramp oil
• Conductivity

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Caring for Soluble Oil Systems
• Foaming
– High concentration?
– Contamination from cleaner?
– Filters too fine?

• Bacteria
– Concentration too low?
– Poor housekeeping?
– Too much tramp oil?
– Circulating over the weekend?20

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Caring for Soluble Oil Systems
• pH too low
–Bacteria?
–Concentration too low?
• pH too high
–Concentration too high?
–Contamination with cleaner?
• Poor machining
–Concentration too low?
–Flow rates correct?

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Caring for Soluble Oil Systems
• Complaints of irritation
– Bacteria?
– Concentration too high?
• Complaints of rust
– Bacteria?
– Concentration too low?
– pH too low?

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Caring for Soluble Oil Systems
• We can treat with;
– Biocide
– Fungicide
– Antifoam
– Water Hardener
– pH Booster

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Disposal of Soluble Oil

• Refer to technical data sheet

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Operator health and safety
• Refer to MSDS
• Operators should always wear
– Gloves
– Goggles
– Neck to toe clothing
• They should wash their hands regularly
• Remove contaminated clothing

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Product Range
Product For which applications
Gear cutting, hobbing, threading,
Ilocut 103, 106,
tapping, and thread milling
1945
Operations
Ilocut 152, 154, General machining. Used on older
155 & 156, machines where cross contamination
Supercut 156LM with hydraulic oils isLikely
Drilling, boring, milling and honing
Ilocut 171
operations on high speed
Supercut 171
Machines
Deep hole drilling and trepanning
lIocut 334, 3341& operations. Also can be used for
534 gear hobbing and gear shaving
operations on NC machines
Honing of cast iron liners, ball
Honilo 980, 981& bearing races, super finishing
982 operations, on hardened metals &
also flat honing operations
Thread grinding, form grinding,
IIocut 482
milling, automatic lathe work etc.
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For which material
Not recommendedd for use on
curprous metals
Both ferrous and non-ferrous
metals Non- corrosive and
Non staining on cuprous metals.
Both ferrous and non-ferrous
metals
Not recommendedd for use on
curprous metals
Ideally suited for Aluminium,
aluminium alloy, rod and wire
drawing applications
Ideally suited for machining of
both ferrous and non-ferrous
Metals
Benefits
• Excellent tool life
• Low oil drag out
• Improved surface finish
• Ideal grades for
rationalization
Excellent flushing action
• High surface finish
• Excellent cooling
properties
• Reduced wear of guide
lands
• Improved surface finish
• Extended tool life
Economy in usage
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Product Range
Product For which applications
Ilobroach No.11 &
Broaching operations
Ilobroach R-13
General purpose soluble oil for various
Cooledge SL & mild & medium duty applications
Cooledge HWS Cooledge HWS gives good hard water
stability.
For all general purpose machining
Clearedge AA
Applications
Wildest range of applications, including
Clearedge EP 284
some heavy duty applications.
For gear roughing, broaching, deephole,
multi spindle automats including creep
feed grinding and high speed grinding.
Superedge No.7
Value particularly seen in arduous
machining operations where high degree
of finishing is required.
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For which material
Not recommended for use on
cuprous Metals
Can be used foe both ferrous and
non-ferrous metals
Can be used foe both ferrous and
non-ferrous metals
Can be used foe both ferrous
and non-ferrous metals.
Particularly suited for ferrous
materials, aluminum and
alloys including high silicon
grades, copper and its alloys
Suited for centralized systems
also can be used for both
ferrous & non-ferrous materials
for a wide range of application.
Benefits
• Excellent heat dissipation
• Long broach life
• Excellent resistance to bacterial
decomposition
• Good anti-rust properties
• Usable at high dilutions, particularly for
grinding
• Ensures longer wheel life due to high
dilution
• Excellent emulsion stability at elevated
temperatures
• Stable transparent emulsion with long
service life
• Ensures good surface finish
• Increases tool life due to EP properties.
• Long service life
• Non-staining to copper
• Good anti-rust properties
• Eliminates forming in high speed
grinding
• Extended tool life
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Thanks for your
attention!!

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