Optimise your machining process with the right combination of metalworking fluids

Every detail matters in the machining world, and metalworking fluids are the key to producing consistently high-quality end products. 

Using the ideal cutting fluid for your application can drastically impact your shop's efficiency, productivity, and end product. Combined with the proper cleaners and rust preventives, your end products will be top quality and preserved for as long as needed. 

Choosing the correct cutting fluid depends on several factors and can seem complex. But the best fluids, in the right combination, can extend tool life, keep productivity high, and ensure consistent work products. While the categories and subcategories of metalworking fluids can seem overwhelming, they’re all designed for specific purposes, environments, and metals. 

In this post, you’ll learn about the different fluids, their jobs, and how they contribute to a well-performing shop.

Machining is an intense, high-friction, and high-heat process that produces a lot of debris. It can easily damage machinery, leading to expensive repairs and inconsistent and subpar end products. Enter industrial high-performance metalworking fluids.

Industrial metalworking fluids provide a buffer against the extremes of machining, and there are three types: 

• cutting fluids: lubricate and cool
• cleaners: remove chips and other debris
• rust preventatives

Four types of metalworking oils accomplish these “jobs:”

• Neat Oils: lubricate but don’t cool
• Water-soluble oils: lubricate, cool, and protect against rust but may foam
• Synthetic Fluids: lubricate and help resist bacteria and fungus
• Semi-synthetic fluids: lubricate, cool, and aren’t likely to foam

High heat and friction are natural occurrences in machining and are the enemies of tools. Cutting and grinding fluids mitigate these, providing hard and soft dollar savings: longer tool lifespan and less maintenance. The proper cutting oil optimizes your shop’s performance. 

There are two categories of cutting fluids: neat oils and coolants. Neat oils consist of mineral oils and additives and require no dilution, while metalworking coolants are water-dilutable emulsion-forming fluids. 

Metal-cutting coolants are broken down further into the types of products that make them up.

• best for applications where cooling is more important than lubrication
• ideal for light and medium-duty operations

• ideal for resisting bacteria and fungus growth
• provide modest lubrication 

• low foaming and maintenance
• work for all cutting applications

Regular fluid quality checks are necessary to ensure your fluid is working as anticipated. Any contaminant, such as debris or bacteria, reduces its effectiveness and lifespan.

After selecting the ideal cutting fluid, you’ll need to tailor how it’s applied based on several factors, including the type of metalworking you’re using. Keep in mind, the four types of applications are flooding, mist, jet application (high-pressure gas or liquid), and brush on.

In order to achieve optimal application, be sure to:  

• Match the delivery method to the application 
• Consider the tradeoffs for one method vs. another
• Check fluid regularly
• Consider the possible impact on the environment and health and safety

Cutting fluid flow is the amount of cutting fluid applied to and used on a workpiece, and flow rate is the amount applied over time. Maintaining the appropriate rate is critical to producing high-quality products and keeping your tools working longer. You can do so by

• Performing routine checks and maintenance to stay ahead of potential issues
• Ensuring regular filtering to remove contaminants
• Adjusting flow rates to the process (one rate doesn’t fit all)
• Watching water quality, particularly hardness
• Monitoring the optimal temperature to prevent deterioration 
   

Ultimately, the best practices for using cutting fluids in machining processes come down to:

• Choosing the right fluid for the type of work and metal
• Using the right application
• Following the manufacturer’s specifications for concentrations
• Keeping fluids clean and replacing them when necessary
• Considering the environmental impact

Creating and maintaining a monitoring and maintenance schedule is the easiest way to optimize your fluids. You’ll be able to produce quality end products consistently and efficiently and maximize your machine life leading to more revenue and lower costs. 

Depending on your use cases, our team can provide valuable guidance as you develop your cutting fluid maintenance schedule. 

Cleaning is essential for removing dirt and debris and preparing surfaces for rust prevention. Depending on their pH level, cleaners can be as caustic as drain cleaner and battery acid or as gentle as baking soda. 

The type of cleaner that works best varies based on your product and application. Here are a few pros and cons to get your thinking started.

Pros:

• Remove contaminants like salts, oxides, and chips
• Are generally easier and cheaper to dispose of than solvents
• Emit less VOC (volatile organic compounds), which is better for indoor air quality

Cons:

• May contribute to rust and corrosion 
• Less effective at cleaning oils, greases and waxes

Pros:

• Extremely powerful; remove oils, greases and waxes
• Dry quickly
• Work on a multitude of surfaces

Cons:

• Disposal can be complex and costly due to hazardous waste 
• Emit VOCs, which can be hazardous if not mitigated. 
• Flammable

Regular cleaning is essential to save tool wear and tear and consistently produce quality end products. Incorporating cleaning into your shop’s fluid monitoring and maintenance schedule easily integrates it into your shop’s workflow. 

Rust isn’t just a nuisance or eyesore in the shop. It can have severe financial and safety ramifications. The ideal rust preventatives, applied correctly, will save money on unnecessary repairs and tool replacement, ensure quality products, and keep staff safe. 

Industrial rust inhibitors form a barrier that prevents water and oxygen from penetrating the metal surface. The type of rust preventative you need and how it’s applied hinges on several factors, including the type of metal and other materials used. 

Three types of fluids help prevent rust and corrosion: 

Water-based rust Inhibitors (water-soluble rust inhibitors) remove moisture from metal surfaces, leaving a thin, protective film behind.

• Use: provides temporary protection and can be easily removed before subsequent work
• Application: spraying or dipping 

Oil-Based Rust Inhibitors form a thin film between metal, moisture, and oxygen. 

• Use: protects machined components, tools, and equipment while in storage or during transportation
• Application: spraying, dipping, or brushing

Volatile Corrosion Inhibitors (VCIs)—similar to the “do not eat” packets found in consumer products—use vapor to form a protective shield. 

• Use: hard-to-reach areas; often used for packing and storing anything metal during shipping and storage
• Application: dry and doesn’t leave residue

Another consideration when choosing a rust preventative is matching how it’s applied to what it protects—here are three common applications and when you’d use them.

• Spraying: large surfaces and those with hard-to-reach areas
• Dipping: smaller parts or components, in particular, to ensure complete coverage
• Brushing: targeted areas or touch-ups

Rust and corrosion prevention maximizes its lifespan, minimizes maintenance, enhances work quality, and keeps your shop running smoothly, no matter how your tools or products are used, shipped, or stored. 

Detail-oriented processes like machining rely on specialized equipment, and machining fluids make it possible by lubricating, cooling, cleaning, and preventing rust and corrosion. The right combination of properly maintained fluids will keep costs down and efficiency, productivity, and quality high.  By integrating these critical tasks into your daily workflow, you can stay ahead of the game—here are some elements to consider:

• What you need to check do daily, weekly, and monthly
• How frequently “periodic” testing should be
• How frequently you should replace your fluids. 

Monitoring and maintaining your fluids through this flow is key to longer tool and fluid life, lower maintenance costs, and improved end products.

Wondering how to optimize your combination of metalworking fluids? Contact a Quaker Houghton expert. They can also share ways to optimize your budget, including combining orders to save on shipping. Call us at 1-888-872-1375 or email us at Insidesales.support@quakerhoughton.com