Metalworking fluids are often the unsung heroes of machining operations. Vital for cooling, lubricating, and overall process efficiency, many times these fluids can be underutilized or mismanaged, leading to unnecessary waste, tool wear, and even safety risks.
In this expert-led webinar, we discussed the properties and characteristics of metalworking fluids, covered essential best practices, and learned how to identify ideal performance and fluid requirements when selecting a fluid to fit your process.
Watch our Expert Insights webinar and read on to see how to maximize your metalworking fluids for your operations.
In metalworking operations, it’s easy to focus on the machinery, tooling, or materials as the main drivers of production success, but the metalworking fluid (MWF) doing the behind-the-scenes work is just as critical.
Whether you’re cutting, grinding, stamping, or forming, the right metalworking fluid can directly improve tool life, part quality, and operational efficiency.
In industrial environments where precision and productivity matter, selecting and maintaining the right MWF is just as important as the equipment itself.
Metalworking fluids serve multiple purposes beyond just cooling or lubricating. Without proper fluids, manufacturers may experience a variety of challenges including:
High-speed machining generates significant heat. These excessive temperatures can significantly ruin the integrity of both tools and work surfaces. MWFs help to remove heat from the cutting zone, allowing speeds to be increased and reducing the friction between the tool and the metal.
Metalworking fluids provide lubrication between the tool and the workpiece, reducing friction and wear. This helps produce smoother surface finishes and improves machining efficiency, especially in high-pressure applications.
There are three types of lubricities:
MWFs often contain rust and corrosion inhibitors that protect machines, tools, and freshly machined metal parts from oxidation and rust. This is essential during extended downtime, in humid environments, or between process stages.
A key function of MWFs is to flush away metal chips, swarf, and debris from the cutting area. Efficient swarf removal prevents premature wear, poor part finish, and protects operators from metal debris.
Effective MWF programs support more than just productivity. They also help:
Treating metalworking fluids as an essential part of your process – rather than a consumable product – can transform your plant’s efficiency, quality, and uptime. From cooling and lubrication to corrosion prevention and cleanliness, the right fluid program is a strategic advantage in today’s competitive manufacturing landscape.
Even the best metalworking fluid can underperform if the surrounding variables aren’t properly managed. From water quality to the control plan surrounding your fluid, several factors influence MWF performance, longevity, and overall effectiveness.
Understanding these variables helps you troubleshoot issues, fine-tune your fluid management program, and get the most from every gallon.
Water is the foundation of any water-dilutable metalworking fluid, with poor water quality being one of the most common causes of fluid failure. It’s important to tailor your fluid to your water source when possible.
TIP: Always test your water source. In areas with poor water quality, consider reverse osmosis (RO) systems to demineralize, improving consistency and fluid life.
Not all metalworking fluids are created equal. The base chemistry – whether it’s a soluble oil, semi-synthetic, or synthetic – influences everything from lubricity to microbial resistance.
Choosing the right coolant means aligning your fluid to your materials, operations, and environmental conditions.
Coolant systems need consistent filtration to perform their best. Filters remove metal chips, swarf, and debris that can damage tools and operators as well as degrade the fluid. Poor filtration leads to reduce fluid performance, abrasion, and increased maintenance.
A well-maintained filtration system extends both fluid and tool life, making it a critical investment.
Tramp oils – machine lubricants and hydraulic fluids that leak into the metalworking fluid – are a leading cause of coolant degradation.
These oils create a barrier on the surface of the fluid that blocks oxygen from reaching the coolant, promoting anaerobic bacterial growth. Over time, who interact with it as well as foul odors, decreased cooling efficiency, and shortened fluid life.
TIP: Oil skimmers, separators, or coalescers can help to manage tramp oil and maintain fluid health.
Some operations produce high levels of particulate contamination from castings, grinding dust, or other external sources. These contaminants:
Regular cleaning, fluid monitoring, and contamination control are essential to keeping systems healthy.
The type of tools you use, as well as the speeds and feeds you run, place different demands on your metalworking fluid:
Always consider the specific requirements of your tooling and operation when selecting a fluid.
Once a metalworking fluid is in place, it’s critical to implement a consistent fluid control plan. Regular monitoring and maintenance help maintain peak performance and reduce unplanned downtime.
Key elements of a good MWF control plan include:
A consistent monitoring routine ensures your metalworking fluid works as intended, day after day and shift after shift.
Choosing the right metalworking fluid isn’t one-size-fits-all. It requires understanding both the performance requirements of your application and the fluid requirements dictated by your shop environment and operational standards.
Failing to consider both can lead to poor results, tool wear, and fluid breakdown.
TIP: Work closely with your fluid supplier to match products to your specific machining parameters.
TIP: The best-performing coolant still isn’t the right one if it’s incompatible with your waste treatment system.
Interested in learning more about choosing the right metalworking fluid for your operation?
Metalworking fluids directly influence the success, efficiency, and quality of key machining operations. Understanding how fluids function in specific applications helps optimize tool life, surface finish, and operational cost.
Here’s a breakdown of common machining processes that MWFs support:
Drilling operations generate sustained contact and heat, especially at higher speeds or in tougher materials. The fluid’s role here includes lubrication, cooling, and chip removal.
Ideal fluids include soluble oils as they are good for general purpose drilling and tough materials.
Tapping requires precision and control, as the process forms holes and internal threads for screws and bolts that must meet strict dimensional requirements. Tapping fluids often have extreme pressure (EP) protective additives to ensure lubricity and smooth operation.
Ideal fluids include straight oils, soluble oils, synthetics, and specialty tapping fluids
In milling, the cutting tool engages and disengages the workpiece repeatedly, creating varying loads and intermittent temperature spikes. Thermal control, edge protection, and residue-free machining are key variables to keep in consideration for your metalworking fluid.
Ideal fluids include synthetic fluids, semi-synthetic fluids, soluble oils, and straight oils.
Precision grinding demands tight control over temperature, cleanliness, and part integrity. Fluids in this setting must cool aggressively to prevent burn marks and metallurgical damage as well as minimize foam and remove swarf and debris.
Ideal fluids include synthetic fluids and straight oils.
Understanding the type of metallurgy that your operation is machining is critical in determining the fluid selection.
Ferrous Metals contain iron as their main component and typically require products that provide greater rust protection. While their industrial versatility allows these metals to excel in several industries, its high iron content leaves it vulnerable to rust.
Alloys typically require products with higher lubrication levels. Lubricity, cooling, surface finishing, and corrosion resistance are elements that are important to talk through before any process is started.
Yellow Metals require high lubrication level products and other products that can minimize residues. Its qualities allows it to solubilize and create soaps that stick to machines.
Choosing a metalworking fluid isn’t just about cooling or lubrication – it’s about finding a fluid that supports your process, your materials, and your goals. Every shop faces challenges like tramp oil, tool wear, and variable water quality, but with the right fluid strategy these issues can become manageable.
At DuBois Chemicals, our metalworking fluids are developed with real-world manufacturing in mind and tailored to support specific applications, materials, and shop conditions.
Whether you’re drilling, tapping, milling, or grinding, the right fluid can make a measurable impact. Explore our lineup of solutions designed to help you optimize performance, reduce maintenance, and get the most from your operation.
Interested in checking out more of our metalworking fluids? Check out our signature collection
What industries use metalworking fluids? Due to the versatility of MWF and the importance of features like lubricating and cooling, MWF can be used in key manufacturing fields including automotive, aerospace, construction, defense, and more.
How do you store metalworking fluids?
For most MWFs, they need to be stored in a climate-controlled indoor area to keep them from reaching freezing temperatures or too much sunlight. Ensure that they are into an environment that is within 41°F to 100°F
keep them in a climate-controlled indoor area within a temperature range of 41°F to 100°F to avoid freezing and direct sunlight.
How do you dispose of metalworking fluids?
To properly and safely dispose of MWFs, follow local and federal laws and regulations. You should also contact your DuBois technical expert or supplier for more in-depth information.
Can you recycle metalworking fluids?
Yes, MWFs can be recycled. This happens when you remove the fluid from the machine sump. You then circulate it through the recycling unit to remove contaminants like dirt and oil
Metalworking fluids play a crucial part in machining operations for their ability to cool, lubricate, and improve overall function. By understanding MWFs and their role in the machining process, you can better select the option that works best for you.
If you are looking for more information about how to choose or maximize the performance of your metalworking fluids
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