Clean Metalworking Fluids is essential, and this Engineering Hacks blog is the first in our ‘Setting up to ensure machine health’ series for MSC Priority Club members. Setting up to ensure machine health is the first step to getting more out of your machines for less.

Whether you call it Coolant, Metalworking Fluid, ‘Suds’, there are obvious benefits associated with keeping this liquid clean, and then there are the less obvious benefits that you may not have even thought of yet.

So for the first in our series of helping you keep your machines fighting fit, we’re highlighting how keeping your metalworking fluid clean, delivers these benefits 

 

Top 10 benefits of keeping machine coolant clean:

Extended tool life:

Clean, well maintained cutting fluid helps to create more lubrication between the tool and the workpiece. This reduces friction and wear on the cutting tools, prolonging their lifespan and reducing the frequency of tool replacements. Longer tool life and a reduction in replacements directly results in lower costs.

Improved workpiece quality: 

Increased lubrication prevents excess heat buildup, helping to avoid colour distortion of the workpiece material itself and avoiding any reduction in the quality of the workpiece. Contaminated cutting fluid can also lead to poor surface finishes and dimensional inaccuracies. Clean fluid that enables consistent cooling and lubrication therefore leads to higher-quality machined parts.

Enhanced machine performance: 

Clean cutting fluid prevents the build-up of debris and contaminants in the machine, which can cause pump blockages and damage to internal components. Doing so helps to maintain optimal machine performance and reduce downtime.

 Increased energy efficiency:

Clean cutting fluid increases the efficiency of cooling and lubrication - reducing the load on your machine spindle - meaning that your machine does not have to work so hard. This reduces the amount of energy required for machining operations, leading to lower energy consumption and operational costs.

Health and safety: 

Coolant that is not well maintained gets contaminated. Contaminated cutting fluid can harbour harmful bacteria and fungi, posing health risks to workers through skin contact - leading to the development of skin conditions such as dermatitis. Unmanaged coolant also increases ‘misting’, which is not always cleared by extraction units within the machine cabinet. Inhalation of mist by workers can cause occupational asthma. Clean fluid therefore maintains a safer working environment and reduces the risk of occupational illnesses.

Cost efficiency: 

Regular maintenance of cutting fluid reduces the need for frequent fluid replacement and disposal, leading to cost savings in purchasing new fluid and managing waste. Correctly maintained fluids will also reduce the requirement - and cost of - additives such as anti-foaming, bactericide and fungicide, as well as prolonging the life of your coolant. Clean fluid also lowers the likelihood of machine repairs and production delays, enhancing overall cost efficiency.

Consistent lubrication: 

Clean cutting fluid maintains its chemical properties, ensuring consistent lubrication, which reduces heat generation and prevents damage to both the tool and the workpiece. This is of increased importance when working with non-ferrous metals that have a lower melting point (leading to them getting hotter, quicker). Correct Coolant concentration will ensure effective cooling, whilst also ensuring that the swarf and chips coming off the workpiece remains cool enough to avoid sticking to your tool - creating further issues.

Environmental compliance: 

Proper maintenance of cutting fluids helps your company adhere to environmental regulations and standards by minimising hazardous waste and the potential for spills or leaks. This is closely linked to corrosion prevention, another benefit that we will now cover…

Corrosion prevention: 

Tramp oil’ (fungus or bacteria) forming within your Coolant can cause the Coolant to become acidic. This in turn will start to rust your sump, leading to costs of cleaning and repair. Should this contaminate nearby waterways, it would result in significant Health, Safety and Environmental consequences. Clean cutting fluid also protects both the machine and the workpieces from corrosion, which can occur if the fluid becomes contaminated with water, dirt, or metal particles.

Reduced odour and staining:

Enjoy working in an environment that smells like rotten eggs? No, us neither. Contaminated cutting fluid can produce this kind of unpleasant odour. Throwing in ‘coolant mints’ may help to disguise the odour, but it is not a sustainable solution to overcome other challenges associated with unclean Coolant, such as staining on workpieces and equipment. Keeping the fluid clean therefore helps to maintain a more pleasant working environment as well as better product aesthetics.

 

What are the best ways to keep metal working fluid clean?

To keep metalworking fluid clean, regularly monitor its condition by checking for contaminants and pH levels. Implement effective filtration systems to remove particles and debris, and skim the surface to eliminate oils and chips. Use biocides to prevent microbial growth and ensure proper storage in sealed containers. Establish a replacement schedule based on usage and contamination levels, and train staff on proper handling techniques. Additionally, maintain machines and sumps to prevent sludge buildup and ensure cooling systems function correctly. These practices help prolong fluid life and enhance machining performance.

Coolant Additives 

Chemical additives for metalworking fluids (MWFs) play a vital role in enhancing their performance during machining and manufacturing processes. These additives serve several key purposes: they improve lubrication to reduce friction between tools and workpieces, aid in cooling to dissipate heat, and inhibit corrosion to protect metal surfaces. Additionally, they assist in emulsification, ensuring stable mixtures in water-based fluids, and provide biostability to prevent microbial growth, thus extending the fluid's usable life.

Common types of chemical additives include lubricants like fatty esters and sulfur compounds, which enhance lubrication and extreme pressure performance; corrosion inhibitors such as nitrites and phosphates that protect metals; emulsifiers like non-ionic and anionic surfactants that stabilize oil-in-water emulsions; biocides that control microbial growth; anti-foam agents that reduce foam formation; and pH stabilizers that maintain optimal fluid conditions.

The benefits of these additives are significant, leading to improved tool life, better surface quality on machined parts, cost efficiency through reduced fluid consumption, and enhanced operational safety by minimizing overheating and corrosion risks. Overall, chemical additives are essential for optimizing metalworking fluids, ensuring efficient and effective machining processes.

Fluid Conditioners: 

A fluid conditioner for metalworking fluids (MWFs) is a chemical additive designed to enhance the performance and longevity of the fluid. These conditioners improve various properties of MWFs, ensuring they remain effective during machining processes.

Skimmers: 

Skimmers are devices used in metalworking fluid (MWF) management systems to remove contaminants from the surface of the fluid, helping to keep the MWF clean and effective. They operate by floating on the surface of the MWF and collecting floating contaminants, such as oils, chips, and debris.

Overall, skimmers play a crucial role in maintaining the cleanliness and effectiveness of metalworking fluids.Using a combination of these products and regular maintenance practices will help keep metalworking fluids clean and effective, ensuring you gain the benefits identified.

 

How can MSC Help you?
Explore a wide range of metalworking fluids at MSC Industrial  where our Priority club members receive 10% off over 60,000 metalworking SKU’s on www.mscdirect.co.uk

Our selection includes high-performance industrial lubricants, cutting fluids, and machining fluids designed to optimize metalworking processes. Enhance the efficiency and effectiveness of your metalworking operations with our quality products tailored to meet your specific needs.

Want to learn more about our Priority club? Take a look here