KEY SELECTION CRITERIA FOR CUTTING FLUIDS
For various industries, from Automotive, Steel, mining to agriculture, machining serves as the core activity that drives the sector's growth. As a result, cutting fluids are always a hot topic of discussion amongst manufacturers. They are always on the lookout to maximize cutting tool lifespans and make the process cost-effective through optimum selection of Cutting Fluids. Against this backdrop, cutting fluids emerge as a multi-purpose inclusion that can deliver to these expectations. This post will look at what you need to know before buying cutting fluids to maximize your ROI.
What are cutting fluids?
Industrial lubricants comprise a wide range of fluids to serve various purposes. And cutting fluids are one of them.
As the name indicates, cutting fluids are used in cutting for three primary purposes:
1. For cooling the tool & workpiece
2. To lubricate the tool
3. To flush away chips and debris from the cutting zone.
By doing so, cutting fluids can enhance tool performance, increase its life, cool and clean the tool, minimize friction, limit thermal distortion, cut down machine or tool wear and tear, and grant the perfect surface finishing.
Given this vital role played by cutting fluids, it only makes sense to spare no expense or research while selecting or committing to one.
Types of cutting fluid
Cutting fluids can be classified into the following categories:·
- Soluble cutting fluids
Soluble cutting fluids are oil-based emulsions that combine soluble oil, emulsifiers, additives, and water. They are used mainly for lubrication and disperse upon coming in contact with water. They are typically used for non-ferrous materials. This belong to the conventional technology and previously all metallurgies were machined using this category of Conventional soluble cutting fluids.
- Mineral oil with EP additives.
Mineral oils with EP additives are employed in heavy cutting activities as they possess excellent lubricating properties. They are typically used in production machines where high metal removal rates are required. They are compatible with Multi-Metals and can be used for machining tough alloys such as Titanium, Nickel & Steel
- Semi-synthetic cutting fluids these cutting fluids
are designed to work with ferrous and non-ferrous materials and help in lubrication, corrosion resistance, and decontamination. They provide excellent flushing property and ease in filtration. They contain a blend of emulsions and synthetic fluids to produce a micro-emulsion, with particle sizes varying from 0.01 to 0.1mm. They help in reducing consumption when compared to a conventional cutting fluid.
- Synthetic cutting fluids
Synthetic cutting fluids are oil-free, water-based fluids, making them more suited for ferrous and high-speed applications. These cutting fluids contain polymers, rust inhibitors, and other organic materials blended in water, which make them clean to run. Unlike oil-based cutting fluids, these enjoy a longer shelf-life, which is another advantage in their favor.
What to keep in mind while selecting a cutting fluid
Given the importance of cutting fluid in the machining process, paired with the fact that you have several options to choose from, it can be overwhelming to select one that works for you. To make this selection easier, the following are a few pointers to bear in mind to expedite the process:
- Properties of the cutting fluid
Naturally, the properties of the cutting fluid should be your first consideration while making a pick. Different cutting fluids will have different properties, which may react with the tool material.For instance, we have seen that synthetic cutting fluids are more apt for ferrous applications. In contrast, they can stain or result in a build-up for non-ferrous settings. As such, research the pros and cons of each cutting fluid and align it with the process.
- Nature of machining action
Just because they are called "cutting" tools, their scope is not limited to cutting alone. In fact, they are heavily used in turning, milling, boring, finishing, threading, and other machining actions. Hence, the role of the cutting fluid changes if you were to use it to remove chips and debris while boring versus cleaning while finishing. As such, you also have to account for the machining process.
- Cooling effect required
Cutting fluids should ideally have a high heat-carrying capacity to prevent overheating and reduce friction. Apart from dissipating heat, the rate thereof should also be comparable to the existing requirements, considering that certain applications would need this quality more than others. Given that the cooling effect of cutting fluid is closely related to tool life, matching the heat source with a proportionate sink can offer a bouquet of benefits while machining.
Storage and handling
Regardless of the cutting fluid you choose, they must be stored and handled carefully for optimum performance. Standard practices for storing and handling cutting fluid include:
- Store them in drums made of non-reactive materials.
- Keep them protected from sunlight and temperature extremes.
- Ensure that no oxidizing agents are stored with cutting fluids.
However, read up on the cutting fluid of your choice to know more about how you can get the most from it.
Cutting fluids play a crucial role in machining. And if you're looking for cutting fluids, Castrol should be your first option. As a global leader in industrial lubricants, we offer a wide range of cutting fluids that can deliver to your expectations and beyond. So, embrace efficiency and profitability with Castrol!