Content

1. MWF Basics & Functions

2. Mixing Guidelines

3. Maintenance – MWF

4. Maintenance – Filtration
MetalWorking Fluids Knowledge
Sharing
5. Training
Trouble Shooting
 What is Soluble Oil?

Oil when mixed with water forms an `Emulsion'

Emulsion:
Dispersion / suspension of small oil droplets in the water is called Emulsion.

Milky Emulsion has large droplets, and it is oilier. (Size of particles - 2 to 4µ )

A clear Emulsion has smaller droplets and is less oily. (size of particles
<=0.5 to 1.5µ)

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 Categories of Metal Working Fluid?

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 Categories of Metal Working Fluid?

Metal working fluid can be divided into two main class that is water
soluble and straight oil type

Water soluble oil

Can be used water mix form
Water soluble type has excellent cooling
performance but it has poor lubricity than
Cooling Lubricity
the neat oil

Straight oils (Neat oil)

Can be used neat form
Neat oil has excellent lubricity but poor
cooling performance
Lubricity Cooling

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 Types of Metal Working Fluids
Water Miscible / Coolants

Soluble Oil Semi-Synthetic Synthetic

- Light translucent / Opaque - True solution, clear fluid

- Milky emulsion of oil in water
emulsion of oil in water
- Oil content, 50-90% - Oil content, 0%
- Oil content, less than 50%
- Low sump life - Sump-life comparable to
- Longer sump life than soluble oil semi-synthetic
- Higher maintenance
- Additives limited by solubility
 Functions of Metal Working Fluid

Primary Function Reduce heat and Friction

Secondary Function

Enhance Tool Desired Good washing Corrosion

life Finish(Ra) protection

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 Metals & Materials – Machineability of Metals

Nickel Alloys
Titanium Alloys
High Speed Steel (Tool Steel)
DIFFICULT
High Chrome Steel (Stainless)

Alloyed Steels
MODERATE
Carbon Steels

Cast Iron
EASY TO
Aluminum Alloys
MODERATE
High Strength Copper

Copper & Brass

EASY
Magnesium (!)

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 Mixing Guidelines

Correct method to prepare coolant

 Add Coolant to Water and not Vice-versa

Water Oil

 Maintain Recommended Concentration at Any Point Of Time

 Measure ph, Water to Oil Ratio, Water Addition, Coolant
Addition on Daily Basis

 Record the Above Procedure And Display Visually

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 Mixing Guidelines

General rule for the preparation of emulsion: always concentrate in to the water

Oil = Oil in last !!!

Water

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 Mixing Guidelines –Proper Mixing

Parts of concentrate mixed in water

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 Mixing Guidelines – Concentration Range

15 • Residue
TOO
• Foam
14 STRONG • Cost
13 • Dermatitis
• Cleanliness
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Concentration in Water in %

10 UPPER LIMIT
9
8
7
TYPICAL OPERATING RANGE
6
5
LOWER LIMIT
4
3
2
1
0

11 Cono Balbo, Intern. Product Management December 2011

 Monitoring and coolant specification

COOLANT SPECIFICATION
pH : 8.9 to 9.3

Concentration : Grinding 3.0 % - 4.5% & Machining 5%-7%

Hardness : < 200 ppm.

Chlorides : < 80 ppm.

Tramp oil : < 0.5%.

Dirt Content : < 30 mg/lit.

B-M-Y : 0-0-0

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 pH and Concentration

 Coolant health depends on two basic parameters

WHAT IS pH ?
 pH will indicate whether the liquid is Acid or Alkali
 We maintain pH of Coolant as 8.9 -9.3 to have good washing action, Rust
protection & anti-bacterial function

Methods of checking pH
Digital pH meter pH Paper

Accurate method Less Accurate method

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 Effect of pH on coolant health

Issue-
pH too low
Bacteria?
Concentration too low?
pH too high
Concentration too high?
Contamination with cleaner?
Action-
Additives treatment to kill Bacteria
Increase Concentration

Reduce coolant Concentration and maintain

Dump contaminated coolant and make fresh emulsion

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 WHAT IS COCENTRATION ?
Concentration is nothing but water to coolant(Concentrate) ratio
 Low Concentration - (More water & less coolant ) Lead to rusting ,
bacterial growth and poor finish.
High Concentration- (Less water & more Coolant)Leads to foam and skin
irritation
Methods of checking
By using Ra and Brix Refractometer

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How to use Refractometer?

1. Clean the 2. Reset the zero 3. Measure by

measuring plate point by using using samples
water

Measuring Scale reading

 Reading the Refractometer

Soluble oils read 1:1

Synthetics and semisynthetic must be
multiplied by refractometer factor found
on the Product Application Sheet

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WHAT IS TRAMP OIL ?
This nothing but the other oils like Lube oil/ Hydraulic oil/
Spindle oil/ Rust preventive oil contaminating the coolant

More Tramp oil - lead to low washing action of the coolant

, rust, bad smell & higher coolant consumption

Tramp oil Coolant with out

Tramp oil
 Maintenance – MWF

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 Maintenance – MWF

System Cleaners for water miscible MWFs (to clean a system)

The following procedure is well established:

 Drain the Used Coolant

 Fill Sufficient Quantity of fresh Water

 Add 1.5- 2% System Cleaner

 Circulate 1-2 Hours

 Physically Clean All Machines, Pipelines during Circulation

 Drain out Entire Cleaner

 Rinse Entire System With Fresh Water

 Fill with Good Water, Add Coolant Concentrate at
Recommended Concentration
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 Maintenance – MWF

Machine tool area Machine tool area, covered

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 Maintenance – Filtration

Why filtration?

Filtration

Higher lifetime of Higher lifetime of Higher tool life Higher surface

the MWF pumps + valves quality

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 Trouble Shooting

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 Trouble Shooting

Questions:

1. What is the concentration?

2. What type of condition is the coolant in?
3. What types of contamination can occur?
4. What is the water quality?
5. Where and when is the corrosion occurring?
6. What does the corrosion look like?
7. If the parts are corroding in storage, where are they being stored?

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 Trouble Shooting

 Corrosion
 Skin
 Odor
PROBLEMS
 Foam
 Tool Life
 Microbial Growth

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PROBLEM SOLVING
Corrosion

 Low Concentration
 Low ph
 High Chlorides
 High Sulphates
 High Dirt Content Corrosion

 Tramp Oil
 WIP
 Environment
 Bacteria
 Storage Bins
PROBLEM SOLVING
Skin/Eye/Throat Irritation
 Machine Guard
 Too much of
Misting
 High
Concentration
 High Dirt
 Tramp Oil Irritation
 Handling MTO,
RP by Workmen
 Allergy
 Additive Abuse
 High Bi-
Carbonates
 PROBLEM SOLVING
Foul Smell

Bacteria infected water

Low concentration
& Low pH

High Sulphates in water

High Dirt

Tramp oil Coolant not used more

than 24 hrs
 PROBLEM SOLVING
Foaming

 High Concentration
 Low Water Hardness
 Pump Pressure
 Tank Size to Coolant
Flow (LPM) Foam

 Free Fall of Coolant

 Filter Paper
 Too Many Bends In
the Return Line
 Pipe Line Puncture
 Trouble Shooting – Corrosion Testing

 Concentration (Alkalinity, Acid Split)

 pH pH

 Hardness

 Chlorides

 Dirt

 Bacteria

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 Trouble Shooting – Dermal Irritation

Questions:

1. What is the concentration?

2. What is the pH?
3. What types of contamination can occur?
4. What type(s) of metal(s) are being cut?
5. How much dirt is in the system?
6. Do the operators affected practice proper hygiene? Do they use
appropriate PPE?
7. Is this a fresh charge?

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 Trouble Shooting – Dermal Irritation Testing

 Concentration (Alkalinity, Acid Split)

 pH pH

 Dirt

 Metals (Cr, Co, Ni, Zn)

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 Trouble Shooting – Residues

Questions:

1. What is the concentration?

2. What is the appearance of the residue?
3. What types of contamination can occur?
4. What is the hardness of the system?
5. What is the overall condition of the coolant?
6. How often do the areas with the residues get cleaned?
7. How adequate is the system’s filtration?

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 Trouble Shooting – Residues Testing

 Coolant
– Concentration (Alkalinity, Acid Split)
– pH pH
– Hardness
– Dirt levels

 Residues
– IR
– Metals by x-ray
– Formation of fungi and staining

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 Trouble Shooting – Bacteria comes from …

 Low concentration - Tramp oil

- Other coolants
 Stagnant coolant
- Food and other waste
 Poor cleanout - Floor cleaners
 Contamination - Human waste

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 Trouble Shooting – Eliminating Bacteria

1. Minimize contamination potential

2. Increase concentration if possible
3. Use biocides as sparingly as possible

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 Thank you very much for your attention and your
interest!
Fuchs Lubricants (China) Co. Ltd.
Any Questions
Phone +86 (21) 3912 2000
Questions?
Fax +86 (21) 3912 2100

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