The two main functions of metalworking coolant is cooling cutters and reduce the friction in the process of cutting.
Coolant other jade to clear functions include chip, to prevent corrosion, ensure the biological stability, and to provide for the operator friendly environment. Cooling fluid made up by complex chemical formula, in order to meet the performance requirements.
Machine processing factories usually have many different processing operations, each with their specific cooling fluid requirements. In order to meet these requirements, cooling fluid formula has been derived several hundreds of its products have different functions.
In the past, machine processing plants are often prepared at the scene into play different coolant to cater to the engineer for each drum machine tools using the requirements of the cooling fluid. Processing workshops, however, different coolant caused the problem such as cross contamination and waste liquid are incompatible. In addition, a variety of coolant also caused the increase in inventory.
Nowadays, machine processing plants tend to be in the workshop for all process using one or a limited number of cooling fluid.
This prompted coolant suppliers develop a more comprehensive products and help in making quality products at the same time solve the cooling and lubrication, corrosion and microbial control and other issues. And so on many kinds of technology and the market on a large coolant, machine processing plant for its operation and choose the best performance, the most economical cooling fluid and met with complex challenges.
In addition, for each specific process this problem, the best coolant always exists the phenomenon of many things. A basic understanding of the three types of main coolant - pure oil, soluble oil and synthetic agent - how the various components of an effect on performance, the selection of the cooling liquid can be simple.
The function of the oil soluble ingredient component function
Mineral oil lubrication and rust
Oils and fats increase lubricity
Extreme pressure additive (sulfur, phosphorus, chlorine) improve the knives' service life
Emulsifier allow mixed with water
PH initiator Improve the rust resistance and biological stability
Insecticides to control bacteria and mold
To control bubble to bubble
antioxidant To prevent oxidation, make the luster
Pigment, essence customer preferences
Basic characteristics of the cooling fluid
(in descending order, not including the effect of the additives)
Lubrication cooling
Pure oil composition
Semi-synthetic soluble oil
A composite Oil soluble
Synthesis of pure oil
Pure oil
Does not dissolve in water of pure oil from oil (mineral oil), animal or vegetable oils derived, not diluted can use "direct".
The oil has good lubricity and anti-rust oil groove, long life and easy maintenance etc, in addition, they will not go bad, because life is usually only to survive in the aqueous fluid.
Can be a pure oil or a mixture of different base oil, and may contain boundary and/or extreme pressure additives, such as sulfur, phosphorus and chlorine compounds. Pure oil can reduce the force created by the tool when cutting metal, thus cutting and cutting tools can be clean on the surface of workpiece formed on the smooth.
Additives can improve the lubricity of pure oil, strengthen by cutting metal and cushion layer between the cutting tool. Processing in extreme cases, the additive is likely to exceed 20% of the ingredients of the products.
Although they did not add any additives products more expensive, but it was very important for the surface roughness and the tool life process such as squeeze grinding, demanding and the process of tapping and deep hole drilling, the pure oil with additives have a vital role.
In addition, the pure oil can also prevent micro coherence in the heavy load processing, additive can improve the bonding performance of metal.
However, pure oil will not flame retardant, smoke, thus forming the operator is not friendly processing environment. Pure oil may also be at the factory almost every leave unpleasant oil film on the surface.
Oil soluble
Soluble oil is suitable for light to heavy burden to the machining operation, including non-ferrous metals and ferrous metal processing.
Wetting agent and extreme pressure additives can extend the using range of soluble oil and include more generally with pure oil heavy loading process.
Soluble oil usually are classified as either half synthesis, are classified as either real soluble oil, is mainly based on the oil content in the concentrate.
Oil soluble concentrate containing 40% or more oil, the mixed with water forming a metal cutting fluid, the cutting fluid for oil mixed with water to provide cooling water has a high heat capacity and good heat dissipation, embellish ability is attached by oil mixed with water, they are usually in the moving parts of machine tools on the left a layer of protective coating.
Although the soluble oil can prolong tool life of high quality lubricants, but they are not always with the same level of pure oil lubrication performance. They are also better than pure oil require greater maintenance. The use of water makes the history of soluble oil prone to microbes, and easier to corruption, therefore, factory must comply with strict preventive maintenance measures to extend the service life of the tank.
Operators need to note the more closely, and type of water soluble oil junction station.
If mixed with hard water, the soluble oil can produce precipitation on the workpiece and machine tool: groundwater may be a hard, also may contain accelerate the corrosion of chlorine ion and sulfate.
Machine processing factory should adopt and sufficient corrosion first-class cooling fluid, or they may need to be added in the cooling liquid tank preservatives. On the other hand, the use of soft water and soluble oil-based coolant machining may be a bubble issues, so need to be adopted, such as a foam agent, oil tank such as agent.
Semisynthetic coolant
Semisynthetic coolant is added in the water diluted concentrate made from up to 40% of the oil. Can also be added, such as emulsifier, wetting agent, preservative, extreme pressure components and pesticides, etc.
The coolant is usually translucent, but can also be transparent or opaque completely.
Semisynthetic cooling fluid can be widely used in cutting tools, they provide good lubricity of medium and heavy load processing. Through them, the operator can at higher cutting speed and feed, because they are generally than soluble oil has better cooling and wetting performance.
Semisynthetic coolant with less oil preparation, sometimes has better precipitation and cleaning performance. Because of their oil content less than pure oil or soluble oil are, therefore, they produce a smoke less.
The disadvantage of semisynthetic coolant are similar to those of soluble oil - water hardness influence its stability. Hard water and water composite mixed use, may cause to form hard water in the tank sediment, and mixed with soft water, will produce bubbles.
Synthesis of coolant
Synthesis of cooling liquid contains no petroleum base oil. Typically, they contain lubricating oil and rust inhibitor does not dissolve in water. Suppliers to concentrate the form composition, and the soluble oil is very similar, they are mixed with water to form cooling fluid.
Because only additives and added to the water in the concentrate, synthesis and has a high cooling functions. At the same time they are best used in high temperature and high speed metal cutting, such as plane grinding, etc., has a far-reaching influence on lubricity additives, when added to certain synthetic objects, can be pure oil yield better than an additive lubricating effect.
Heavy load composition in the past few years has been fully developed, now you can deal with most add process.
Composite cooling liquid based on its components can be divided into several levels:
Simple cutting fluid used for light load grinding operation. After they are mixed in a tank will form a transparent liquid, so the operator can see are cutting of metals.
Complex cutting fluid contains synthetic lubricating oil, can used for high speed to medium/heavy duty cut. They also form a transparent solution in the tank.
Formation can be emulsified cutting fluid contains a particular chemical characteristic of lubricating oil, and its appearance is similar to soluble oil.
Composite has the ability of acidic to prevent all bad, generally good microbial inhibitory. Most of the composites used for corrosion protection, and it has outstanding cooling capacity.
Traditionally, the composite has many disadvantages. Synthetic usually is more expensive than the same kind of oil. In addition, some synthetic running very clean.
That is to say, its like a cleaner feature can cause some synthetic cause skin and mucous membrane drying machine seal failure, the operator. Many synthetic cooling fluid will leave a sticky, gooey residue.
Some people believe that. Synthesis of agent to oil atomization, but that's not necessarily true. According to its composition and operation, they may not produce such as soluble oil mist often appear, but they still may oil atomization, cause nose, throat and eye mucous membrane inflammation. Because they are not oily, composite damage to human skin may be higher.
Correct selection of cooling fluid
The best cooling fluid can protect the machine and prolong tool life, at the same time provide operator and environmental health and safety departments approved by the environment.
Choose the best cooling fluid to optimize all the parameters based on machine tool manufacturer and coolant supplier best advice.
Plant operators and engineers often depend on coolant supplier's proprietary knowledge to discuss and recommend the best cooling fluid in view of the processed material. Most of the factories want to reduce the type of coolant to reduce the cooling fluid maintenance and disposal expenses, and can further savings buying large coolant.
Some machine tool manufacturers for their products require the use of specific cooling fluid. A large number of machine tool manufacturers to provide a list of recommended coolant, and if the user does not use the recommended coolant, warranty. When processing factory in considering buying machine, should find machine tool manufacturer and explain the current workshop is using the cooling fluid. Then, manufacturer and coolant suppliers can determine the active cooling fluid effects in all kinds of new machine tools.