How to make neat oil application safe
Neat cutting oils are widely used in manufacturing applications across industrial sectors for their high lubricity. Different types of neat cutting oils are also used to impart specific properties like pressure and heat reduction, chip removal, and high-temperature viscosity for some manufacturing applications.
The neat cutting oil market is projected for heavy expansion due to upscaled production post-pandemic and increasing cutting oil consumption for machining applications. Technological advances in plant and machinery used in automotive, infrastructure, aviation, electrical, maritime, railways, telecoms, utility and healthcare are also expected to propel the neat cutting oil market growth.
Despite highly improving the tool and workpiece life and enhancing the surface finishing, among other useful processes in industrial applications, neat oil is a difficult fluid to handle.
Neat cutting oil definition and uses
Neat cutting oils are non-emulsifiable fluids typically based on mineral oils and utilised for cutting without any subsequent dilution, as specified by the producer. They are invariably mineral oil blends with various other additives.
Neat cutting oils are used in several manufacturing industries to increase the durability of tools and machines while also decreasing wear and tear. They provide lubrication between the workpiece and the tool during machining to decrease friction. This, in turn, enhances surface finishing and tool life. Neat cutting oils are used for light machining and heavy-duty industrial applications. The most common neat cutting oil applications are broaching, cutting, drilling, grinding, hardening, honing, milling, and hot or cold rolling.
Hazards to man or machine from neat cutting oil use
Heat is caused during manufacturing due to friction between the workpiece and the tool. This heats the neat cutting oil and results in the formation of an aerosol known as oil smoke. As neat cutting oil is meant to be used as supplied by the manufacturer without dilution, the oil smoke does not contain any water. This causes the oil smoke to pose a fire hazard. The aerosols can cause the machine to explode or catch fire if the temperature crosses a certain threshold or if the machining process causes sparks.
These oil smoke particles cannot be filtered due to their infinitesimally small size. They negatively impact their surroundings and human health.
How to reduce smoke oil emissions
The chances of a health and safety incident increase with the amount of oil smoke. Neat cutting oils with a lower viscosity index produce less oil smoke emissions than highly viscous cutting oils. Some manufacturers offer specialised neat cutting oil formulations which produce less oil smoke in high-temperature environments. But these special formulations are expensive.
Another method to reduce smoke oil is through the minimum quantity lubrication or MQL method. This method applies a small volume of high-quality oil to the tool or workpiece. The purpose is to reduce the overall smoke caused by the evaporation of neat cutting fluid by using less neat cutting fluid.
Highly worn-out machining tools overheat more as compared to tools in top condition. Using sharpened tools reduces the volume of oil smoke produced and increases operational efficiency.
How to extract oil smoke
Oil smoke formed during machining should ideally be removed as soon as possible to reduce the risk of fire explosions. Installation of an aerosol or oil mist collector helps reduce the formed aerosol smoke. This is done with a filter that collects and drains the aerosol smoke particles. While several mist collectors can collect droplets, only selective mist collectors have the capability of draining the collected droplets.
The way going forward
The amount of neat cutting oil required is directly proportional to the complexity of the machining process. Complex machining processes emit a higher volume of oil smoke. This increases the risk factor for manufacturing factories and their employees. With the implementation of MQL, these risks can be significantly reduced.
Awareness of the risks of using neat cutting fluid is necessary so that newer manufacturing factories can install proper filtration systems to deal with oil smoke.
Conclusion:
Cutting oils are essential for machining processes. However, they pose significant risks to life and property if used improperly. It may also further jeopardise the metalwork's effectiveness.
Castrol is the global leader in liquid engineering. We provide a comprehensive range of cutting oils for all industrial sectors that address every requirement. Our metalworking fluids are proven to improve machining efficiency and manufacturing processes while prolonging machine life.