Machine Tool Cutting Fluids - Industrial Engineering and Productivity Aspects

Lesson 61 of Industrial Engineering ONLINE Course.

Lesson 18 of Process Industrial Engineering FREE ONLINE Course (Module)

In study of the current state of productivity science in various elements of machining, industrial engineers have to remember the initial consolidation of the topic done by F.W. Taylor

IE Research by Taylor - Productivity of Machining  - Part 1 - Part 2  - Part 3  - Part 4 - Part 5 

In industrial engineering literature, a synthesis comparable to Taylor's initial work has not appeared so far in the area of productivity science of machining. These collection of lessons are an initial attempt to present the productivity science in an unsophisticated way to demonstrate the possibility of culling out the relevant aspect from the production technology books and various papers published by faculty in the industrial engineering departments. I welcome all industrial engineers to give suggestions and comments and put forward their point of view.


According to Taylor (1906) productivity effect of cutting fluid at that was:

283 (E) Whether a copious stream of water or other cooling medium is used on the tool.

Proportion is as 1 for tool running dry to 1.41 for tool cooled by a copious stream of water. 

The Current Understanding

Study of metal cutting fluids is to be done by industrial engineers as a cost reduction alternative as the cost of coolant system and coolant come up to even 20% of the total machining cost. The range is given as 10 to 20%. In comparison, the cost of tool is only around 5%.

1. Introduction
2. Types of Cutting Fluids
3. Coolant Application
4. Filtering
5. Condition Monitoring and Waste Treatment
6. Dry and Near-Dry Machining Methods

2. Types of Cutting Fluids

i) Cutting oils
ii) Water-based fluids
iii) Gaseous fluids and gaseous-liquid mixtures

3.  Coolant Application

i) Low-pressure flood application systems
ii) High-pressure flood application systems
iii) Through tool coolant systems

4. Condition Monitoring and Waste Treatment

Common parameters to be monitored include concentration, percent solid and tramp oil, bacteria and fungi count, water quality, and temperature.


5. Dry and Near-Dry Machining Methods

Minimum quantity lubrication is providing cost reduction benefits. Ford is using minimum quantity lubrication as a cost reduction initiative as well as an initiative to reduce health problems of operators and environmental issues.

Machine Tool Cutting Fluids - News

New Cutting Fluids - Cutting Fluid Alternatives - Productivity Engineering Applications

https://nraoiekc.blogspot.com/2020/09/cutting-fluid-alternatives-productivity.html

2020

Benefit of High Pressure Coolant

Machining 1018 Low Carbon Steel

Using Normal Coolant

Drilling 10X dia. depth

PSI: 300

Tool: 0.130 Dia. Carbide Drill

3000 holes

Inconsistent tool life (53 drills used)

RPM: 3300

IPM: 10

FPR: 0.003

Peck Cycles: 5

End Result:

225 holes (1.3” deep)

Drills used: 4

Cycle Time: 1 hour, 35 minutes

Using High Pressure Coolant

Drilling 10X dia. depth

PSI: 1000

Tool: 0.130 Dia. Carbide Drill

3000 holes

1 drill used

 

RPM: 10,000

IPM: 60

FPR: 0.006

Peck Cycles: 0

End Result:

225 holes (1.3” deep)

Drills used: 1

Cycle Time: 7.5 minutes

https://lns-northamerica.com/how-high-pressure-coolant-delivery-improves-profits-productivity-for-metalworking-manufacturers/

2019

Cutting Fluids | Functions, Types, Properties, Methods of Application
By ClubTechnical | March 24, 2019
https://clubtechnical.com/cutting-fluids

How to apply coolant and cutting fluid in turning
https://www.sandvik.coromant.com/en-gb/knowledge/general-turning/pages/how-to-apply-coolant-and-cutting-fluid-in-turning.aspx



Castrol Launches New Cutting Fluid
https://www.machinerylubrication.com/Read/31259/castrol-cutting-fluid

Hydraulic oils - Chevron Soluble Oil B
https://www.chevronlubricants.com/en_us/home/products/chevron-soluble-oil-b.html

BONDERITE L-MR Bactericide-free Cutting Fluids
Bacteria have to stay outside!
https://www.henkel-adhesives.com/in/en/industries/metal-processing/metal-working/machining-and-grinding/bonderite-l-mr-bactericide-free-cutting-fluids.html

Metalworking Fluid Management and Best Practices
7/2/2019
https://www.productionmachining.com/blog/post/metalworking-fluid-management-and-best-bractices

2011

Coolant recycling process at GKN Aerospace St Louis - April 2011 - $6,000 monthly savings

Iowa Waste Reduction Guide for Cutting Fluids - 2003

Mobile cutting fluid recycler - economic analysis November 2003

Selecting the Right Cutting and Grinding Fluids

Cutting Fluids (Coolants) and Their Application in Deep-Hole Machining



Cutting Oil Recovery and Recycling

Lubriserv Mobile Coolant Cleaning Service

Master Chemical Coolant and Coolant Recovery Systems

Mercatus systems provide coolant oil suitable for use for five years through recycling - 2009 article

Nederman Cooling recovery systems - They have an India office at Pune. Brochure can be downloaded from the site.

Smart Skim Coolant Recovery Systems
Benefits of Smartskim products - Big listing


Waste steams in machining

Environment Friendly Fluid Application System - 2004 article

Ud. 2.8.2024

Pub. 16.9.2020