When it comes to metalworking, there are several categories of problems that can become a grievance to the machinery process. There are many reasons why you might encounter concerns while working with metalworking fluids. From poor performance to a rancid smell, when there is a sign something is wrong, you must take the correct steps to address it to avoid future problems.
These eight issues are the most common problems associated with using metalworking fluids. By understanding these issues and the effects they have, you will be better equipped to troubleshoot them.
Corrosion is a common problem that can arise when working with metalworking fluids. It occurs through an electrochemical process that involves the metal and its reaction to the environment. When parts show signs of corrosion, it can lead to costly cleanup, scrap, downtime, and reduced machine tool life.
It is imperative to carefully diagnose the cause of your corrosion problem before you attempt any solution. Often, corrosion can be caused by several factors that must be analyzed to determine the cause. The concentration, pH, and mineral levels are just some of the causes to investigate.
Most common causes of corrosion: Low concentration, contamination, part handling and storage, dirt, water quality, improper mixing, galvanic reaction, weather.
Foam can quickly become a problem in machining operations. It forms when air is entrained within a fluid. The foam could be chemical or mechanical in origin. To determine which is the source of your machine tool’s foam, put the sump’s fluid in a clear covered container and shake for ten seconds. If it results in a layer of foam that does not expel quickly, the cause is chemical. If the layer is shallow or fades quickly, the cause is mechanical. No matter the cause, eliminating foam will improve performance and efficiency.
Most common causes of foam: High concentration, soft water, inadequate fluid level, high speed applications, temperature, contamination.
Oily and tacky residues can be left behind by metalworking fluids when fluids splash and mist evaporates. This can leave behind dissolved solids, swarf, and dirt. The cause of this can be mechanical or chemical. Determine the origin by checking the concentration of the machine tool’s fluids.
You can also minimize the amount of deposits on your equipment by adding guards or shields. These tools reduce splashing and misting.
Most common causes of residues: High concentration, hard water, improper mixing, heavy misting, humidity, dissolved solids.
Contact with metalworking fluids can cause irritation to the skin that includes redness, dryness, cracking, and small bumps. Skin irritation, including conditions like contact dermatitis, can happen through exposure of chemicals and metals. Employ safe metalworking handling practices to help reduce issues. This could involve controlling system contaminants, keeping fluids free from oil and dirt, and wearing safety gloves and goggles.
Most common causes of skin irritation: High concentration, dirty rags, contaminants, pre-existing allergies, seasons, solvents.
When neglected or overlooked, metalworking fluids can cause inadequate tool life. This problem can be the result of a combination of issues including poor coolant mixing, foam generation, and process changes. One important solution to check first is concentration. Poor concentration control is the number one issue when investigating a metalworking fluid issue.
Most common causes of poor tool life: High or low concentration, fluid nozzle position, water quality, high dirt level.
Having a poor surface finish in your operations can occur due to similar reasons as poor tool life. This is why careful care and consideration is needed to avoid poor concentrations and fluid instability. Checking for changes in coolant, tooling, and materials can help remedy this problem.
KEY INSIGHT: A poor surface finish may have irregularities like high surface roughness, waviness, or chatter marks.
Most common causes of poor surface finish: Tooling set up, improper speeds and feeds, change in metal source, high dirt level.
A foul odor emitting from your machines is a sign of rancidity in your production. This smell can be biological or chemical in nature. If biological, the problem could stem from mold or bacteria growth. If chemical, the odor is often caused by either fluid or contaminants. Ignoring rancidity could lead to problems that will impact the fluid’s performance and workers’ health.
Most common causes of rancidity: Low concentration, contaminates, lack of circulation, weather.
Emulsion instability occurs when a mixture of oil and water breaks down and negatively impacts the fluid’s performance. This can happen due to hard water, contaminants, and the improper maintenance of fluids. Using high-quality water, controlling contaminants, and using a consistence maintenance schedule can prevent and correct this.
Most common causes of emulsion instability: Hard water, low concentration, contaminants.
There are several pitfalls you could run into while using metalworking fluids. However, there is no need to worry. By being aware of the possible concerns and implementing consistent check and cleanings, your operations will be able to run smoothly.
If you are looking to learn more about what to look out for with your metalworking fluids
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