Machine shops struggling to lower costs amid surging inflation may be able to get a break by upgrading to high-performance cutting fluids that prolong tool life and reduce high recycling expenses.
The newest, most advanced fluids can also help metalworkers take fuller advantage of state-of-the-art machine tools as well as deal with the challenges of specialty metal alloys that are not only far more durable than their predecessors but more difficult to cut and shape.
“Metals are getting tougher and machine tools are getting faster, so whether it’s tooling, programming software or cutting fluids, it behooves shops to stay current with the latest technology,” says John Treese, director of global training for Master Fluid Solutions.
Both Master Fluid Solutions and Castrol displayed some of their most recent innovations last fall at IMTS 2022, the largest manufacturing trade show in the Americas.
For Castrol, that category includes its XBB line, a biocide- and boron-free water-soluble oil that’s been engineered to stringent industry standards.
Watch Video: IMTS 2022—Breakthroughs from Master Fluid Solutions
While boron has long been praised as a “magical” additive, thanks to its ability to inhibit corrosion, reduce foam and keep cutting fluids stable, it has some significant drawbacks, says Jennifer Johns, an applications engineer for Castrol.
“Its use creates some health concerns for the operator, as do biocides,” she says. “In addition, most machinists are familiar with that yellow, sticky film that forms on machine surfaces and is almost impossible to remove. That’s boron.”
Removing that film doesn’t quite require a jackhammer, but it’s close, she says—one customer even experienced machine damage when a boron-encrusted spindle jammed during a tool change.
“I’ve since found one of our alkaline cleaners—S 5001—does a nice job on boron, but it doesn’t change the need to eliminate it from metalworking fluids,” she says.
Fluid Price vs. Performance
While water-soluble cutting fluids have been around for decades, work well, are relatively inexpensive and last for months if well-maintained, there are reasons besides eliminating potentially harmful ingredients to continue refining them.
Productivity is a major one, and recent additions to the TRIM lineup of cutting and grinding fluids at Master Fluid Solutions—among them TRIM E715, TRIM MicroSol 642RX and TRIM E860, are all designed to achieve maximum metal removal across a range of alloys and operations. They also feature high lubricity and low foaming.
Price, however, often outweighs such capabilities in purchasing decisions.
“A typical shop might use hundreds of different cutting tools but only one cutting fluid, so it’s pretty easy to zero in on that line item when you’re looking for cost reductions,” says Treese, the director of global training for Master Fluid Solutions.
That kind of thinking may hurt more than it helps.
Cutting tools represent 3 to 5 percent of total machining costs and cutting fluids make up only about 10 percent of that amount, or less than half a percent overall, Treese says, citing studies by major tooling providers.
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I would appreciate a call from Mr. Hanson to discuss recently published advances in tool wear reduction, surface finish improvement and occupational safety advantages associated with electrostatic spraying of cutting fluids. I can be reached at 609-915-5956.
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Dr. Arnold Kelly
48Thank you for interesting article based on interviews with professional persons. I agree with this article that regular maintenance of coolant is getting more and more important.
FYI, our company has developed coolant-cleaner to remove dirty materials from coolant to extend coolant life time double, or more than double. If you are interested, please contact us, we can arrange demo for you.
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