MWF Training

Metalworking
Training
(C) 2020 United Oil Company Pte Ltd. All Rights Reserved
Contents
➢ Part 1 – Industrial Oils
➢ 1.1 Hydraulic Oil
➢ 1.2 Slideway Oil
➢ Part 2 – Metalworking Operations

➢ Part 3 – Metalworking Fluid (MWF) Basics
➢ Part 4 – Metalworking Fluid (MWF) Types
➢ 4.1 Soluble Oil
➢ 4.2 Neat Cutting Oil
➢ 4.3 Forming/Drawing Oil
➢ 4.4 Quenching Oil
➢ 4.5 Rust Preventives
Part 1.1
Hydraulic Oil
Types of Hydraulic Oil
United Vesta Hydraulic Properties
H Zinc-based; Antiwear
HV High viscosity index for large temperature range
HX Zinc-free; Ashless
HP Premium, for severe pressure & complex systems
HC UTTO - Universal Tractor Transmission Oil
HT-4 TDTO - Transmission & Drive Train Oil
EFR Fire-resistant, ester-based
GFR Fire-resistant, glycol-based

Hydraulic Oil
Thermal Stability
Part 1.2
Slideway Oil
Primary Function
➢ Overcome the frictional “stick-slip” motion of machine

tool slides, table and feed mechanisms
➢ Anti-wear performance
➢ Provide vertical part anti-adhesion protection
properties
Primary Requirement
➢ Pass demulsibility test (ASTM D1401)
➢ Pass Cincinnati Machine performance level (P-47 for ISO 68
viscosity) – stick-slip test
Part 2
Metalworking
Operations
Types of Operation
1. Metal Removal Process

➢ Metal Cutting & Grinding
➢ Turning, Milling, Broaching, Sawing… etc.
2. Metal Forming Process

➢ Forging, Rolling, Drawing, Stamping, Punching & etc.
➢ Broaching
➢ Hobbing
➢ Gear Cutting & Shaving Heavy
➢ Tapping & Threading
Severity ➢ Honing
➢ Reaming
Of
➢ Form Grinding
Machining ➢ Deep Hole Drilling
Operation ➢ Multi Spindle Autos
➢ Milling
➢ Turning
➢ Drilling Light
➢ Grinding
Metalworking Process Severity
➢ Light – Medium Duty
➢ Grinding, Turning, Milling, Boring, Threading, etc.
➢ Heavy Duty
➢ Drilling, Reaming, Tapping, Gear Hobbing, etc.
Grinding Process Severity
➢ Light – Medium Duty

➢ Rotary, Centerless, Surface, OD, ID & etc
➢ Medium - Heavy Duty

➢ Double Disc, Form, Cylindrical & etc
Grinding / Honing
Drilling
Boring
Reaming
Tapping
Drilling, Tapping, Boring
Turning
Milling
Grooving / Cut Off
Threading
Threading
Gear Hobbing
Making a Gear
Broaching
Broaching
Types of Metal
Ferrous vs Non-Ferrous
➢Ferrous
➢ Metals which contain Fe → Iron
➢ e.g. Steel, Stainless Steel, other Iron Alloy
➢Non-Ferrous
➢ Any metal or alloy that does not contain Iron.
➢ e.g. Brass, Copper, Bronze, Aluminum and etc.
➢ Also known as Yellow Metal.
➢ Titanium Alloy
➢ Nimonic
➢ Inconel
➢ Nickel
Metal Hardness ➢ Stainless Steel

➢ High Carbon Steel
&
➢ Copper
Machinability ➢ Mild Steel
➢ Silicon Aluminum Alloy
➢ Unleaded Bronze
➢ Zinc Base Alloy
➢ Brass
➢ Magnesium
Part 3
Metalworking Fluid
Basics
Basic Functions of Cutting Oil
➢Cooling
➢ Dissipates heat
➢Lubricating
➢ Reduces friction
➢ Better finishing
➢ Extends tools’ life
Basic Functions of Cutting Oil
➢Chips/Swarf Flushing
➢ Remove chips / swarf to sump
➢Corrosion and Rust Proctection

➢ Oil film or additives to protect bare metal surface
Cutting Oil Categories
➢Neat Oil
➢To be used straight / as it is
➢Soluble Oil
➢Also known as cutting coolant
➢To be mixed with water before use
Viscosity of Oil
➢Viscosity → resistance to flow of a fluid
➢Unit of viscosity
➢ Centistokes (cSt)
➢ Define at specific temperature (e.g 40 deg C)
➢ Example at room temperature:
➢ Gasoline = 0.5 cSt
➢ Water = 1 cSt
➢ Olive Oil = 80 cSt
➢ Ketchup = 100,000 cSt
➢ Peanut Butter = 250,000 cSt
➢ Neat Cutting Oil – Typical Range: 10 cSt to 50 cSt @ 40oC
➢ Forming Oil – Typical Range: > 40 cSt to > 10,000 cSt @ 40oC
Viscosity Influence
Cooling &
Lubricity
Flushing
Viscosity Viscosity
Properties – Neat vs Soluble Oil
Neat Oil Soluble Coolant
Cooling / Flushing
Lubrication
House Keeping
Fluid Maintenance
Cost Effective
Part Finishing
Corrosion / Rust
Protection
Part 4.1
Soluble Oil
Soluble Oil Components
➢Emulsifier
➢ Emulsify oil into water (oil soluble coolant)
➢Anti-Microbial
➢ Kills/prevents growth of germs
➢ Either biocide or fungicide or combination
➢ Added in fluid formulation or post treatment of system
➢Defoamer
➢ Significantly reduces foaming potential
Coolant Maintenance
➢Coolant Mixing Procedure
✓ Always add oil to water

✓ Always premix coolant before adding to
the coolant tank
Coolant Maintenance
➢Water Quality
➢ The inorganic salts in water will affect the coolant stability and
foaming
Ideal Water
Hardness (calcium
carbonate) appx 100-
200ppm
Chloride zero
Sulfate zero High Salts
Soap formation
Low Salts
Coolant
Excessive instability
foaming
Corrosion
Bacterial attack
Coolant Maintenance
➢Coolant Concentration
✓ Always maintain the recommended
concentration
Coolant Maintenance
➢pH Reading
4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0
acidic neutral alkaline
soluble
oils
favours bacterial good corrosion

growth protection
acceptable to skin
Coolant Maintenance
➢Machine Cleanliness
✓ Use skimmer to remove tramp oil
✓ Routine house-keeping
✓ Very important as it affects Coolant life
Tramp Oil Skimmer
How a Skimmer works
Common Coolant Issues
➢Rancidity / Smell
➢ Caused by bacteria
➢ From sump that contain chips, swarf, tramp oil, sludge & etc
➢Rust
➢ Bacteria increase, pH drop from alkaline to acidic level
➢ Desirable pH should be between 8~10
➢ Too high pH will cause stain particularly on Aluminum
➢Poor Tool Life

➢ Bacteria will consume ingredients of coolant and hence reduce
lubricity and EP.
➢Dermatitis / Skin Inflammation

➢ Very fine chips from work piece, such Aluminum
➢ Bacteria infection of already affected area
➢ Workman personal hygiene
➢ Overdose of biocide by workman
➢Excessive Foam
➢ Depletion of anti-foam in coolant. A very small dose of anti-
foam on tank side will solve the problem.
➢Concentration Control
➢ Water will evaporate and lead to higher concentration drag
out. Hence higher cost.
➢ Insufficient concentration will affect cutting performance as
well as tools life.
Soluble Oil / Coolant Types
➢Mineral (usually called Soluble Oil)
➢ 100% oil, combination of base oil and chemical ingredients
➢ High oil content, forms milky emulsion
➢Semi-Synthetic (usually called Cutting Coolant)

➢ Contain less oil, generally < 10%, balance are chemical ingredients
➢ Forms translucent emulsion
➢Fully Synthetic
➢ No oil content, 100% chemical ingredients
➢ Forms transparent emulsion
Typical Questions to Ask
Soluble Oil / Coolant
1. Current product being used?
2. Milky or translucent or transparent type?
3. What is the process?
4. What is the material?
Part 4.2
Neat Oil
Neat Oil Components
➢Base Oil
➢ Highly refined oils of high, medium and low viscosity
➢ Hydro-treated, hydro-cracked oils that provide excellent
oxidation stability
➢Lubricity Agents
➢ Natural fats
➢ Natural plant ester
➢ Synthetic ester
➢Corrosion Inhibitors
Neat Oil Components
➢Extreme Pressure (EP) Additives
➢ Fatty Oils (Effective 100oC- 150oC)
➢ Chlorinated paraffin (Effective 250oC- 450oC)
➢ Phosphorous (Effective 350oC- 400oC)
➢ Sulfur (active / non active) (Effective >600oC)
➢Anti-Wear Agents
➢ Zinc dialkyldithiophosphates (ZDDP)
Neat - Cutting Oil Types
➢Cutting
➢ Eg. Turning, milling, drilling, tapping, threading, broaching, etc.
➢ Oils without Extreme Pressure (EP)
➢ Oils with EP
➢ Chlorinated
➢ Sulfurized (Active/Inactive)
➢ Mixture
➢ Non-traditional EP
EP - Sulfur Additive
➢Active vs Non Active
➢ Sulfurized additives being used as EP in oil.
➢ Copper Corrosion test (ASTM D130)
➢ Active → WILL stain yellow metal
➢ Non-Active → WILL NOT stain yellow metal
Neat Oil
1. Current product being used?
2. Any issues faced with current product?
a) Process details, production video, pictures?
5. Is lubricant allowed to contain chlorine?
Part 4.3
Forming Oil
Neat – Forming/Drawing Oil Types
➢Forming/Drawing
➢ High viscosity oils
➢ Typical KV: 60 cSt to > 10,000 cSt
➢ Usually contains high EP content
➢ Fast evaporating, Low viscosity oils

➢ Solvent-based Forming
➢ Typical KV: < 5 cSt
➢ May contain EP
Drawing
Fast Stamping
Progressive Die Stamping
Rolling
Forging
Basic Functions Of Forming Oil
➢ Cooling
➢ Dissipate heat
➢ Lubricating
➢ Reduces friction
➢ Better finishing
➢ Extended tools life
➢ Corrosion and Rust Protection

➢ Oil film or additives to protect bare metal surface
Types Of Forming Oil
➢Evaporable Oils
➢ Typically provide a thin lubricant layer (Very Low
Viscosity)
➢ Swiftly evaporates after machining (no need for
subsequent cleaning)
➢ Low EP, low Lubricity (Think Material)
➢ Low flash point (Low OELs – occupational exposure
limits)
➢Medium Range Hydrocarbon Fluids
➢ Example: Kerosene & White Spirits
➢ Mostly self-drying, but may take up to 48 hours
➢ Low to medium EP & Lubricity
➢ Oils For Hot Forming
➢ Low to medium viscosity
➢ High oil content
➢ Generally content very high EP & Lubricity properties.
➢ Oils For Cold Forming

➢ Medium to high viscosity (up to 300cst at 100oC)
➢ Proportion of additives generally higher than oil
➢ Very high EP & Lubricity properties.
Forming Oil
1. Viscosity of current product?
a) Initial and final shape of item (pictures if possible)
4. If stamping
a) Fast or slow stamping?
b) Need fast evaporating oil?
Part 4.4
Quenching Oil
Primary Functions
➢Hardening of steel
➢ Facilitates hardening by controlling heat transfer (or cooling
speed) during quenching
➢Minimize distortion & cracking

➢ Enhance wetting of steel during quenching to minimize
formation of undesirable thermal & transformational gradients
which may lead to increased distortion and cracking
3 stages of Cooling Curve
Monitor of Quenching Oil
➢Viscosity
➢ Oil viscosity may change over time due to degradation and
hence affect the performance
➢Water Content
➢ Water from contamination or degradation may cause soft
spots, uneven hardness, staining and even fire.
➢Flash Point
➢ For safety precaution, the minimum flash point under normal
operating conditions should be 90 deg C ABOVE the oil
temperature being used.
➢Total Acid Number

➢ Oil degrades or oxidation will forms acidic by-product.
➢ Excessive acid number would suggest oil change required.
➢Sludge Formation
➢ The presence of sludge may cause uneven heat transfer,
increase thermal gradients and increased cracking and
distortion.
➢Elemental Analysis
➢ Element within additives used will deplete over processes.
➢ Fresh oil and used oil analysis will provide good comparison.
➢Cooling Rate
➢ ASTM D 6200 – Cooling Curve Analysis
• Inconel 600 Steel Probe

• Heated to 840oC
• Dropped into 1000ml oil
• Quench oil at room temperature
• Cooling curve generated
➢Cooling Rate (time taken to reach 200s)
➢ Fast 10 – 25 sec
➢ Medium 26 – 34 sec
➢ Slow 35 – 40 sec
➢Cooling Rate
➢ Alternative test: GM Nickel
ball test
Quenching Oil
We will require sample from customer for testing.

Preferably 1L.
Part 4.5
Rust Preventive
Primary Functions
➢ Forming a barrier between metal surfaces and
contaminants such as air, water and other corrosive
materials.
➢ General Rule: The thicker the coating, the longer is the

protection.
Application
➢ Dipping
➢ Spraying
➢ Flushing
➢ Brushing
Primary Properties
➢ Water displacement (dewatering) (DWF)
➢ Acid neutralizing
➢ Easy apply and easy removal
➢ Resistance to moisture penetration
➢ Resistance to weathering
➢ Non-staining
Common Product Types
➢ Solvent Base
➢ Oil Base
➢ Water Base
Common Tests
➢ Humidity Cabinet, ASTM D1748
➢ Simulated testing for indoor storage
➢ Salt Spray, ASTM B117

➢ Simulated testing for outdoor storage
➢ Stack Stain, MIL-C-22235A

➢ Simulated testing to determine the effect of water contamination, heat and
metal to metal contact on coiled or stacked metal surfaces.
➢ Water Displacement, MIL-PRF-16173E
Rust Preventive
1. Protection length
a) No. of weeks, months, years?
2. Protection condition
a) Indoor or outdoor?
3. Product type requirement?
a) Solvent, oil or water-based product?
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Metalworking

➢ Part 2 – Metalworking Operations

HV High viscosity index for large temperature range

HP Premium, for severe pressure & complex systems

HC UTTO - Universal Tractor Transmission Oil

HT-4 TDTO - Transmission & Drive Train Oil

EFR Fire-resistant, ester-based

GFR Fire-resistant, glycol-based

➢ Overcome the frictional “stick-slip” motion of machine

1. Metal Removal Process

2. Metal Forming Process

➢ Light – Medium Duty

➢ Medium - Heavy Duty

Metal Hardness ➢ Stainless Steel

➢Corrosion and Rust Proctection

➢Coolant Mixing Procedure

✓ Always add oil to water

acidic neutral alkaline

favours bacterial good corrosion

How a Skimmer works

➢Poor Tool Life

➢Dermatitis / Skin Inflammation

➢Semi-Synthetic (usually called Cutting Coolant)

➢ Fast evaporating, Low viscosity oils

➢ Corrosion and Rust Protection

➢ Oils For Cold Forming

➢Minimize distortion & cracking

➢Total Acid Number

• Inconel 600 Steel Probe

We will require sample from customer for testing.

➢ General Rule: The thicker the coating, the longer is the

➢ Salt Spray, ASTM B117

➢ Stack Stain, MIL-C-22235A

➢ Water Displacement, MIL-PRF-16173E

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