Coolants & Metal cutting

fluids
Dr James Wakiru
Mechanical Engineering Department

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Functions of Cutting Fluids
• A cutting fluid may be defined as any substance (may be liquid, gas or solid) which is applied to a tool during
a cutting operation to facilitate removal of chips.

Functions of Cutting Fluids

1. To cool the cutting tool and the workpiece.
2. To lubricate the chip, tool, and workpiece.
3. To help carry away the chips.
4. To lubricate some of the moving parts of the machine tool.
5. To improve the surface finish.
6. To prevent the formation of built-up-ridge.
7. To protect the work against rusting.

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Primary requirements
• Reduce friction
• Reduce tool wear
• Prolong tool life
• Reduce machine tool power consumption
• Improve surface of workpiece
• Cool workpiece
• Reduce frictional heat between tool and chip
• Heat dissipation properties
• Remove debris and chips from work area
• Provide temporary corrosion protection
• Avoid oxidation caused by air , humidity and heat
• External aggressive agents
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Heat between tool and chip

95% of energy during cutting becomes heat

CHIP
TOOL

O
O 500 - 700 C
300 - 600 C
1
2

WORKPIECE 4
Heat at deformation zone 1-2
Other
Heat at friction zone 3-4

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Secondary requirements
▪ Product and emulsion stability
o The product concentrate must be stable
o The emulsions must not separate oil or form soaps
▪ Have good detergency
o Emulsions must keep the machines clean
▪ Biological Resistance to bacteria and fungi
▪ Part compatibility
o The fluid should not cause staining, corrosion or excessive residues
▪ Water compatibility
o The coolant should be low foaming and not produce scum
▪ Tool compatibility
o must not leach tool metals
▪ Machine compatibility must not attack paint or rubber
▪ Not Produce Misting or Smoking
▪ Environmentally Friendly comply with local laws

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Requirements of Cutting Fluids
A cutting fluid should possess the following qualities in order to be of practical value :
1. It should provide sufficient lubrication between the tool and work and the tool and chips so as to
minimise tool wear and reduce power consumption.
2. It must carry away the heat generated during the process and, thus, cool the tool andworkpiece both
in order to minimise the tool wear and prevent distortion of the workpiece.
3. Its flash point should be amply high.
4. It should be able to impart antiwelding properties to the tool and the workpiece, otherwise very poor
finish may result.
5. It should not discolour the finished work surface.
6. It should be non-poisonous and should not cause skin irritation.
7. It should carry such constituents which will prevent the finished work surface and the tool from being
rusted or corroded.

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Types of Cutting Fluids
1. Straight or neat-oils :
• These are derived from petroleum, animal, marine, or vegetable substances and may be used straight or in
combination.
• Their main function is lubrication and rust prevention.
• They are chemically stable and lower in cost.
• They are usually restricted to light-duty machining on metals of high machinability, such as aluminium,
magnesium, brass and leaded steels.
2. Water miscible cutting fluids :
• Water miscible fluids form mixtures ranging from emulsions to solutions, which due to their high specific
heat, high thermal conductivity, and high heat of vaporisation, are used on about 90% of all metal-cutting
and grinding operations.
• The water blend is usually in the ratio of one part oil to 15 to 20 parts water for cutting and 40 to 60 parts
water for grinding.

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Types of Cutting Fluids
3. Synthetics (chemical) or semichemical cutting fluids :
• Synthetic coolants refer to any coolant-lubricant concentrate that does not contain petroleum oil.
• Semichemical coolants contain a small amount of mineral oils plus additives to further enhance the
lubrication properties. These are gaining wide popularity in industry today because they incorporate the best
qualities of both chemicals and normal water emulsions.
Advantages and disadvantages of chemical fluids :
Advantages :
(i) A very light residual film that is easy to remove.
(ii) Heat dissipation is rapid.
(iii) Good detergent properties.
(iv) An easy concentration to control with no interference from tramp oils.
Disadvantages :
(i) The lack of lubrication “oiliness” may cause some sticking in the moving parts of machine tools.
(ii) The high detergency may irrirate sensitive hands over a long period of time.
(iii) As compared to oils, there is less rust-control and lubrication, and there is some tendency to foam.
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Coolant types and origins

• Types (two main categories)

• Neat cutting oil used at 100% concentration
• Water solubles which should be diluted in water
(sometimes called emulsifiables)
• Sources of their Raw Materials

ANIMAL VEGETABLE MINERAL SYNTHETIC

▪ Lard oil ▪ Pine oil ▪ Petroleum ▪ Chemistry
▪ Beef ▪ Canola oil ▪ Esters
▪ Lanolin ▪ Peanut oil ▪ Glycols
▪ Castor oil
▪ Palm oil
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Functional ingredients
• Carriers
• Water and / or mineral oil
• Dissolve the additives
• Carry additives to the cutting point
• Emulsifiers
• Boron soaps, ethoxylated alcohols
• Provide detergency
• Make oil and water miscible
• Lubricants
• Fatty acids, esters, and EP additives reduce friction
• Corrosion inhibitors
• Foam control
• Finely dispersed calcium soap or anti foam
• Biological inhibition
• Boric acid with amines (biostatic)
• Biocides to kill micro-organisms (bacteria & fungi)

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Soluble Oil
▪ Used for Moderate to Heavy-duty Machining and grinding
➢ Water soluble
➢ Oil based lubrication 60% + mineral oil
➢ Use Concentration 4 - 15 %

Oil Concentrate composition Pictorial representation of the emulsion

Mineral oil
or Synthetic lubricant
Solvent Milky appearance Water phase
Emulsifiers
• Water Oil
Oil
• Glycols

• Boundary Lubricant
• Corrosion inhibitor Oil
• Extreme-pressure (optional)
• Biocide
• Particle Size 2-10 microns Emulsifiers

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Synthetic
▪ Traditionally Light Duty Machining, light to moderate Duty
grinding
➢ Water soluble (solution)
➢ No oil, no emulsifiers
➢ Use Concentration 3 - 15 %
➢ Optimal cooling
➢ Optimal tramp oil rejection

Concentrate composition Pictorial representation of an solution

Water Transparency

Corrosion inhibitors Water phase

• Water soluble lubricant

• Surfactant
• Biocide
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• Defoamer
Semi Synthetic
▪ Wide range of light to Moderate Duty Machining and all
ranges Grinding
➢ Water soluble
➢ Oil based lubrication 5 - 45 % mineral oil
➢ Use Concentration 4 - 15 %
➢ Combination of synthetic & soluble oil

Oil concentrate composition Pictorial representation of a semi-synthetic

Translucent

Emulsifiers Oil
Mineral oil
Oil
Water Water phase

Oil

• Boundary lubricant
• Corrosion inhibitor
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• Biocide Emulsifiers
 Neat oil Vs Soluble Oil
• Neat oil used 100 % • Water soluble used 3 - 15 %
• Positive • Positive
• Low maintenance cost • Good cooling versus neat oil due to water
• Good lubricity • Low misting (lower oil content)
• Good chip removal • Fire proof so no need for CO2 equipment
• Easily filtered (recycled) • Low cost initial fill
• No bacteria • Easily cleaned.
• Good tool life • Lower drag out so less is used
• Negative • Can also give better tool life
• Poor cooling versus soluble • Negative
• Can give heavy misting (5mg limit) • Higher maintenance
• Risk of fire (can need CO2 equipment) • Not easily recycled especially small customers
• High cost initial fill
• Difficult to wash off
• High drag out on chips (chip spinner)
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Cutting fluids used in different operations
Operations Suggested fluids
Turning Emulsions or straight oils.
Tapping and threading Active type mineral fatty oil.
However, occasionally, emulsions of soluble oils are also used.
Drilling and boring Soluble oils
Reaming Soluble oils
Planing and shaping Usually no cutting oil is used
Milling Sulphurised mineral fatty oils or emulsions in ample quantity
Broaching Heavy, active type cutting oils ; particularly in horizontal internal broaching.
Thread rolling Straight mineral oil or emulsions.
Gear cutting and shaping Active type mineral oils and compounds
Sawing Soluble oil.
Grinding, lapping and honing Active type mineral oils and compounds ; emulsions of soluble oils or paste type.
Machining plastic materials Brittle materials can be machined dry or with an air blast ; in case a fluid is required, a
dilute solution of soluble oil should be used in ample quantity.
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