When machine failures and mechanical problems rear their ugly head in your operations, it’s important not to panic. Staying calm and having an established troubleshooting plan in place will make finding a solution much easier.
The process of troubleshooting involves defining the problem you are experiencing, collecting important data, and then analyzing the information. Once you have done that, you can brainstorm and implement possible solutions.
Problems with metalworking fluids can include health and safety issues, operational problems, and maintenance complications. This list of common
This list of common causes of metalworking fluid problems and the solutions you can use to fix them will save you time, money, and energy down the road.
It’s important to note that poor concentration is the number one issue when investigating a fluid problem. This is always the first item to examine and correct.
First, check your metering system to receive an accurate measurement of the concentration of your fluid. You can do this using a refractometer. Once you are aware of what the current concentration is, you will be able to adjust it to the recommended operating range.
KEY INSIGHT: A refractometer measures the refractive index of a substance. It can be used to determine its composition, concentration, and purity.
The improper handling of parts and storage can lead to rust, corrosion, and safety concerns. To troubleshoot this, implement clean plastic dividers to allow parts to dry without touching. For short and long term storage, use a supplementary rust preventive or inhibited corrosion paper. Ideally, parts should be stored inside at room temperature.
When dirt contaminates your operations, investigate the filtration to ensure proper circulation. This will allow for removal of the particulates. Further steps should be taken to drain the oil fluid and physically clean the machine to prevent further problems.
Fluid issues can occur based on the quality of the water used. Water is considered hard when it has a parts per million (ppm) of 200 or greater. This can create tackiness with some coolant chemistries. When you encounter this, use treated water including de-ionized, reverse osmosis, or softened water.
On the other hand, soft water, which has a ppm of 0, will promote foam. In this case, select a product with excellent defoaming characteristics.
When your fluid is mixed improperly, there could be concerns about the quality of the mixture. The oil and water components could separate, causing an inefficient and instable coolant.
Treat improper mixing by always adding coolant concentrate to water. The coolant should be premixed prior to introduction. The concentrate should not be added directly to the sump.
Through changing weather and temperatures, ensure that the recommended concentration of the fluid is maintained. Parts should be treated with supplementary rust preventive if short or long term storage is required. Store parts in locations that are not exposed directly to open doors or severe temperature fluctuations.
When a fluid level is too high or low, validate that the sump is at capacity to optimize fluid retention time. This will allow air to escape from the coolant. If the pump intake is below the coolant level, low air can be pulled into the coolant, causing foam. Follow a consistent monitoring schedule to check the pH and concentration.
Delivery systems for fluids include flooding, misting, precision spray, and more. When the delivery system is poor, drops and sharp turns in troughs will exacerbate foaming conditions.
To solve this, improve the delivery system’s accuracy by using automated systems and employing tools like mechanical skimmers and demineralized water. Keeping the water at the correct concentration is also a way to support your fluid delivery systems.
Where there is a large concentration of mist, there are several steps you can take to remedy it. These can include confirming machine speeds, implementing routine cleaning of machine surfaces, and reducing tramp oil contamination. Additionally, personal protective equipment like gloves or safety googles can provide safety for operators.
When humidity impacts your fluid operations, you must control the environment. Reducing the temperature will reduce the amount of humidity in the production area. You should also clean residues from machines as soon as possible. Higher humidity causes quicker evaporation of water, which creates more product residues.
The recommended pH value for fluid is often determined to be between 8.0 and 9.5. A lower pH may indicate the presence of microbiological growth. If appropriate, increase concentration or implement a tank-side biocide.
Tramp oils are unwanted in fluids operations as these contaminants can weaken fluid quality and reduce performance efficiency. To solve this, first locate and address the oil leakage. Then utilize skinners or coalescers to remove free-floating tramp oil.
Being prepared and having a troubleshooting plan in place is the best defense against problems that may arise with your fluids.
Gaining a better understanding of these 12 metalworking fluid issues and their respective solutions will allow for a smoother troubleshooting process.
Learn more about how to troubleshoot your metalworking fluids by contacting DuBois’ technical experts.
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