8 Safe Ways to Ensure Seamless Metal Cutting with Metal Working Fluids and Lubricants

Metal cutting is a process used by most industries to form and shape metal parts for different applications. As you know, metals are highly durable, so cutting and working them is not easy. It produces a lot of heat and friction, which is detrimental to tools and metal surfaces. Metal working fluids are used to ensure the dissipation of heat. These fluids act as coolants and lubricants to ensure seamless metal cutting. Thus, metal working fluids and lubricants are essential in metal cutting. These fluids reduce heat, minimize friction, and extend the life of tools.

Even with the use of all the metal working fluids, there are still many safety precautions that all workers must take. In this blog, we will learn about some of the ways to ensure seamless metal cutting with the help of cutting fluids.

1. Types of Metal Working Fluids

Metal cutting fluids are of different types. There are oil-based and water-based fluids. The type of fluid used also differs according to the metal type and the cutting process. Metalworking base oil is also a necessary ingredient in such fluids. It also improves the quality of the cutting process. Using the right fluid makes metal cutting effective and safe.

Choosing the Right Metal Working Fluids and Lubricants

All cutting fluids are not equal. Some are designed for specific metals and cutting tools. Choosing the proper metalworking fluids and lubricants assists in cutting smoothly. The wrong fluid can ruin tools, reduce performance, and be more expensive. When you use the right fluid for the right job, it ensures compatibility and better overall performance.

Water-based fluids are best suited for cooling. Water-based fluids prevent overheating metal and tools. Oil-based fluids provide better lubrication and reduce tool wear. Some of the fluids contain additives to keep rust and bacteria from developing. Fluid is based on numerous parameters. Tool, cutting speed, and metal all play a part in choosing the fluid. Aluminum has different fluids to use compared to steel because aluminum is a soft metal. Increased cutting speeds produce more heat; hence, cooling is even more necessary.

2. Keeping Fluid Levels at the Right Point

The right amount of fluid is as vital as the correct type. Too low, and cutting creates too much heat and destroys tools. Too much fluid will generate waste and extra costs. Running at the optimum amount of fluid produces maximum safe, effective cutting.

Fluid levels must be checked regularly. There must always be enough fluid in the cutting area to lubricate and cool the metal and the tools. Certain machines have automatic fluid supply systems, which provide the right amount. In machines without this facility, fluid levels must be checked manually. Fluid levels reduce because of evaporation over a period of time, so they must be checked and refilled accordingly.

3. Keeping Fluids Clean for Best Performance

Cutting fluids become dirty and contaminated as time passes. Swarf, dirt, and bacteria can find their way into the fluid. The dirty fluid does not cut well and can damage tools and metal parts. Keeping the fluids clean provides the best cutting performance and a longer life.

One way to maintain fluid cleanliness is through filtration systems, which remove metal particles and dirt from the fluid. The second way is by maintaining the fluid, which involves skimming off impurities and replacing them with new fluid when necessary. Metalworking fluids and lubricants are also appropriately stored to keep them clean. They are in sealed packages so they will not get contaminated and extend the fluid life.

4. Using the Right Metal Working Base Oil

Metal working base oil is a significant component of most cutting fluids. It lubricates and cools. The quality of the base oil reflects the performance of the cutting fluid. Correct application of the appropriate base oil increases tool life and cut quality.

Several base oils are used in metal working. They can be mineral or synthetic. Synthetic base oils perform better under high-temperature use and can potentially provide better lubrication and cooling capacity than mineral oils. The base oil is selected depending on the cutting process and metal type used.

5. Monitoring and Controlling Cutting Temperatures

Heat is the primary concern when cutting metal. Heat causes tool wear, metal deformation, and low surface finish at elevated temperatures. Temperature control is required for continuous and safe cutting. Metal working fluids and lubricants help in temperature control.

Proper cutting fluid usage reduces heat generation. Water-based fluids are better for cooling, and oil-based fluids are better for lubrication to reduce friction. Tool material and cutting speed also play roles in the quantity of heat produced. Less heat is produced at low speeds, but higher speeds require better cooling. Cut temperature is controlled to prevent overheating and tool failure.

6. Using Proper Application Methods for Fluids

The performance of cutting fluids depends on their application. The proper application involves more than just pouring the liquid on the cutting surface. It causes the liquid to seep into the right places to cool and lubricate.

Flood cooling is one of these methods, and its general application is to provide a constant flow of liquid to the cutting area. High-speed cutting is suited to this method. Misting application is another method, providing fluid as a fine spray. This is economical for fluids but provides lubrication and cooling. Internal fluid supply systems are available on some machines, which provide fluid directly on the cutting edge. Optimizing the application system improves cutting efficiency.

7. Ensuring Workplace Safety When Handling Fluids

Lubricants and metalworking fluids contain chemicals that need to be handled carefully. Exposure to certain fluids can lead to skin irritation or breathing problems. Safety measures eliminate any possibility of risk in the workplace.

Workers must wear gloves and safety glasses when handling fluids. Ventilation must be employed to avoid inhaling the fumes. Proper fluid storage minimizes spills and contamination risk. Frequent leak checks and prompt spill cleaning enhance workplace safety. Trained employees in the safe handling process also avoid accidents.

8. Regular Maintenance of Cutting Tools and Equipment

The right cutting equipment and tools must also be in good working condition. Blunt or broken tools create more heat and friction since they lower the cutting efficiency, affecting finer quality cuts. Good maintenance, such as sharpening tools and changing the worn-out ones, provides this.

Equipment can even be checked for leakages, blockages, or mechanical malfunctions. Wiping the equipment after use prevents fluids from accumulating and becoming contaminated. Storage of tools and fluids maintains their lifespan. Maintenance of cutting systems ensures efficient operations and averts costly breakdowns or repairs in the future.

Understanding the Role of Additives in Metal Cutting Fluids

Certain metal cutting fluids contain unique additives to improve performance. The additives inhibit rusting, stabilize bacterial growth, and lubricate.

• Anti-rust additives inhibit metal surface corrosion, especially when ferrous metals are involved.

• Biocides inhibit bacteria and fungal growth in water-based fluids to ensure long-term stability.

• Extreme pressure (EP) additives reduce cutting friction and are best applied in high-speed operations.

Understanding these additives makes selecting the most appropriate fluid for an application simple. Selecting fluids with the proper additives enhances tool life, safety, and metal cutting efficiency.

Reducing Environmental Impact with Proper Fluid Disposal

Metalworking fluids and lubricants are disposed of to avoid environmental damage. Poor disposal can pollute soil and water bodies, causing severe environmental problems. Most fluids contain chemicals that need to be handled with care during disposal. Recycling and reuse of liquids, where applicable, minimizes waste and saves money.

Others utilize oil separation operations to extend fluid life. Municipal codes usually provide guidelines for disposing of used fluids safely and in an environmentally friendly manner. Proper personnel training in disposal procedures upholds environmental legislation. Environmental fluid management practices preserve the ecosystem without interfering with productive metal-cutting processes.

Atlantic Grease and Lubricants – Your Reliable Partner

Atlantic Grease and Lubricants provide high-end metal working fluids and lubricants. They carry a range of products mainly meant for effective and smooth metal-cutting. Their fluids are perfect coolants, oils, and protectants of metal surfaces and tools. Being in the business for years, Atlantic Grease and Lubricants promises better performance and reliability. Their products are high quality and used by experts from all over the world. When you need metal cutting fluids or metal working base oil, they have a solution to your needs. Contact them now to get access to the best lubricants in the UAE.