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High-speed cutting imposes high demands on cutting fluids. Choosing high-quality cutting fluids can better ensure smooth processing. Reasonable chemical management can extend the service life of cutting fluids and reduce consumption, thereby reducing the overall cost of cutting fluid use. .
High quality cutting fluid improves cutting efficiency
High-speed cutting means large feeds and higher spindle speeds. Increasing the unit feed means an increase in the processing load. It requires a stronger processing (lubrication) capacity and cooling capacity in the machining fluid to reduce heat generation during the cutting process and deformation of the workpiece and reduce the energy required for the cutting process. This may require high pressure, high flow coolant pumping. Increasing the spindle speed means that the tool or workpiece line speed is increased. In the case of high flow and high pressure pumping, the resulting impact agitation will bring more gas into the cutting fluid, creating a tendency to foam, while the slot design of modern machine tools More and more compact, the defoaming time of the processing fluid is also getting shorter and shorter, which poses new challenges to the antifoaming and defoaming capabilities of the processing fluid.
Good anti-foam performance and water quality adaptability of high-quality cutting fluid effectively ensure the smooth progress of high-speed cutting. Some Auto Parts processing, such as steering gears and crankshafts, require the use of oil-based cutting fluids. High-temperature cutting and high-speed cutting may cause atomization of oily cutting fluids. These oil mists floating in the air will affect the workshop. The physical and mental health of the operating environment and work, and the drift of oil mist also means the loss of oil products. Total's researchers successfully reduced the production of oil mist by more than 60% through the optimization of base oil and oil mist additives, reduced the generation of oil mist from the source, and reduced the negative impact of cutting fluid on HSE. It is at the lowest and reduces the consumption of cutting fluid and reduces the cutting cost.
Chemical management reduces the overall cost of cutting fluid use
For the time being, the core of chemical management is coolant management. Taking an engine factory as an example, the current engine factory mostly uses a centralized liquid supply system. The entire system capacity can reach 300 to 500 cubic centimeters. The initial amount of concentrated liquid used can reach 20 to 30 tons. The service life of the entire system requires 2 years. Above, this puts high demands on the management and maintenance of the entire system. We know that in the course of the use of metalworking fluids, there will be a lot of debris such as guideway oil, spindle oil, hydraulic oil, and iron filings mixed into the cutting fluid, which contains a large number of microorganisms, and these substances are all microbial reproduction. The root cause of the fouling and deterioration of the cutting fluid in the food is the large amount of microorganisms growing in the cutting fluid. The large number of microorganisms in the cutting fluid will bring very serious consequences, such as the generation of odor, deterioration of the environment and the impact on human health; the consumption of cutting fluid additives and oily agents, so that the cutting fluid lubrication performance, affect the quality of the workpiece processing; bacterial metabolism The resulting acidity destroys the stability of the cooling, and the mass reproduction of the fungus also plugs the pump, the sedimentation tank, and the filter. In order to prevent spoilage during the use of the cutting fluid, it is important to enhance the sequential management of the cutting fluid while improving the antibacterial ability of the cutting fluid itself.
The processing of large quantities of iron parts puts high demands on the rust resistance of the cutting fluid. Especially in the warm rainy season, the detection of the rust resistance of the coolant will be a very important part of the coolant management. Reducing the workpiece from rework due to rust is equivalent to increasing productivity.
Only from the above two points can be seen that the use and maintenance of cutting is not a simple matter. Based on experience, the author hereby proposes the following recommendations for the use and management of cutting fluids:
1. Coolant management is best handled by a dedicated chemical management company or coolant supplier, liberating itself from the management of coolant and focusing on its core business. The best designated person who does not have the conditions is responsible for the management of the coolant.
2. The professional company helps to select the most suitable product.
3. In the later stage of management, attention should be paid to removing oil slicks, controlling the concentration (detected daily), paying attention to the detection of PH value and microbiological content (testing weekly and putting bactericidal agents according to the test results), and paying attention to the detection of rust prevention of cutting fluids (tested weekly Increase the frequency of detection when the humidity is high.
Through the above management measures, processing companies can greatly extend the service life of cutting fluids, reduce the consumption of coolant, reduce the discharge of waste fluids, improve the processing accuracy and product qualification rate of workpieces, and achieve the purpose of improving efficiency and reducing costs and increasing efficiency.
High quality cutting fluid improves cutting efficiency
High-speed cutting means large feeds and higher spindle speeds. Increasing the unit feed means an increase in the processing load. It requires a stronger processing (lubrication) capacity and cooling capacity in the machining fluid to reduce heat generation during the cutting process and deformation of the workpiece and reduce the energy required for the cutting process. This may require high pressure, high flow coolant pumping. Increasing the spindle speed means that the tool or workpiece line speed is increased. In the case of high flow and high pressure pumping, the resulting impact agitation will bring more gas into the cutting fluid, creating a tendency to foam, while the slot design of modern machine tools More and more compact, the defoaming time of the processing fluid is also getting shorter and shorter, which poses new challenges to the antifoaming and defoaming capabilities of the processing fluid.
Good anti-foam performance and water quality adaptability of high-quality cutting fluid effectively ensure the smooth progress of high-speed cutting. Some Auto Parts processing, such as steering gears and crankshafts, require the use of oil-based cutting fluids. High-temperature cutting and high-speed cutting may cause atomization of oily cutting fluids. These oil mists floating in the air will affect the workshop. The physical and mental health of the operating environment and work, and the drift of oil mist also means the loss of oil products. Total's researchers successfully reduced the production of oil mist by more than 60% through the optimization of base oil and oil mist additives, reduced the generation of oil mist from the source, and reduced the negative impact of cutting fluid on HSE. It is at the lowest and reduces the consumption of cutting fluid and reduces the cutting cost.
Chemical management reduces the overall cost of cutting fluid use
For the time being, the core of chemical management is coolant management. Taking an engine factory as an example, the current engine factory mostly uses a centralized liquid supply system. The entire system capacity can reach 300 to 500 cubic centimeters. The initial amount of concentrated liquid used can reach 20 to 30 tons. The service life of the entire system requires 2 years. Above, this puts high demands on the management and maintenance of the entire system. We know that in the course of the use of metalworking fluids, there will be a lot of debris such as guideway oil, spindle oil, hydraulic oil, and iron filings mixed into the cutting fluid, which contains a large number of microorganisms, and these substances are all microbial reproduction. The root cause of the fouling and deterioration of the cutting fluid in the food is the large amount of microorganisms growing in the cutting fluid. The large number of microorganisms in the cutting fluid will bring very serious consequences, such as the generation of odor, deterioration of the environment and the impact on human health; the consumption of cutting fluid additives and oily agents, so that the cutting fluid lubrication performance, affect the quality of the workpiece processing; bacterial metabolism The resulting acidity destroys the stability of the cooling, and the mass reproduction of the fungus also plugs the pump, the sedimentation tank, and the filter. In order to prevent spoilage during the use of the cutting fluid, it is important to enhance the sequential management of the cutting fluid while improving the antibacterial ability of the cutting fluid itself.
The processing of large quantities of iron parts puts high demands on the rust resistance of the cutting fluid. Especially in the warm rainy season, the detection of the rust resistance of the coolant will be a very important part of the coolant management. Reducing the workpiece from rework due to rust is equivalent to increasing productivity.
Only from the above two points can be seen that the use and maintenance of cutting is not a simple matter. Based on experience, the author hereby proposes the following recommendations for the use and management of cutting fluids:
1. Coolant management is best handled by a dedicated chemical management company or coolant supplier, liberating itself from the management of coolant and focusing on its core business. The best designated person who does not have the conditions is responsible for the management of the coolant.
2. The professional company helps to select the most suitable product.
3. In the later stage of management, attention should be paid to removing oil slicks, controlling the concentration (detected daily), paying attention to the detection of PH value and microbiological content (testing weekly and putting bactericidal agents according to the test results), and paying attention to the detection of rust prevention of cutting fluids (tested weekly Increase the frequency of detection when the humidity is high.
Through the above management measures, processing companies can greatly extend the service life of cutting fluids, reduce the consumption of coolant, reduce the discharge of waste fluids, improve the processing accuracy and product qualification rate of workpieces, and achieve the purpose of improving efficiency and reducing costs and increasing efficiency.
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