Heavy-duty water-soluble cutting fluids are designed for use in all metal cutting processes and play a vital role across many industries. These cutting oils are most commonly referred to as soluble oils, although they are not entirely soluble in water and only become an emulsion when added to water. These fluids also contain additives to improve their lubricating properties and act as corrosion inhibitors.
These cutting fluids are widely used across some of the most challenging and heavy-duty machining operations like threading, reaming, and broaching, where reducing friction is essential. Because of the extreme pressure additives in its formulation heavy-duty water-soluble cutting fluids offer excellent lubrication in these processes, prolonging the life of cutting tools and delivering a perfect surface finish.
A. Types of heavy-duty water-soluble cutting fluids
Heavy-duty water-soluble cutting oils are differentiated into three categories depending on the mineral oil base.
1. Mineral oil -based: These heavy-duty water-soluble cutting oils are suitable for most machining applications on ferrous and non-ferrous metals, with a machining ability rating above 70%. These cutting fluids are fortified with extreme pressure additives to promote better tool life and surface finish on metals. These products provide hard water stability, bio-resistance, reverse alkalinity, and short-term corrosion protection.
2. Synthetics: The synthetics are true solutions and completely clear. They primarily consist of organic and inorganic salts dissolved in water. Synthetic solutions are less prone to microbial infestation with superior settling and cleaning properties that help extend fluid life. Synthetic water-soluble cutting fluids offer high pH stability, corrosion protection, biological control, foam control, and enhanced lubricity.
3. Semi-synthetics: These oils have a lower oil content of 5-35% and are suitable for any machining operations. However, extreme pressure additives are necessary to improve heavy-duty machining performance. As a result, they provide an improved cooling effect and usually have better cleaning and settling properties than emulsified oils, thereby prolonging bath life.
B. Applications of heavy-duty water-soluble cutting fluids
1. Heavy-duty water-soluble cutting fluids are widely used in the machining operation of high tensile stainless steel and nickel-chromium alloys on automats, drilling/reaming, gear cutting, and thread cutting machines.
2. They are also used for metal cutting, centerless grinding, drilling, milling, turning, and surface grinding.
However, there are certain safety and handling precautions an operation must follow. For instance, the material must be handled as an industrial chemical. An operator must be wearing protective equipment, following preventive measures as mentioned in the MSDS, i.e. material safety data sheet. Besides, these cutting oils should be stored in a dry, ventilated area. The container should be closed and kept away from spark, flames, and heat.
C. Benefits of heavy-duty water-soluble cutting fluids
1. Reduced forces on the tool and thus, economic efficiency in power consumption.
2. Increased tool life by cooling the cutting edge.
3. Better finish on the workplace
4. Minimised tool-chip friction by providing a lubricant between chip and tool.
5. Improved lubricant machine movements.
6. Decreased tendency to form ‘built-up edge’.
7. Reduced distortion caused by heat generation, thereby maintaining dimensional accuracy.
8. Limited corrosion of newly machined surfaces.
9. Lubrication to guiding tooling portions, including drills or piloting in a brush.
D. Requirements of an ideal heavy-duty water-soluble cutting fluid
1. The ideal cutting fluid should be an efficient coolant and provide robust lubrication.
2. It should be easy to store, handle, and prepare and have an optimum service life and minimum cost with no adverse effects on normal machining lubrication.
3. The cutting fluid should be non-toxic and non-fuming to operators.
4. It should be non-corrosive to tooling machines or components.
Conclusion
It goes without saying that certain heavy-duty machining operations require specialised fluids like water-soluble cutting oils. These fluids ensure optimum efficiency and minimum downtime. While it is crucial for an operator to understand the different properties and applications of water-cutting fluids, it is equally important to know which cutting oil manufacturer to choose.
Castrol, a leading industrial lubricants manufacturer, provides a wide range of heavy-duty water-soluble cutting fluids designed to be used in diverse machining operations. These water-soluble cutting fluids can deliver the desired operational results,