PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar • Gill • Smid

Cutting Fluids—Types
and Applications
Unit 34

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Permission required for reproduction or display.
 34-2

Objectives

• State the importance and function of cutting

fluids
• Identify three types of cutting fluids and
state the purpose of each
• Apply cutting fluids efficiently for a variety
of machining operations
 34-3

Cutting Fluids
• Essential in metal-cutting operations to
reduce heat and friction
• Centuries ago, water used on grindstones
• 100 years ago, tallow used (did not cool)
• Lard oils came later but turned rancid
• Early 20th century saw soap added to water
• Soluble oils came in 1936
• Chemical cutting fluids introduced in 1944
 34-4

Economic Advantages to Using

Cutting Fluids
• Reduction of tool costs
– Reduce tool wear, tools last longer
• Increased speed of production
– Reduce heat and friction so higher cutting speeds
• Reduction of labor costs
– Tools last longer and require less regrinding, less
downtime, reducing cost per part
• Reduction of power costs
– Friction reduced so less power required by
machining
 34-5

Heat Generated During

Machining
• Heat find its way into one of three places
– Workpiece, tool,
Act aschips
disposable
heat sink

Too much, cutting edge

will break down rapidly, Too much, work
reducing tool life will expand
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Permission required for reproduction or display.
 34-6

Heat Dissipation

• Ideally most heat taken off in chips

• Indicated by change in chip color as heat
causes chips to oxidize
• Cutting fluids assist taking away heat
– Can dissipate at least 50% of heat created
during machining
 34-7

Characteristics of a Good
Cutting Fluid
1. Good cooling capacity 6. Rust resistance
2. Good lubricating 7. Nontoxic
qualities
8. Transparent
3. Resistance to
rancidity 9. Nonflammable
4. Relatively low
viscosity
5. Stability (long life)
 34-8

Types of Cutting Fluids

• Most commonly used cutting fluids
– Either aqueous based solutions or cutting oils
• Fall into three categories
– Cutting oils
– Emulsifiable oils
– Chemical (synthetic) cutting fluids
 34-9

Cutting Oils
• Two classifications
– Active
– Inactive
• Terms relate to oil's chemical activity or
ability to react with metal surface
– Elevated temperatures
– Improve cutting action
– Protect surface
 34-10

Active Cutting Oils

• Those that will darken copper strip immersed
for 3 hours at temperature of 212ºF
• Dark or transparent
• Better for heavy-duty jobs
• Three categories
– Sulfurized mineral oils
– Sulfochlorinated mineral oils
– Sulfochlorinated fatty oil blends
 34-11

Oil Categories
• Sulfurized mineral oils
– Contain .5% to .8% sulfur
– Light-colored and transparent
– Stains copper and alloys
• Sulfochlorinated mineral oils
– 3% sulfur and 1% chlorine
– Prevent excessive built-up edges from forming
• Sulfochlorinated fatty oil blends
– Contain more sulfur than other types
 34-12

Inactive Cutting Oils

• Oils will not darken copper strip immersed
in them for 3 hours at 212ºF
• Contained sulfur is natural
– Termed inactive because sulfur so firmly
attached to oil – very little released
• Four general categories
– Straight mineral oils, fatty oils, fatty and
mineral oil blends, sulfurized fatty-mineral oil
blend
 34-13

Emulsifiable (Soluble) Oils

• Mineral oils containing soaplike material
that makes them soluble in water and causes
them to adhere to workpiece
• Emulsifiers break oil into minute particles
and keep them separated in water
– Supplied in concentrated form (1-5 /100 water)
• Good cooling and lubricating qualities
• Used at high cutting speeds, low cutting
pressures
 34-14

Three Types of Emulsifiable Oils

1. Emulsifiable mineral oils
• Mineral oils to which various compounds to
make oil soluble in water
2. Superfatted emulsifiable oils
• Minerals oils with fatty oil added
3. Extreme-pressure emulsifiable oils
• Contain sulfur, chlorine and phosphorus
• Mixed 1part oil with 20 parts water
 34-15

Chemical Cutting Fluids

• Also called synthetic fluids
• Introduced about 1945
• Stable, preformed emulsions
– Contain very little oil and mix easily with water
• Extreme-pressure (EP) lubricants added
– React with freshly machined metal under heat
and pressure of a cut to form solid lubricant
• Reduce heat of friction and heat caused by
plastic deformation of metal
 34-16

Chemical Agents Found in

Synthetic Fluids
1. Amines and nitrites for rust prevention
2. Nitrates for nitrite stabilization
3. Phosphates and borates for water softening
4. Soaps and wetting agents for lubrication
5. Phosphorus, chlorine, and sulfur
compounds for chemical lubrication
6. Glycols to act as blending agents
7. Germicides to control bacteria growth
 34-17

Advantages of Synthetic Fluids

1. Good rust control
2. Resistance to rancidity for long periods of
time
3. Reduction of amount of heat generated
during cutting
4. Excellent cooling qualities
 34-18

5. Longer durability than cutting or soluble

oils
6. Nonflammable, nonsmoking
7. Nontoxic
8. Easy separation from work and chips
9. Quick setting of grit and fine chips so they
are not recirculated in cooling system
10. No clogging of machine cooling system
due to detergent action of fluid
 34-19

Three Types of Chemical

Cutting Fluids
1. True solution fluids
• Contain mostly rust inhibitors
• Prevent rust and provide rapid heat removal
2. Wetting-agent types
• Contain agents to improve wetting action of
water, provide more uniform heat removal
3. Wetting-agent types with EP lubricants
• Added chlorine, sulfur or phosphorus
 34-20

Caution

Chemical cutting fluids widely accepted

and generally used on ferrous metals. They
are not recommended for use on alloys of
magnesium, zinc, cadmium, or lead. They
can mar machine's appearance and dissolve
paint on the surface.
 34-21

Functions of a Cutting Fluid

• Prime functions
– Provide cooling
– Provide lubrication
• Other functions
– Prolong cutting-tool life
– Provide rust control
– Resist rancidity
 34-22

Functions of a Cutting Fluid:

Cooling
• Heat has definite bearing on cutting-tool wear
– Small reduction will greatly extend tool life
• Two sources of heat during cutting action
– Plastic deformation of metal
• Occurs immediately ahead of cutting tool
• Accounts for 2/3 to 3/4 of heat
– Friction from chip sliding along cutting-tool face
• Water most effective for reducing heat (rust)
 34-23

Functions of a Cutting Fluid:

Lubrication
• Reduces friction between chip and tool face
– Shear plane becomes shorter
– Area where plastic deformation occurs
correspondingly smaller
• Extreme-pressure lubricants reduce amount
of heat-producing friction
• EP chemicals of synthetic fluids combine
chemically with sheared metal of chip to
form solid compounds (allow chip to slide)
 34-24

Cutting fluid reduces friction and

produces a shorter shear plane.

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 34-25

Cutting-Tool Life
• Heat and friction prime causes of cutting-
tool breakdown
• Reduce temperature by as little as 50ºF, life
of cutting tool increases fivefold
• Built-up edge
– Pieces of metal weld themselves to tool face
– Becomes large and flat along tool face,
effective rake angle of cutting tool decreased
 34-26

Built-up Edge
Built-up edge keeps
breaking off and
re-forming

Result is poor
surface finish,
excessive flank
wear, and cratering
of tool face

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 34-27

Cutting Fluid's Effect on

Cutting Tool Action
1. Lowers heat created by plastic deformation
of metal
2. Friction at chip-tool interface decreased
3. Less power is required for machining
because of reduced friction
4. Prevents built-up edge from forming
5. Surface finish of work greatly improved
 34-28

Rust Control
• Water best and most economical coolant
– Causes parts to rust
• Rust is oxidized iron
• Chemical cutting fluids contain rust
inhibitors
– Polar film
– Passivating film
 34-29

Rust Inhibitor Films

Negatively charged, long, Inhibitors combine chemically

thin molecules attracted to with metal and form nonporous
and firmly bond themselves protective coating that prevents
to metal rust

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 34-30

Rancidity Control
• Rancidity caused by bacteria and other
microscopic organisms, growing and
eventually causing bad odors to form
• Most cutting fluids contain bactericides that
control growth of bacteria and make fluids
more resistant to rancidity
 34-31

Application of Cutting Fluids

• Cutting-tool life and machining operations
influenced by way cutting fluid applied
• Copious stream under low pressure so work
and tool well covered
– Inside diameter of supply nozzle ¾ width of
cutting tool
– Applied to where chip being formed
 34-32

Refrigerated Air System

• Another way to cool chip-tool interface
• Effective, inexpensive and readily available
• Used where dry machining is necessary
• Uses compressed air that enters vortex
generation chamber
– Cooled 100ºF below incoming air
• Air directed to interface and blow chips away
 34-33

Lathe-Type Operations
• Cutting fluid should be applied to that
portion of cutting tool producing chip

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 34-34

Drilling and Reaming

•Use “oil-feed” drills and hollow-shank reamers

•This type transmit cutting fluid directly to cutting edges
and at same time flush chips out of hole
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 34-35

Milling
• Face milling
– Ring-type distributor recommended to flood
cutter completely
– Keeps each tooth of cutter immersed in cutting
fluid at all times
• Slab milling
– Fluid directing to both
sides of cutter by fan-shaped
nozzles ¾ width of cutter
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 34-36

Grinding
• Cutting fluid cools work and keeps grinding
wheel clean
– Applied in large quantities; very little pressure
• Three types of grinding
– Surface
– Cylindrical
– Internal
 34-37

Three Methods of
Surface Grinding
• Flood method (one most commonly used)
– Steady flow of cutting fluid applied through
nozzle.
• Through-the-wheel method
– Coolant fed to special wheel flange and forced to
periphery of wheel and to area of contact by
centrifugal force
• Spray-mist system (most effective)
– Compressed air passing through a T connection
syphons small amount of coolant from reservoir
and discharges it at chip-tool interface
 34-38

Cylindrical and Internal

Grinding
• Cylindrical grinding
– Important entire contact area between wheel and
work flooded with steady stream of clean, cool
cutting fluid
• Internal grinding
– Cutting fluid must flush chips and abrasive
wheel particles out of hole being ground
– As much fluid as possible should be applied