Metal Cutting Fluids

Why do we need them?

Cooling
Lubrication
Also provides: Swarf Flushing
Corrosion Protection

Metalworking Fluids

Basic Principles of Metal

CuttingFluids ; What they are &
how to use them correctly

What are neat cutting oils?

The performance of a neat cutting oil is
influenced by 3 factors:-

Viscosity
Additives
Levels of additives

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

Effects of viscosity
Cooling &
Swarf Flushing

Lubricity

Viscosity

Viscosity

Lubricity additives
Base Mineral Oils
Highly refined oils of high, medium or low
viscosity

Esters
Natural fats
Vegetable oils
Synthetic esters

Lubricity additives
Anti-wear additives
Typically phosphorous compounds or ZDDP

E.P. (extreme pressure ) additives

Chlorinated paraffins
Sulphur
Usually sulphurised esters or polysulphides

Neat Oils vs
Soluble Coolants
Cooling
Neat
Oils
Soluble
Coolants

Lubrication

What are coolants?

Lubricity
Additives
Add to
water

Emulsifiers &
detergents
Corrosion
Inhibitors
BioProtection

HOCUT ?

Metalworking
coolant
or
emulsion

Oil in water emulsion

Coolant jargon

Conventional soluble oil

Semi-synthetic
Synthetic
Extreme pressure
Biostable

Factors affecting Coolant

life
Micro-Organisms
Tramp oil
Water Quality
System Design
People

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

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

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

Water Quality

The presence of inorganic

salts in coolant make up
water will affect:Coolant stability
Foaming

Water Quality
Ideal Water

Low
salts
Excessive
foaming

Hardness =
100-200ppm.
Chloride zero
Sulphate zero

High
salts
Soap formation
Coolant instability
Corrosion
Bacterial attack

Water hardness expressed as ppm. (parts per million )

as calcium carbonate.

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

Monitoring & control

Always
maintain
concentration
between
specified limits.

Monitoring & control

If concentration becomes too high.
Possible. skin
irritation
Expensive
(product waste)
Foaming

Monitoring & control

If concentration becomes too low.
Bacterial attack
Corrosion
Increased
disposal
Expensive

Monitoring and control

How is concentration measured?

Refractometer
Titration
Instrumentation

--- on-site
--- on-site / lab.
--- lab.

Fluid Concentration Chart

12 .0

R
E
F
R
A
C
T
O
M
E
T
E
R
R
E
A
D
I
N
G
B
R
I
X

Hocut B60
10 .0

8 .0

6 .0

4 .0

2 .0

.0
0

FLUID CONCENTRATION (%)

10

How is Condition Measured?

pH readings
4.5

5.0

5.5

6.0

acidic

6.5

7.0
neutral

7.5

8.0

8.5

9.0

9.5

alkaline
soluble
oils

favours bacterial
growth
acceptable to skin

good corrosion
protection

10.0

Monitoring corrosion
protection

IP 125
Steel swarf on
a cast iron plate.
(overnight test)

IP 287
Cast iron swarf
on a filter paper.
(2 hour test )

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
24/48 hours
Empty & rinse
Refill with pre-mixed coolant at correct
conc.

for

Health and safety

Skincare

Handling concentrates
Concentration control
Hygiene
Proper use of skin creams
Good housekeeping
HSE guide to metalworking

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

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

Environmental &
H&S Issues
Chlorine
Disposal by burning can form dioxin,
carcinogen
Special incinerators needed for safe
disposal
Disposal cost is very high in Europe

Chlorine is an environmental issue, not health and safety

FLUIDCARE SERVICES

Health risks and MWF mists

More
Preventing respiratory diseases and
metalworking fluids
ScandMist air filtration equipment

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.